Auto Gear Teeth Burnishing Machine Using Servo Control

Abstract

A typical vehicle transmission is comprised of between five and six gear sets and a series of gear trains that allows a driver to control how much power is delivered to the vehicle without changing how fast the engine runs. This transmission makes noise such as burrs, nicks, high points and heat treat scales are the leading causes of noise in power transmission. There are many different causes of gear noise, all of them theoretically preventable. Unfortunately, the prevention methods can be costly, both in equipment and manpower. If the design of the gear and its application are appropriate, in theory all that is necessary is to have a tight control on the process of producing the finished gear. In reality, there are many variables that can cause a process, no matter how well-controlled, to deteriorate, and thus cause errors, some of which will cause a gear to produce unwanted noise when put to use. The effective way to eliminate this noise the process known as "Gear Burnishing". The proposed system uses gear shaving cutter as a master for burnishing or deburring operation of gear teeth with servo mechanism (includes servo motor and servo drivers), Programmable logic controller (PLC), Human machine interface (HMI) to remove gear inaccuracies and so as to reduce or eliminate transmission noise and provide more life and reliability to transmissions in vehicles resulted into noise free vehicles.