Research On Gear Mapping Optimization Method And Its System Implementation

Gear mechanism is widely used in modern machinery. Gear mapping is a very important technology in equipment maintenance and machine imitation. Since its multitudinous parameters and complicated shape, gear's mapping is deemed to be a niggling job that requires the workers to be equipped with lots of gear-mapping experience and skillful knowledge about gear design and manufacture.To map a gear with the classical mapping method, we need to combine calculation with graph and table looking-up. It is a process consists of repeatedly testing calculation and checking computations, and a lot of artificial judgments are needed during the job. The result from the classical mapping method is a relatively rough approximation, and is hard to achieve the optimal precision.In the research, I probed into the combination of optimization ideas and gear mapping, and presented a method to map the gear based on optimization theory. The gear mapping optimization method requires just the same measured data which can be obtained with common measuring tools as in the classical ones. But the data processing is different that the method firstly establishes an optimization objective function by squaring the deviation of the measured data and the corresponding theoretical value, and then figures out the optimal approximation that meets the constraints by solving the optimization problem to be the value of the initial design parameters.To the gear mapping optimization method presented above, firstly I validated the optimal algorithm by mapping spur involute cylinder gear, helical involute cylinder gear and straight bevel gear via MATLAB Optimization Toolbox, and then I designed and realized a gear-mapping-system software with C# in the IDE of Visual Studio 2008. The research opened a new avenue to map the gears. It enhanced the mapping precision and efficiency by avoiding the testing calculation, artificial judgments and simplify the calculation process, and can be used straight in engineering applications.The gear mapping method which is based on ideas of optimization could be extended to apply in the mapping of the other kinds of gears and among the parameter retrieving of the akin productions.