Design And Implementation Of On-line Quality Monitoring And Quality Forecasting System For Gear

Gear is an important part in mechanical transmission.The machining quality can be characterized by single geometric error and comprehensive error.The detection items of single geometric error are various and slow,used to high precision gear machining process.With the improvement of production efficiency,fast and effective testing equipment,such as one-flank gear rolling tester,two-flank gear rolling tester and gear sorting machine have been widely used to the gear processing production lines with middle and low accuracy.In this paper,a gear quality monitoring and quality prediction system is designed by integrating Statistical Process Control theory into the gear quality control process,which takes mass gear machining quality monitoring as the object.The system can carry out real-time analysis on the gear quality inspection data online,and can also carry out quality traceability for the introduced offline data.By monitoring the key data of gear quality,the system can monitor the working state of gear machining production line,can also predict the changing trend of gear machining quality,avoid defective products and improve production efficiency.The research contents of this paper are as follows:(1)Taking the system’s function requirement as the premise,the requirements were analyzed from three aspects of gear including quality monitoring,quality prediction and the main function of the system,realizing the overall functional module design goal to complete the functional structure design of the system.(2)Based on the design requirements of database,SQL Server2008 was selected to complete the design of the data dictionary of account information,basic parameters of gear,gear quality inspection data,quality monitoring results and abnormal workpiece information,which realized the dynamic creation of data forms,the backup and management of quality inspection data and quality information data.(3)Adopting the designing of Qt Designer system,containing the main function module,data import and error calculation module,the gear quality monitoring module and gear quality prediction module,it was the realization of the user management and multistage permissions to ensure data security,to bring about the online data acquisition or offline data import function,to complete error calculation according to the national standards,and to accomplish the gear quality charts which can be set up according to the standard or custom statistical chart floor,abnormal quality prompt alarm,and other functions.(4)According to the characteristics of gear machining process and gear quality detection data,the least square method,dynamic exponential smoothing method and autoregressive moving average method were used to predict the change trend of gear machining quality,and the gear quality was monitored.The simulation software was also used to verify the prediction algorithm.(5)The online quality monitoring and quality prediction system of gear classifier is tested by taking the span of the gear separator as the monitoring item.The test results show that the machining quality of gear and the state of production process,can be monitored,the changing trend of gear quality can be predicted.And it will be an early warning when out of tolerance.