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Hard Finishing with 100% Quality Inspection 2020/2021 solutionsgear manufacturing technology magazine Game Changer: Technology in Action Forest City Gear Shapes Faster Power Skiving of Larger Gears Hard Finishing Iwasa Tech Excels at Inspection With 100% Quality KISSsoft Inspection Optimizing Manufacturability GAMA 3.2 Inspection Gets Smarter 1 Welcome to Gleason Dear Valued Customers: These past months have been the most challenging and turbulent in a generation. The global economic environment has never been more unpredictable. In times such as these, with the unprecedented convergence of powerful social, political, health John J. Perrotti and economic forces, companies must rethink their President and strategies, and put tradition to the test. Chief Executive Officer Gleason is no different. While we have been proactive, industries; always evolving with more efficient and more for example, in the pursuit of the new technologies resource-saving technologies supported by cloud-based needed for eDrives, no one could have predicted the or local analysis and optimization. With Gleason’s arrival of COVID-19 nor its impact on the way we Closed Loop and in-process inspection coupled to interact with customers, suppliers and employees. It manufacturing, for example, we offer customers a real is a testament to the dedication of our global team, ‘game changer’ in terms of productivity and quality and their willingness to adapt to change, that we have control – with optimization feedback in real time, swiftly adapted to many new ways of doing business, accompanied by solutions for smart tooling setup and while at the same time working to make our customers’ optimized machine performance. lives as easy and convenient as possible. These new These are difficult times to be sure, but if history has told methodologies have included everything from virtual us anything, it’s that amazing progress will be made as a machine acceptances to live product demonstrations, to result. We believe that 2021 reinvestment goals are critical free services like our new Gear Trainer Webinars and to compete; we will be at your side with the broadest support apps such as the Gear Calculator App. portfolio of gear solutions including design, manufacture Going forward, there is a sense of both urgency, and and inspection. With our global footprint we strive to be great optimism, in the work our company is doing to your partner to help meet the challenges of tomorrow. prepare for a future where a premium will be placed Yours sincerely, on innovation and adaptability to change. Our new manufacturing technologies are tailor-made to deliver much-needed design and manufacturing solutions for eDrive, aerospace, energy, construction and farming 2 Welcome to Gleason 04 Cover Story: Hard Finishing with 100% Gear Inspection 08 Faster Shaping Lands at Forest City Gear 04 12 Power Skiving for Larger Gears 14 Inspection Never Gets Old at Iwasa Tech 08 18 Introducing: The Diff2 e-drive 20 Best In Class: The New and Improved 280G 12 24 New Pitch Line Fixture Minimizes Runout 26 KISSsoft Connects Design to Manufacturing 14 30 GAMA™ 3.2 Inspection Software: Most Powerful Version Yet 32 Inspection Solutions for Quieter Gears 18 34 Introducing Gleason Connect Cloud 36 Now Streaming: Gear Trainer Webinar Series 20 38 Gear Design on the Go! 39 Gear Calculations: There’s an App for That 26 36 © 2020 Gleason Corporation. All Rights Reserved. solutions magazine is published regularly throughout the year, and distributed worldwide. Please address correspondence to: Christian Albrecht, Editor solutions magazine. Gleason Corporation. 1000 University Ave., P.O. Box 22970, Rochester, NY 14692-2970 U.S.A., +1 585-473-1000 • www.gleason.com • [email protected] 3 Hard Finishing Cell HFC Hard Finishing with 100% Quality Inspection Gleason’s vision becomes reality: The world’s first system for hard finishing of gears with gear measurement in-process and Closed Loop feedback. t the 2019 MPT show in Detroit, Technology in a single system to finally randomly. This is due to the significantly A Michigan USA, Gleason unveiled address – and solve – the challenge of longer measuring times required in its new Hard Finishing Cell (HFC) random gear inspection that has long comparison to the actual production with integrated inspection of up to existed in high volume gear production. time and limited measuring capacity. It 100% of all gears in process. For the is not unusual in continuous generating first time, the Gleason HFC combines grinding to measure only one or the latest Threaded Wheel Grinding 95% of Gears Go Untested two components per dressing cycle. with revolutionary new GRSL Gear Depending on the dressing cycle, this In conventional gear manufacturing, Rolling System with Integrated Laser corresponds to only about 5% of the quality control is carried out only 4 Hard Finishing Cell HFC components actually produced. In this means that only about 50% of the the possibility of up to 100% inspection order to guarantee an almost 100% actually intended drawing tolerances are of all manufactured components. End reliability, statistics are instead used to available as manufacturing tolerances. result? There is no need for additional validate most of the gears produced. narrowing of tolerances and the Typical measuring characteristics 100% inspection of all manufactured can be represented and statistically A Better Way components can be accomplished in- evaluated on a Gaussian bell curve. process. In today’s world, that’s not good enough. By deliberately narrowing down the The constantly increasing power density tolerances on the actually measured of gears and the growing importance components, it is possible to guarantee Many Technologies, One System of noise behavior are leading to compliance with the actually required increasingly tight tolerances. Clearly, The HFC thus offers significant added drawing tolerances with a sufficiently the heavy reliance on statistics poses a value. It’s a fully automated system with high probability (typically > 99.99%). significant problem for a growing number robot loading that integrates modules This method is commonly used for of gear manufacturers. for auxiliary processes in order to meet machine and process capability studies specific customer requirements easily and is recognized worldwide. The Gleason’s new GRSL roller testing and flexibly. The complete process machine or process capability values device with integrated optical measuring sequence includes gear grinding, cmk and cpk frequently taken as a basis technology opens up a world of new washing, laser marking, measuring are usually above 1.67. Statistically, the possibilities by reducing measuring time and part handling in a stackable basket reject rate is only 0.57 components per so that it can realistically be done within system. The HFC approach can be 1 million manufactured components, but the actual production time. This provides grind basketize wash mark fingerprint gtools closed loop reject inspect test 5 Hard Finishing Cell The Hard Finishing Cell is the world’s first fully-automated, closed loop manufacturing system including revolutionary in-line gear checking with real-time analysis and automatic feedback of corrections to the Threaded Wheel Grinding Machine. taken with any desired process, with from the machine and providing the is equipped with the latest Gleason a single system replacing a number of measurement result. With HFC’s accessories, including the Quik-Flex® machines in a Closed Loop system. in-process inspection and Closed Plus modular fixture, which allows Loop, the desired correction ensuring changeovers in minutes, and Gleason HFC’s 100% inspection capability results optimum quality during the ongoing dressing tools. from the new Gleason GRSL analytical production process is much faster. and composite inspection unit which is fully integrated into the system. The Components whose characteristics lie In Summary component to be tested is loaded by outside the tolerances are automatically the robot onto the double-flank rolling rejected. It is also possible to create HFC is indeed a highly desirable solution test device. During the gear inspection, extensive trend analyses of individual for many industries and applications a laser scanner is used to measure all features and perform further gear noise where consistent high quality is gear characteristics. Thus all relevant analysis. important, such as the production of information for profile, pitch and runout high precision e-drive gears with minimal and, if desired, lead measurement is noise characteristics. A single system for available. This is done for each tooth and 4.0 Inside the fast and high-quality production with not, as is usually the case, only on four 100% gear inspection, long the dream of In addition to the many analysis teeth distributed over the circumference. many customers, is now reality. options that the system provides for Deviations are fed back directly into optimizing workpiece quality, the Hard the production machine by means of Finishing Cell is also equipped with a closed correction loop. Both fully the latest 4.0 functions. The Gleason automatic correction and real-time Fingerprint™ Machine Analysis for adjustment of the corresponding predictive maintenance allows the user Dr. Antoine Türich Director Product parameters can be achieved. Compare to keep planned machine availability Management of Hard that to the conventional measurement at peak levels. Gleason’s “gTools” tool Finishing Solutions process in the quality lab, where management
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