The design and analysis of single flank transmission error tester for loaded gears

To strengthen the understanding of gear transmission error and to verify mathematical models which predict them, a test stand that will measure the transmission error of gear pairs under design loads has been investigated. While most transmission error testers have been used to test gear pairs under unloaded conditions, the goal of this report was to design and perform dynamic analysis of a unique tester with the capability of measuring the transmission error of gears under load. This test stand will have the capability to continuously load a gear pair at torques up to 16,000 in-lb at shaft speeds from 0 to 5 rpm. Error measurement will be accomplished with high resolution optical encoders and the accompanying signal processing unit from an existing unloaded transmission error tester. Input power to the test gear box will be supplied by a dc torque motor while the load will be applied with a similar torque motor. A dual input, dual output control system will regulate the speed and torque of the system. This control system's accuracy and dynamic response were analyzed and it was determined that proportional plus derivative speed control is needed in order to provide the precisely constant torque necessary for error-free measurement.