To reduce wind turbine failures by defective drive trains, deviations in the geometry of large gears (diameter ≳ 1 m) must be extensively determined with single-digit micrometer uncertainties. Fixed measuring volumes limit standard measuring methods like coordinate and gear measuring instruments for large gear measurements. Therefore, a model-based scanning multi-distance measurement approach for gear shape parameters is presented. The measurement approach has a scalable design and consists of a confocal-chromatic sensor, rotary table as a scanning unit and model-based signal processing. A preliminary study on a midsize spur gear demonstrates the general feasibility of the model-based scanning multi-distance measurement approach. As a result, the mean base circle radius as the fundamental gear shape parameter is determined with an uncertainty of <5 μm. The calibration and adjustment of the sensor arrangement were performed with a known calibration gear. Scalability is not experimentally validated in this article. However, simulations verify the scalability of the measurement approach in a first step. For gears with 1 m in diameter and varying tooth flank geometries, the estimated achievable uncertainty of the mean base circle radius is still <5 μm. Therefore, the model-based scanning multi-distance measurement approach is a promising alternative for gear inspection.

中文翻译：

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使用基于模型的扫描多距离测量方法进行齿轮形状参数测量。

为了减少因传动系统故障而导致的风力涡轮机故障，大齿轮（直径≳1 m）的几何偏差必须以个位数的千分尺不确定度来确定。固定的测量体积限制了标准测量方法，例如用于大型齿轮测量的坐标和齿轮测量仪器。因此，提出了一种基于模型的齿轮形状参数扫描多距离测量方法。该测量方法具有可扩展的设计，由共焦色传感器，作为扫描单元的旋转工作台和基于模型的信号处理组成。对中型正齿轮的初步研究证明了基于模型的扫描多距离测量方法的一般可行性。结果是，确定平均基本圆弧半径作为基本齿轮形状参数，不确定度<5μm。传感器装置的校准和调整是通过已知的校准装置进行的。本文未通过实验验证可伸缩性。但是，仿真第一步验证了测量方法的可扩展性。对于直径为1 m且齿面几何形状变化的齿轮，估计的可达到的平均基圆半径不确定度仍小于5μm。因此，基于模型的扫描多距离测量方法是齿轮检查的有希望的替代方法。仿真第一步验证了测量方法的可扩展性。对于直径为1 m且齿面几何形状变化的齿轮，估计的可达到的平均基圆半径不确定度仍小于5μm。因此，基于模型的扫描多距离测量方法是齿轮检查的有希望的替代方法。仿真第一步验证了测量方法的可扩展性。对于直径为1 m且齿面几何形状变化的齿轮，估计的可达到的平均基圆半径不确定度仍小于5μm。因此，基于模型的扫描多距离测量方法是齿轮检查的有希望的替代方法。