Honing ring
In gear honing, a broken honing ring can damage the machine and leave faulty gears in the process. Vibration analysis monitors the honing ring live, stops the machine if it breaks and rejects affected parts.
Honing ring at a glance
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Gear honing: monitoring the honing ring by vibration
In the solution example, Schaeffler Digital Solutions' autinityVC software runs on an industrial PC directly at the machine. It records the analogue signals of several vibration sensors, breaks them down into individual frequencies using the fast Fourier transform and compares them with stored reference spectra. It also reads process parameters from the programmable logic controller and links them to the spectra. In the event of an impact alarm, it accesses the machine control via an interface and triggers an emergency retraction. The VibroAnalyzer evaluates the data with a Campbell diagram and trend analysis; the data is also available in CSV and Q-DAS format and stays on premises by default.
The example comes from gearbox production at the Schaeffler Group, with scrap reduction and tool wear as use cases. During honing and grinding, vibrations between tool and workpiece create micro-waviness, which often leads to noise problems in gears. If it is only noticed at the end-of-line test, the entire gearbox may have to be dismantled again. autinityVC detects acoustically critical components while they are still in the machine and marks or rejects them. Subsequent workpieces remain undamaged, and consequential damage and long unplanned downtime are avoided. The software also detects tool wear, so the tool is replaced in good time.
Gear honing: frequently asked questions
How is honing ring breakage detected immediately?
Honing ring breakage causes a sudden peak in the vibration signal, which impact monitoring detects. In the Schaeffler example, autinityVC then raises an alarm, triggers a notification and stops the machine. Via the interface to the control system, the software initiates an emergency retraction and rejects the affected parts. Fragments of the honing ring therefore cause no consequential damage in the machine.
How is a gear honing machine monitored with vibration sensors?
Several vibration sensors on the honing machine send analogue signals to an industrial PC directly at the machine. There, autinityVC breaks them down into frequencies using the fast Fourier transform and compares them with reference spectra. Process parameters from the PLC are automatically linked to the spectra, creating references specific to each work step and material. If limits are exceeded, the software raises an alarm.
What causes gear waviness during honing?
Micro-waviness is caused by vibrations triggered by relative movements between tool and workpiece during finishing. In gears, these periodic geometry deviations often lead to noise problems in the gearbox. Schaeffler uses autinityVC to detect affected components while they are still in the machine. The workpiece is rejected or marked for tracking instead of being noticed only at the end-of-line test.
How can vibration data improve the honing process?
Vibration data shows where anomalies arise in the honing process and makes it measurable. autinityVC provides an analysis tool for evaluating production processes and optimising cycle time. The VibroAnalyzer displays the data with a Campbell diagram, trend analysis and filter functions. The software also detects tool wear, so the tool can be replaced in good time.
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