Industrial robots have become integral to many industries and provide high-quality results while performing different tasks. New technology has evolved, which is why robots have become more accurate and efficient with time. The precision and repeatability of robotic machining depend more on gears and gearboxes. These components play a crucial role in handling torque and motion to synchronize different parts of robots while performing any task.
Cutting the smaller gears with specific measurements is necessary for precise results during machining. Power skiving is a crucial process toward precise robotic machining and operations, it’s a new way to improve the coordination of robot parts by forming high-precision gears.
Basic Principles of Power Skiving
The gear manufacturing industry depends upon three things: hobbing, gashing, and broaching. But they all have some limitations; some are good for internal gears, and some for external gears.
However, with power skiving, it is possible to form external and internal gears more efficiently. Unlike other methods, power skiving is a multitasking machine that performs hobbing and shaping together to form gear components.
Power skiving differentiates itself depending on the capability of performing continuous cutting processes. The cutting process depends upon the engagement between the cutting tool and the surface of the gear. This skiving tool moves along the rotating gear to form the gear teeth. Coordination between the skiving tool and the gear surface generates the rotational motion required for cutting the surface. This produces an accurate shape of the teeth in gear.
The meshing of a tool with the gear depends upon the rotation speed because cutting the gear and forming a tooth profile depends upon it. So, generating the required speed is necessary to get the results.
Now, the question arises, What is the exact rotation speed generated between the tool and the gear? This depends upon the material used, tool design, tooth profile requirement, and machine stability.
The inclination between the gear and the tool’s axis also influences the cutting speed. So, one must focus on the angle between the gear and the tool for the required results while using this tool. Tools must be inclined properly to remove material while cutting for better engagement and effective cutting action.
Power Skiving for Robotics
Robotic machining depends upon the synchronization of different robot parts. The robot arm consists of different components, and gears are one of them to ensure proper movement. Gears are responsible for the transmission of torque and controlling motion. They can crash the entire system if they are not flexible and versatile enough. In case of any error, robotic machining can affect their performance and the quality of the workpiece.
Power skiving has enhanced the efficiency and precision of robotics in many ways. Power skiving has reduced the machining time because there is no need to reposition the workpiece repeatedly. The traditional ways need repositioning or adjusting to a new position for multiple operations. This consumes time and affects efficiency.
Robotic components are full of intricacies and need precision for high performance. Different types of gears have different orientations, like vertical and parallel. This can be achieved because of the different cutting tool designs in a shorter time.
The traditional method of scraping involves imperfections after cutting a robotics tool, but Power skiving has reduced this problem by forming surfaces without imperfections. So, now manufacturers need only a single skiving process by eliminating the finishing step at the end. It impacts the overall cost of the manufacturer during production.
Also, CNC robotics has enhanced the control of the movement of the tool for more precision and accuracy. So, as a robotics manufacturer, you can produce high-quality components in less time and optimize your production process.
How can power skiving offer precise motion control in robots?
Power skiving controls the motion of robots by generating precise tooth profiles during the process. Transmitting torque and motion from one part to another depend upon the tooth profiles in the gear. This leads to precise motion control in robots.
Some specified dimensional limits need to be followed during tooth profile generation. Any error can lead to mismatched gear and adversely affect the robot’s part’s coordination.
CNC machining robotics provides assistance to power skiving to control movements. CNC robotics helps manufacturers to create components with the desired specifications or measurements. After integrating this computer-based technology, precision has increased in the cutting processes of gear surfaces.
Using Robot CNC machines in power skiving ensures accuracy within less time, leading to more productivity. Integration of CNC with power skiving has increased the manufacturing process multiple times compared to other methods.
This technique has eliminated human errors because of the predefined computerized instructions for the movement of the CNC robot arm. Robotic arms follow the programmed instructions and the machine specifications to form tooth profiles during gear cutting.
CNC machines can efficiently perform tasks based on the input received. They then position the robot arm and take care of the right angle between the gear and the tool to make precise cuts on the gear surface.
If there is no motion control or poor motion control, it will generate inefficiency and waste of time. It will affect the rate of production and the cost as well.
Final Words
Power skiving works continuously in one go and performs the task in less time than other methods. Other methods of manufacturing gear are not as efficient because the machine tool needs to return to the starting point every time after performing cutting.
Power skiving combined with CNC machining brings higher flexibility and accuracy to tooth-scraping. It provides a controlled motion that produces precise gear with specific measurements and takes care of safe scraping operations.
Power skiving is the flexible option that manufacturers should opt for a precise machining process.
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