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Compensation method for the alignment angle error in pitch deviation measurement

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2016 Meas. Sci. Technol. 27 055006

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 Measurement Science and Technology

Meas. Sci. Technol. 27 (2016) 055006 (10pp) doi:10.1088/0957-0233/27/5/055006

Compensation method for the alignment

angle error in pitch deviation measurement
Yongsheng Liu1,2, Suping Fang2,3, Huiyi Wang2, Tetsuya Taguchi4
and Ryohei Takeda4
1
  Key Laboratory of Road Construction Technology and Equipment, MOE, Chang’an University,
Xi’an, Shaanxi 710064, People’s Republic of China
2
  State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering,
Xi’an Jiaotong University, Xi’an, Shaanxi 710049, People’s Republic of China
3
  School of Mechanical Engineering, Hefei University of Technology Xuancheng Campus, Xuancheng,
Anhui 242000, People’s Republic of China
4
  Osaka Seimitsu Kikai Co., Ltd., Higashi-Osaka, Osaka 577-0032, Japan

E-mail: lysh@chd.edu.cn and spfang@mail.xjtu.edu.cn

Received 1 December 2015, revised 2 March 2016

Accepted for publication 14 March 2016
Published 6 April 2016

Abstract
When measuring the tooth flank of an involute helical gear by gear measuring center
(GMC), the alignment angle error of a gear axis, which was caused by the assembly
error and manufacturing error of the GMC, will affect the measurement accuracy of pitch
deviation of the gear tooth flank. Based on the model of the involute helical gear and the
tooth flank measurement theory, a method is proposed to compensate the alignment angle
error that is included in the measurement results of pitch deviation, without changing the
initial measurement method of the GMC. Simulation experiments are done to verify the
compensation method and the results show that after compensation, the alignment angle error
of the gear axis included in measurement results of pitch deviation declines significantly, more
than 90% of the alignment angle errors are compensated, and the residual alignment angle
errors in pitch deviation measurement results are less than 0.1 μm. It shows that the proposed
method can improve the measurement accuracy of the GMC when measuring the pitch
deviation of involute helical gear.

Keywords: involute helical gear, pitch deviation, alignment angle error, compensation method

(Some figures may appear in colour only in the online journal)

1. Introduction
Involute helical gears are widely used in vehicles, machine
tools, and a variety of industrial equipment. The deviations
of tooth flank will affect the vibration and noise of gears, so
the measurement of gear tooth flank is of great importance for
lifetime, power transmission, and noise control [1–4]. In gear
measurement, as well as the profile deviation, the measurement
of tooth pitch deviation is also important to improve the geo-
metrical accuracy and ensure the performance of gears [5, 6].
As the manufacturing and assembly error of the GMC
exists, there is an alignment angle error between the upper
and lower centers (figure 1). This alignment angle error causes
the gear axis not parallel to the vertical axis of GMC, and
also causes the actual measuring point not coincides with the
theoretical measuring point. Furthermore the alignment angle
error leads to the measurement error when measuring the gear
tooth pitch deviation [7, 8].
Many measurement and compensation methods are avail-
able for pitch deviations of gear tooth flank. Younes et al [9]
use laser light to measure the tooth thickness and pitch of the
spur gear, and Robinson et al [10] use camera and image anal-
ysis software to measure the pitch error of the gear, but neither
of the two methods are suitable for the involute helical gear as
the adjacent tooth may interfere the light. Lotze and Haertig
[11] propose an universal substitute model of the helical gear
which allows measuring of the pitch anywhere on the flank
instead of exactly at the defined lines. Komori et al propose

0957-0233/16/055006+10$33.00 1 © 2016 IOP Publishing Ltd  Printed in the UK

Meas. Sci. Technol. 27 (2016) 055006
Figure 1.  The alignment angle error of gear axis.
some methods to evaluate lead and pitch measurement acc­
uracy by using a wedge artifact [12, 13] and magnetically self-
aligned multiball pitch artifact [14, 15]. Zhang et al [16] give
a new method of gear tooth lead error and pitch error by using
a special master gear with three kinds of measuring tooth
and a transmission tooth. Suh et  al [17] present an indirect
measurement method to measure various error of the gears,
such as profile error, lead error and pitch error. Takeoka et al
[18] analyze the effects of the error factors on measurement
results and point out that the eccentricity between upper and
lower centers is one of the six error sources of the measure-
ment results of gear tooth flank. Considering the positioning
errors as one of the measurement uncertainties, Sammartini
and Chiffre [19] develop a new type of master gear for pitch
and tooth thickness measurement. Wink and Serpa [20] point
out that manufacturing errors such as pitch error, profile error,
and misalignment and lead errors of gear tooth surfaces affect
the transmission error of spur and helical gears. Kondo et al
[21] report a method of evaluating lead measurement acc­
uracy using a wedge artifact, and consider the setting error as
the eccentricity and tilt error of rotation axis. Wang et al [22]
derive a rule of profile deviation caused by the comprehensive
eccentricity of involute gear. Mark [23] provides a computa-
tional algorithm to correct the rotation axis imperfections by
using a high-quality spur gear as the measurement artifact.
Using a rotary profiling system, Xu et al [24] measured and
compensated the pitch deviation of an involute spur gear
caused by the eccentric error. However, with all the methods
mentioned above, the eccentricity error and the inclination
error were not considered simultaneously, or the initial meas-
uring steps of the GMC needed to be modified, so they are not
suitable for the precision measurement of pitch deviation of
gear tooth flank.
In this paper, without changing the initial measuring steps
and initial data process of GMC, we propose a compensation
2
Y Liu et al
method for the alignment angle error of the gear axis in tooth
pitch deviation measurement, and design simulation experi-
ments to verify this method. Simulation results show that after
compensation, the alignment angle error of the gear axis that
is included in the measurement results of tooth pitch deviation
reduces remarkably, and this method can improve the meas-
urement accuracy of the GMC significantly when measuring
the tooth flank forms.
2.  Measurement principle of tooth pitch deviation
The tooth pitch of a gear is the arc on the reference circle
between two successive equal-handed tooth flanks (right or
left flanks), and it is determined by the helix curves that are
intersected by the reference circle and two successive equal-
handed tooth flanks [25].
According to the measurement principle of the gear pitch
deviation by GMC, when measuring the tooth pitch, as shown
in figure 2(a), the probe is set at y  =  rb, where rb is the radius
of the base circle of the gear. When the gear tooth rotates to
the specific position, the probe moves along X-axis to touch
the gear tooth flank and measures the measuring point.
The steps to measure the pitch of the tooth flank include:
(a) Set the probe tip at z0  =  h;
(b) Move the probe along the X-axis and measure the X coor-
dinate value x1 of the measuring point P1 on the first tooth
flank;
(c) Move back the probe along Y-axis, rotate the gear around
the rotation axis (Z-axis) by an angle τ  = 2π/z, where z
is the number of the gear teeth, and then move the probe
along Y-axis to y  =  rb;
(d) Move the probe along the X-axis and measure the X coor-
dinate value x2 of the corresponding measuring point P2
on the adjacent tooth flank;
(e) The actual pitch of gear could be expressed as follows:
Pt = rτ − (x2 − x1),
(1)
where, r is the radius of the reference circle;
(f) The pitch deviation of the tooth flank could be expressed
as follows:
fp = x2 − x1.
(2)
However, when the alignment angle error of the gear axis
exists, as shown in figure 2(b), the actual measuring point may
not be on the helix curve intersected by the tooth flank and the
reference circle, so there will be a discrepancy between the
actual measuring point and the theoretical measuring point,
and this discrepancy will lead to the measurement error of the
tooth pitch deviation.
According to equation  (2), the pitch deviation could be
obtained by the difference from the measurement value of two
adjacent tooth flanks. This difference could reduce the effect
of the alignment angle error, but can not completely elimi-
nate. The alignment angle error still exists in the measurement
result of pitch deviation and can not be ignored.
Meas. Sci. Technol. 27 (2016) 055006 Y Liu et al

Figure 2.  Measurement of tooth pitch deviation.

3.  Model of tooth flank with alignment angle error

of the gear axis

The model of involute helical gear is shown in figure  3.

Tooth flank 1 and tooth flank 2 are two adjacent tooth flanks.
According to reference [26], the gear tooth flank is determined
by the following equations:
⎧ x (ϕ, θ ) = X (ϕ ) cos θ − Y (ϕ ) sin θ
⎪
⎨ y(ϕ, θ ) = X (ϕ ) sin θ + Y (ϕ ) cos θ ,
(3)
⎪ z(θ ) = pθ
⎩
where, ϕ is the spread angle, θ is the polar angle, p is the pitch
of the screw, and X(ϕ) and Y(ϕ) represent the involute curves.
When the gear axis is in eccentric and inclined condition,
the alignment angles γx (around the X-axis) and γy (around the
Y-axis) of the gear axis can be calculated by the eccentricity
value. The model of tooth flank in eccentric and inclined con-
dition could be expressed as follows: Figure 3.  The model of the involute helical gear.

⎡ x (ϕ, θ, γx, γy ) ⎤ ⎡ x (ϕ , θ ) ⎤
⎢ ⎥ ⎧ xP = x (ϕ, θ, γx, γy, τ ) + r P ⋅ nx
⎢ ⎥ ⎪
⎢(4)
y(ϕ, θ, γx, γy ) ⎥ = Rx (γx ) ⋅ Ry(γy ) ⋅ ⎢ Y (ϕ, θ ) ⎥ + T (ex , ey ),
⎢ z (ϕ , θ , γ , γ ) ⎥ ⎨ yP = y(ϕ, θ, γx, γy, τ ) + r P ⋅ n y .
⎢⎣ Z (ϕ, θ ) ⎥⎦ (6)
⎪
⎣ x y ⎦
⎩ zP = z(θ, p, γx, γy, τ ) + r P ⋅ nz
where, Rx, Ry are rotational matrices, and T is the translational
matrix.
Considering the probe tip radius, equation  (4) could be 4.  Compensation method for alignment angle
yielded as follows: error of the gear axis in tooth pitch deviation
⎧ xP = x (ϕ, θ, γx, γy ) + r P ⋅ nx
measurement
⎪
⎨ yP = y(ϕ, θ, γx, γy ) + r P ⋅ n y ,
(5) Assuming that the coordinate of the measuring point is (X, Y, Z ),
⎪
⎩ zP = z(θ, p, γx, γy ) + r P ⋅ nz
and the corresponding rotation angle of the gear is φ, the coor-
dinate value of the measuring point could be derived from
where, rP is the probe tip radius and n→(nx, n y, nz ) is the normal equation (5):
vector.
⎧ X = x p(ϕ, θ, γx, γy ) cos φ − yp(ϕ, θ, γx, γy ) sin φ
Furthermore, when measuring the pitch of gear tooth flank, ⎪
the gear rotates an angle τ to measure the adjacent tooth flank, ⎨Y = x p(ϕ, θ, γx, γy ) sin φ + yp(ϕ, θ, γx, γy ) cos φ .
(7)
so the model of gear tooth flank in equation  (5) could be ⎪
developed as follows: ⎩ Z = zp(θ, p, γx, γy )

3
Meas. Sci. Technol. 27 (2016) 055006 Y Liu et al

Figure 4.  Calculation process of the pitch deviation caused by the alignment angle error.

According to the measurement principle of tooth pitch, the

coordinate value of the measuring point on the first tooth flank
could be derived from equation (7):
⎧ Z = zp(θ, p, γx, γy ) = h
⎨
⎪
,
⎩Y = x p(ϕ, θ, γx, γy, τ ) sin φ + yp(ϕ, θ, γx, γy, τ ) cos φ = r b
⎪

(8)

X1 = x p(ϕ, θ, γx, γy, τ ) cos φ − yp(ϕ, θ, γx, γy, τ ) sin φ.

(9)
Similarly, the X coordinate value of the measuring point on
the adjacent tooth flank could also be derived as follows: Figure 5.  Data process steps to compensate the alignment angle error.

X2 = x p(ϕ, θ, γx, γy, τ ) cos(φ + τ ) − yp(ϕ, θ, γx, γy, τ ) sin(φ + τ ).
The data process of the gear measuring machine with the
(10) proposed compensation algorithm is shown in figure 5. After
The values of ϕ and θ can be obtained from equation (8), and
measuring the actual data of pitch deviation, the system cal-
then substituted into equations (9) and (10), the X coordinate
culates the alignment angle error and then compensates for it.
value x1, x2 of the measuring points on the two adjacent tooth
After compensation, the measured data will be processed by
flanks could be calculated. The pitch deviation could be cal-
the initial data process of gear machining center, and finally
culated by equation (2).
outputs the pitch deviation measurement results.
Assuming that the tooth pitch deviation in theoretical con-
dition is E1, the pitch deviation in the eccentric and inclined
condition is E2, and the measurement error caused by the 5.  Simulation verification and analysis of the
alignment angle error of the gear axis is: compensation method
∆E = E2 − E1.
(11) Two types of involute helical gears (Gear A and Gear B) are
The calculation process of the error ΔE is shown in figure 4, taken as examples to verify the compensation method, and the
and ΔE is considered as the compensation value for the align- basic parameters of the gears are shown in table 1.
ment angle error of the gear axis in tooth pitch deviation The proble tip radius is rP  = 2 mm, the distance between
measurement. the upper and lower center is l  = 230 mm.

4
Meas. Sci. Technol. 27 (2016) 055006 Y Liu et al

Table 1.  Basic parameters of the experimental gears.

Pressure
Modulus/mn (mm) No. of teeth/z Facewidth/B (mm) Helix angle/βb (°) angle/α (°)
Gear A 2.5 26 30 15, 20, 25, 30, 35 20
Gear B 2 20

Figure 6.  Alignment angle errors with different helix angles in pitch deviation measurement of all teeth of Gear A.

Figure 7.  Alignment angle errors with different helix angles in pitch deviation measurement of all teeth of Gear B.

According to figure  4, the theoretical data of the meas-
uring point on the adjacent tooth flanks could be calculated
from the model of gear tooth flank in theoretical condition,
and the measurement data of the measuring point on the
adjacent tooth flanks could be calculated from the model
of gear tooth flank in eccentric and inclined condition. The
pitch deviation and furthermore the alignment angle error
could be calculated by the measurement data and the theor­
etical data.
Two simulation experiments were done to verify the pro-
posed compensation method, with different helix angles and
eccentricity values respectively.
5.1.  Verification of compensation effects with different helix
angles of the gear
According to table 1, in this simulation experiment the helix
angles βb are set as 15°, 20°, 25°, 30°, and 35°, respectively,

5
Meas. Sci. Technol. 27 (2016) 055006 Y Liu et al

Figure 8.  Alignment angle errors with different helix angles for the selected measuring points of Gear A.

Figure 9.  Alignment angle errors with different helix angles for the selected measuring points of Gear B.

and the eccentricity value between the upper and lower center
is set as 5 μm.
5.1.1.  Pitch deviation measurement and compensation.  First
we set the probe tip at z0  =  B/2, and measure the single pitch
deviation of each tooth of two gears. According to the mea-
surement principle of tooth pitch deviation, the pitch devia-
tions of each tooth are identical in simulation experiment, and
the alignment angle errors in each tooth pitch deviation are
also identical. When the helix angles of the gears are different,
the comparison of the alignment angle errors in pitch devia-
tion measurement before and after compensation is shown in
figure 6 (for Gear A) and figure 7 (for Gear B).
6
Figures 6 and 7 show that the alignment angle errors in
pitch deviation measurement results of each tooth of Gear A
and Gear B with different helix angles are more than 0.6 μm
and 0.8 μm, respectively. However, after compensation, the
residual alignment angle errors of the two gears are both
less than 0.1 μm. Figures  6 and 7 also show that although
the alignment angle error in pitch deviation of each tooth is
the same in simulation experiment, the residual alignment
angle errors increase slowly with the helix angles of the gear
become larger.
To research the effect of the alignment angle error in pitch
deviation when the measuring points at different heights along
the facewidth of the gear, 30 measuring points are selected
Meas. Sci. Technol. 27 (2016) 055006
Figure 10.  Compensation effects of pitch deviations with different helix angles of Gear A.
Figure 11.  Alignment angle errors with different eccentricity values in pitch deviation measurement of all teeth of Gear A.
along the helix curves on both one tooth and its adjacent tooth
flanks of the gear, and the measuring points are arranged
according to the increase of the Z coordinate value.
The comparison of the alignment angle errors for the
selected measuring points before and after compensation is
shown in figure 8 (for Gear A) and figure 9 (for Gear B).
Figures 8 and 9 show that, for different measuring points
along the helix curves, the alignment angle errors with dif-
ferent helix angles are more than 0.6 μm for Gear A and
0.8 μm for Gear B before compensation. The residual align-
ment angle errors are less than 0.1 μm after compensation.
Furthermore, as the Z coordinate values of the measuring
points increase, the alignment angle errors and the residual
alignment angle errors in pitch deviation measurement results
increase slowly.
5.1.2.  Compensation effects.  It is very obvious that the com-
pensation effects for pitch deviations are significant. We only
take the 30 selected measuring points of Gear A as an example
to analyze the compensation effects in pitch deviation mea-
surement with different helix angles. As shown in figure 10, the
compensation effects of pitch deviations are more than 90%.
7
Y Liu et al
From figures 6–10, we can easily see that most of the align-
ment angle errors included in measurement results of pitch
deviations are reduced by the proposed compensation method.
After compensation, more than 90% of the alignment angle
errors decline, and the residual errors are less than 0.1 μm.
5.2.  Verification of compensation effects with different
alignment angle error of the gear axis
In this simulation experiment, the gear has a helix angle
βb  =  30°, and the eccentricity values between the upper and
lower center are set as 5 μm, 4 μm, 3 μm, 2 μm, and 1 μm,
respectively.
5.2.1.  Pitch deviation measurement and compensation.  For
different eccentricity values, the alignment angle errors of the
gear axis included in pitch deviation measurement results of
each tooth of the gears are also different. The comparisons are
shown in figure 11 (for Gear A) and figure 12 (for Gear B).
Figures 11 and 12 show that before compensation, as the
eccentricity values change, the maximum alignment angle
error in pitch deviation of all teeth of the gears is about 0.9 μm,
Meas. Sci. Technol. 27 (2016) 055006 Y Liu et al

Figure 12.  Alignment angle errors with different eccentricity values in pitch deviation measurement of all teeth of Gear B.

Figure 13.  Alignment angle errors with different eccentricity values in pitch deviation measurement for the selected measuring points of
Gear A.

Figure 14.  Alignment angle errors with different eccentricity values in pitch deviation measurement for the selected measuring points of
Gear B.

8
Meas. Sci. Technol. 27 (2016) 055006
Figure 15.  Compensation effects of pitch deviations with different eccentricity values (Gear A).
and the minimum value is about 0.15 μm. However, the
residual alignment angle errors of the two gears are less than
0.1 μm after compensation.
We also select 30 measuring points along the helix curves
on both one tooth and its adjacent tooth flanks of the gear,
and research the effect of the alignment angle error for the
measuring points with different heights along the facewidth
of the gear.
The comparison of the alignment angle errors for the
selected measuring points before and after compensation is
shown in figure 13 (for Gear A) and figure 14 (for Gear B).
Figures 13 and 14 show that, as the Z coordinate values of
the measuring points increase, the alignment angle errors of
the selected measuring points increase slowly.
5.2.2. Compensation effects.  We also take the 30 selected
measuring points of Gear A as an example to analyze the com-
pensation effects in pitch deviation measurement with differ-
ent eccentricity values. From figure 15 we can see that when
the eccentricity values change, the compensation effects are
more than 90%, and furthermore, the compensation effects are
not changed along with the different eccentricity values.
From figures 11–15, we can see that after compensation,
more than 90% of the alignment angle errors in pitch deviations
decline, and the residual errors are less than 0.1 μm. We can also
notice that the residual alignment angle errors after compensa-
tion become samller when the eccentricity values decrease.
6. Conclusion
This paper proposes a compensation method for alignment
angle error of the gear axis included in tooth pitch deviation
measurement results. Simulation experimental results show
that the proposed compensation method can decrease the
alignment angle error significantly.
For different helix angles, the alignment angle errors in
pitch deviations are more than 0.6 μm. For different eccen-
tricity values, the minimum alignment angle error in pitch
deviations is about 0.15 μm. After compensation, the residual
alignment angle errors in pitch deviations are less than 0.1 μm.
9
Y Liu et al
Simulation experimental results show that more than 90% of
the alignment angle errors of the gear axis are compensated
for by the presented compensation method, and this method is
helpful for the precision measurement of involute gears.
Acknowledgments
This research is supported by the Science and Technology
Research Project of Zhejiang Province under Grant No.
2014C31094, the Fundamental Research Funds for the
Central Universities of Chang’an university under Grant No.
310825161006 and the Science and Technology Project of
Xi’an city under Grant No. CX12176③. The author would like
to thank Dr X Li and Mr N Cao for their support in this paper.
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