DESIGN AND FABRICATION OF

GEAR DEFECT DETECTION

ABSTRACT

 Appearance defects inspection plays a vital role in gear quality control.

Human inspection is a traditional way to remove defective gears, which
is instable and time consuming.
 we develop a machine vision system for gear defect inspection, which
can inspect various types of defects on gear, such as deformations, rusts,
scratches and so on.
 The proposed system designs a novel image acquisition system to
enhance the defects appearances and get controlled image acquisition
environment.
 A series of image processing methods are proposed or utilized to inspect
the defects.
 The proposed system is evaluated and compared with skilled human by
the recall, precision and F-measure. Experimental results show that the
proposed vision system has high accuracy and efficiency
 INTRODUCTION
 In the industry of machinery, gears are important
components that connect different machine parts to
transmit motion.
 They have been widely used in cars, and many other
rotating machines. The quality of gears can directly
influence the performance of many machines, and
may even cause serious disasters.
 Gears are usually mass-produced with high demand
of precision, and a lot of inspection measures have
been adopted in the production process to ensure the
quality of gears.
TYPES OF GEAR DEFECTS
LITERATURE SURVEY
"Detecting Gear Surface Defects Using
Background-Weakening Method and
Convolutional Neural Network" by Liya Yu,
Zheng Wang, and Zhongjing Duan 19
November 2019.
"Design of Gear Defect Detection System
Based on Machine Vision” by Yu Wang1 ,
Zhiheng Wu1 , Xianyun Duan1 , Jigang
Tong1 , Ping Li1 and min Chen1 , Qinglin Lin2
2017.
In this paper, the gear defect is located by a deep
learning algorithm, which lays a foundation for
more precise quality inspection such as the
subsequent dimension measurement. The
traditional detection of gear manufacturing defect
detection is based mainly on machine vision in
which the contour extraction algorithm is often
used to extract the image features of a single gear
For high speed automatic production lines, using
machine vision method,through access to
detecting object image quality detection, and
machine vision system has simple structure, easy
to move, quick and advantages, such as data
acquisition, required by the visual sensor module
is relatively simple.
 "Investigation of the influence of oil film
thickness on helical gear defect detection using
Acoustic Emission" by Mhmod Hamel,
Abdulmajid Addali, David 2014.
"GEAR CLASSIFICATION FOR DEFECT
DETECTION IN VISION INSPECTION
SYSTEM USING DEEP CONVOLUTIONAL
NEURAL NETWORKS" by Imam Mustafa
Kamal1, Riska Asriana Sutrisnowati2 Hyerim
Bae3, and Taesoo Lim August 2018.
"New approach for gear mesh stiffness
evaluation of spur gears with surface defects"
by Bilal El Yousfia, , Abdenour Soualhia ,
Kamal Medjaherb , François Guillet 7 JULY
2020.
The purpose of lubrication is to ensure an oil
film separates the gear teeth at the meshing area .
Depending on the lubricant film thickness three
different lubrication regimes can be
distinguished: Hydrodynamic lubrication, Elasto-
hydrodynamic lubrication and Boundary
lubrication. Mixed lubrication refers to the
intermediate regime between EHL and boundary
lubrication.
For automatic detection of defective gears, we
propose the use of deep learning with two kinds
of classification approaches, namely the Na¨ıve
approach and the fine grained approach. The
Na¨ıve approach allows deep convolutional
neural networks to directly classify defects and
non-defects in gear images,&the fine-grained
approach harnesses an image processing
technique before using CNN.
Gear tooth surface fatigue is one of the most
common failure modes of gears. Surface fatigue
manifests on two principal phenomena, namely
spalling and pitting. Spalls are localized cavities
on the teeth surface with relatively important
depths, whereas pits are distributed cavities on
all the teeth surface with small depths
PROBLEM STATEMENT
After the manufacturing process of Gears,
to maintain the quality of the product,
inspection of the manufactured gears is
necessary.
But precise inspection of such high
quantity gears is the difficult task. So to
inspect the bulk quantity of manufactured
gears this project is invented.
OBJECTIVE

 To inspect the manufactured Gears.

 To study the nature of defect using the data
collected during the ML process.
 To design a CATIA model.
 To carry out the experimental testing & draw the
result & conclusion.
METHODOLOGY
Step 1: - We started the work of this project with literature survey with the
help of research papers. We gathered many research papers which are
relevant to Defect detection process.
Step2: - After that we discussed about components which are required for
our project.
Step 3: - After deciding the list of components, Concept 2D and 3D
modelling are done by CATIA software.

Step 4: - The components will be manufactured and then assembled together.

 Step 5: - The testing will be carried out and then the result and conclusion
will be drawn.
BASIC DESIGN CALCULATIONS-

Design of belt conveyor-

For the design of conveyor, we are considering some data,

1. We are designing the belt conveyor for light utility, so we took its material as
Rubber.

2. Density of rubber=1522kg/m3

3. Minimum thickness of belt=1.5mm

4. Length of the conveyor(L)=2.5 feet=762mm

5. Mass of the belt=1.7396 kg

6. Coefficient of friction between bottom surface of the belt and top surface of
the rollers having length 200 mm (u)=0.4 (Empirical experimental value)

7. RPM of the rollers (N)=10

8. Mass of the objects placed on conveyor= (25gram*40 pieces of gear )=1 kg.
 Now,

The linear speed of belt conveyor is calculated as, (Here take N=10rpm)

V=2*3.14*N/60

V=1.047 m/s

Now total vertical force applied by packages on belt conveyor

F=(Total mass of gears)*(Acceleration due to gravity)

=(1)*(9.81)

F1=9.81 N

Total weight of the belt=(Mass of belt )*(Acceleration due to gravity)

F1=(1.7396)*(9.81)

F2=17.065 N
Total belt pull=[(Total weight of all packages)+(Total weight of the
belt)]*(Coefficient of friction between belt and rollers)

=[(9.81)+(17.065)]*(0.4)

F =10.755N

Now the total required power to move the conveyor belt is calculated as,

P=(Belt pull)*(Belt speed)

=10.755*1.047 N-m/s

P=11.255 Watts-----------------A

Now we have to give more power than A to move the belt, so select the drive
accordingly.

Here we have taken 12V&2A motor which produces 24-Watt power, so our
design is safe.
Design of the motor used for separator-

For 24 Watt motor at 30 rpm we get 7.63 N-m torque.

So for motor connected with (100mm*100mm*5mm)

separator, the required torque = 0.02 N-m

Hence our design is safe.

ANALYSIS OF DEFECT
DETECTION
SOFTWARE USE - ANSYS 19
GEOMETRY
MESHING
BOUNDARY CONDITION
 BOUNDARY CONDITION 1
Fixed support
 BOUNDARY CONDITION 2

Force applied on belt which is

weight of object place on belt.
So we consider 1kg weight of object
1 X 9.81 = 9.81 N.
 BOUNDARY CONDITION
Standard earth gravity which is
9.81 m/s2
RESULT - TOTAL DEFORMATION
RESULT - EQUIVALENT STRESS
 CONCLUSION
 In this project we perform static analysis on defect
detection cad model using ANSYS software.
 In stactic analysis we find out Total deformation
and equivalent stress generated on body.
 The maximum deformation and equivalent stress
generated on structure is 0.175 mm and 2.77 MPa
respectively.
 The generated stress is not above than yeild point
of material which we use to manufacture the
structure, so our design is safe.
REFERENCE
 Machine parts recognition and defect detection in
automated assembly systems using computer vision
techniques P.Arjun and T.T.Mirnalinee
 Automatic Metallic Surface Defect Detection and
Recognition with Convolutional Neural Networks Xian
Tao , Dapeng Zhang , Wenzhi Ma , Xilong Liu and De
Xu
 Research Progress of Visual Inspection Technology of
Steel Products—A Review Xiaohong Sun , Jinan Gu ,
Shixi Tang and Jing Li
 Automatic Damage Detection of Fasteners in Overhaul
Processes by Sajjad Taheritanjani, Ralf Schonfeld