Overview > CCM Closed Loop System

CCM Closed Loop System

CCM Closed Loop System
Arrow Gear's CCM Closed Loop System allows for the electronic interchange of data for design assistance, manufacturing
and inspection.

Arrow was the world's first gear manufacturer to implement a fully integrated in-house Computer Controlled Manufacturing Closed Loop System. The system allows for the electronic interchange between design assistance, gear manufacturing and inspection - resulting in a highly efficient process for manufacturing bevel gears.

To communicate the scope and details of Arrow's CCM Closed Loop System, an interactive multimedia presentation entitled, "A New Era" is available. In addition, a printed brochure of the same title can be ordered or downloaded from this website. To request these materials, please follow this link to the Materials Request page.

For an overview of the CCM Closed Loop System, please see the information below.


Highlights of Arrow Gear's CCM Closed Loop System

1) Gleason Phoenix Cutter 2) CNC Inspection System 3) Gleason Phoenix Grinder
Gleason Phoenix Cutter Zeiss/Hofler Inspection System Gleason Phoenix Grinder
Machine settings are downloaded to the Gleason cutting machines from Manufacturing Engineering. These settings are made automatically.

Through topographical plotting, the part is checked by the CNC Inspection System. Necessary corrective adjustments are then sent directly to the Gleason cutting machine. The system is also used to control settings on the Gleason tooth grinders. Optimal settings are achieved much faster than with conventional techniques.
Overview of the CCM Closed Loop System

To provide a comprehensive explanation of how the CCM Closed Loop System works, we need to look at the step-by-step process that a typical gear order would follow.

1) Design Assistance by Arrow Gear Engineers
The process begins with Arrow receiving design information and requirements from the customer via electronic media. Once this is received, design engineering assistance takes place. Requiring only gear blank or envelope size and performance requirements, Arrow’s engineers use the Siemens NX Unigraphics System to perform the design assistance work.

2) Manufacturing Engineering
Once design engineering is complete, files are sent to Manufacturing Engineering. Using Gleason CAGE software, the machine settings or summaries are calculated to accurately machine the part. Arrow’s engineers also use CAGE software to analyze the tooth surfaces and their mating contact pattern characteristics before machining operations are performed. This is done through Loaded Tooth Contact Analysis (TCA), which simulates the tooth contact pattern under load. Gleason Finite Element Analysis software is then used to perform real stress analysis of the entire tooth surface and root fillet.

3) Tooth Cutting Machine Setup
After the summary is prepared, machine settings are downloaded from the CAGE software to the Phoenix Gear Cutting Machine. In this step, all machine adjustments are made automatically. After the adjustments are made, the first piece or setup gear is then machined.

4) Inspection of Tooth Cutting
Meanwhile, the digitized master coordinates or the baseline file for the gear are downloaded from the CAGE software to the Coordinate Measuring System (CMS) which will perform the CNC inspection. Once the setup gear has been machined, it is then checked on the CMS to compare the actual tooth surface to the digitized master or baseline file. Using the Gleason GAGE Inspection Analysis software, the CMS measures any deviations in the setup and subsequently determines the required settings adjustments for the Phoenix Cutting Machine.

5) Final Tooth Cutting Adjustments
Required changes are then downloaded to the Phoenix Cutting Machine. The adjustments are again made automatically to the machine. A second gear is then cut, or a trim cut is performed on the setup piece.

6) Final Tooth Cutting Setup Inspection
After machining, the setup gear is inspected again. Once optimal settings are achieved, the production run begins.

7) Tooth Grinding Machine Setup
After tooth cutting and final heat treatment operations take place, the high precision operation of tooth grinding is performed. The process for setting up the Phoenix Grinder is identical to that of the Phoenix Cutting Machine. The CAGE software has prepared the summary for the tooth grinding process. The theoretical settings are downloaded to the Phoenix grinder. As with the cutter, machine adjustments on the machine are made automatically. The setup gear is then ground.

8) Inspection of Tooth Grinding
The tooth ground part is then inspected on the CMS. Any deviations are measured, and the GAGE software determines the required changes.

9) Final Tooth Grinding Adjustments
Required changes are then downloaded back to the Phoenix Grinder - automatically adjusting machine settings. Typically, optimal settings are achieved in one or two corrections.

10) Final Tooth Grinding Setup Inspection
After machining, the setup gear is inspected again. Once optimal settings are achieved, the production run begins.