Gear data exchange: Optimising design and manufacturing

Since 2003, the VDI/VDE Society for Measurement and Automation Technology has established a guideline for the data interchange standard for gears. The VDI/VDE 2610 ‘Exchange format for gear data – Gear Data Exchange Format (GDE Format)’ facilitates the electronic transfer of all geometric parameters for cylindrical gears. It serves primarily in industries that design, manufacture, and analyse gears, such as automotive, aerospace, and machinery. 

GDE aims to establish a standardised format encompassing all geometric specifications for cylindrical gears. This specification would facilitate a smooth transfer of gear data across design, manufacturing, and quality assurance departments. 

GDE not only includes the nominal geometry of cylindrical gears but also contains the specifications for the metrological analysis. It encompasses the scope of quality assurance as well as the specifications of the manufacturing parameters for a variety of production steps in gear manufacturing. 

It also represents a primary data set for various software packages involved in the gear lifecycle. GDE also serves as a digital data carrier for the exchange of metrological data, such as acquired measurement data and calculated evaluations. The GDE exchange file becomes the golden master for all specifications and analysis documentation for cylindrical gears.

Figure 1. Cylindrical gear measurement and data exchange. 

Benefits of GDE

Interoperability: GDE enables seamless exchange of gear-related data between different software applications used in design, manufacturing, and analysis. GDE facilitates interoperability between various software tools used in various stages of the gear manufacturing process, such as CAD (Computer-Aided Design), CAM (Computer-Aided Manufacturing), CAE (Computer-Aided Engineering), and PLM (Product Lifecycle Management) systems. 

This interoperability ensures accurate and efficient data transfer by eliminating the need for manual intervention or data re-entry.

Improved Efficiency: GDE helps save time and resources by streamlining data exchange processes. Engineers and designers can focus more on design iterations, optimisation, and analysis rather than dealing with data conversion or compatibility issues between software tools.

Reduced Errors: Manual data entry and conversion processes are prone to errors. GDE minimises the risk of errors associated with transferring data between different systems, leading to higher accuracy in gear design and manufacturing.

Enhanced Collaboration: GDE facilitates collaboration among different teams and departments involved in the gear manufacturing process. Engineers, designers, manufacturers, and analysts can easily share and access gear-related data, fostering better communication and teamwork.

Cost Savings: GDE can help reduce software procurement and maintenance costs by eliminating the need for redundant software licences or custom data conversion tools. Additionally, reducing errors and rework can lead to cost savings associated with scrapped parts or delayed projects.

Faster Time-to-Market: GDE improves efficiency and reduces errors, expediting the gear design and manufacturing process, resulting in shorter development cycles and faster time to market for new products.

Standardisation: GDE promotes the use of standardised data formats for gear design and manufacturing, ensuring consistency and compatibility across different software platforms and systems.

Structure of a GDE file

Leveraging XML’s flexible structure, gear data can be seamlessly exchanged between design, manufacturing, and quality control software, streamlining the entire gear production process.

A GDE file primarily consists of three sections: “Identification,” “Geometry,” and “Inspection.” These divisions are subdivided as required to detail all relevant gear specifications thoroughly. Additional details can also be included in a “User” section if needed. 

The main sections are again divided into logical sections to capture and organise Gear data, Process data, and Tool data. Geometry includes basic geometry, modifications, tolerances, inspection, measurement conditions, and measurement results. Additional Identification metadata, including customer ID, order number, and drawing number, can also be added to help with categorisation and discoverability. 

To ensure that every software system can reliably import and process consistently structured GDE files, the VDI offers validation files for the respective GDE version, with which a quality check can be carried out.

QUINDOS metrology software 

QUINDOS is the leading modular metrology software for gearing inspection and analysis. Part of Hexagon’s ecosystem of industry-leading software applications and metrology devices, It connects with a wide range of CMMs and sensors to deliver effective gear measurement solutions.

The power of QUINDOS comes from the additional Special Geometry modules, which can be added to the core QUINDOS application. They offer an unrivalled portfolio of modules for powertrains with challenging measurement and evaluation strategies.

The industry-tested modules comply with international standards and guidelines and have been integrated with QUINDOS to deliver automated measurement and evaluation and enable guided routines for operators.

By using a standardised data format like GDE, QUINDOS is able to share data with other software tools or systems to seamlessly exchange gear data without the need for manual transfer or re-entry of information. This helps improve interoperability and efficiency in the design and manufacturing process of gears.

Romax Enduro 
Romax Enduro is part of the Romax Software Suite, an integrated set of applications for the design and simulation of ePowertrains and other geared rotating systems.

It provides rapid and intuitive modelling, detailed structural simulation, and component rating for powertrain durability design, analysis, and optimisation. Enduro helps powertrain engineers and gear designers from small and large OEMs, as well as suppliers and service providers, design durable and robust geared electro-mechanical systems.

Its rapid modelling and analysis make it suitable for designing space exploration and asking what-if questions to improve the performance and robustness of any rotating machine, from initial concept design through to design for manufacturing and virtual testing. 

Gears are a hallmark feature of Romax software. Romax Enduro offers a wide range of features related to gear modelling and design, rating, analysis, optimisation, and manufacturing simulation. 

Gear design software allows for three levels of gear representation: loading gears for quick iteration of ratios and layouts, concept gears to choose module and tooth count combinations, and detailed gears with complete macro and micro-geometry.

The micro-geometry can be defined from typical design inputs such as crowning, slope, tip relief, etc., specified as an arbitrary grid or imported from measurements using Gear Data Exchange (GDE) format from metrology systems such as QUINDOS.