High-Precision Measurement of Gear Geometry with Intelgic’s AI-Driven Vision Systems
Gears are at the heart of countless mechanical systems—automotive transmissions, industrial gearboxes, robotics, wind turbines, and heavy machinery. Even a minor deviation in gear geometry can lead to noise, vibration, premature wear, or catastrophic failure. Traditional gear inspection methods, while accurate, are often slow, contact-based, and unsuitable for modern high-throughput manufacturing.
At Intelgic, we use laser-based 3D cameras (3D laser profilers) combined with advanced algorithms to perform non-contact, high-accuracy, and repeatable gear inspection directly on the production floor. This approach enables comprehensive measurement of critical gear parameters such as measurement over rollers, tooth thickness, tooth depth, outside diameter, and many other checkpoints—all from a precise 3D point cloud.
Why Laser-Based 3D Inspection for Gears?
Unlike 2D imaging systems that rely on contrast and lighting alone, laser-based 3D cameras project a laser line onto the gear surface and capture its deformation using high-resolution sensors. As the gear moves—or rotates on a controlled stage—the system reconstructs a true 3D model of the gear.
Non-contact inspection
No mechanical wear, no risk of surface damage
Micron-level accuracy
Ideal for tight gear tolerances
Material-independent
Works on dark, shiny, oily, or machined metal surfaces
Production-ready
Suitable for in-line or near-line inspection
Core Gear Measurements Using 3D Laser Profiling
Measurement Over Rollers (MOR)
Measurement over rollers is a critical parameter used to verify the effective tooth thickness and pitch diameter of gears.
Using 3D point-cloud data:
- The system virtually places rollers at precise contact points on opposing teeth
- The distance between these contact points is calculated digitally
- Results are highly repeatable and independent of operator skill
This eliminates manual handling and variability common in traditional roller-based gauges.
Tooth Thickness Measurement
Tooth thickness directly affects gear meshing quality and load distribution.
With Intelgic's 3D inspection:
- Each gear tooth is segmented from the point cloud
- Cross-sections are generated at defined reference circles
- Tooth thickness is measured precisely and compared against CAD tolerances
The system can measure every tooth, not just samples—ensuring 100% quality control.
Tooth Depth & Root Geometry
Accurate tooth depth and root profile are essential for gear strength and fatigue life.
Laser-based 3D cameras enable:
- Exact measurement from tooth tip to root
- Detection of undercuts, shallow roots, or machining inconsistencies
- Validation of root fillet geometry against design specifications
This is especially important for high-load gears used in automotive and industrial applications.
Outside Diameter (OD)
Outside diameter impacts gear engagement and assembly fitment.
From the reconstructed 3D model:
- The system fits a virtual circle to the outermost tooth tips
- OD is calculated with high precision
- Ovality and runout can also be derived from the same dataset
Unlike contact gauges, this method works seamlessly even on rotating or partially accessible gears.
Additional Gear Checkpoints
Beyond primary dimensions, Intelgic's system can inspect many additional parameters, including:
All measurements are derived from a single 3D scan, reducing cycle time and system complexity.
Inspection Workflow with Intelgic's 3D Vision System
Gear positioning
The gear is placed on a conveyor, fixture, or rotary stage
3D scanning
Laser profiler captures high-density height data as the gear moves or rotates
Point-cloud generation
A detailed 3D representation of the entire gear is created
Algorithmic measurement
Software automatically extracts all required dimensions and features
Tolerance validation
Measurements are compared with CAD or predefined limits
Pass/Fail decision & reporting
Results are logged, visualized, and optionally integrated with MES or ERP systems
In-Line and Automated Inspection Ready
Intelgic's laser-based gear inspection systems are designed for automation-first manufacturing environments. They can be seamlessly integrated with:
- PLC-controlled rotary stages
- Robotic loading and unloading systems
- Encoders for precise motion synchronization
- Production databases and quality dashboards
This makes them ideal for 100% in-line inspection, not just offline sampling.
Why Manufacturers Choose Intelgic for Gear Inspection
Complete solution
3D cameras, motion systems, and inspection software
High accuracy & repeatability
Suitable for critical gear components
Scalable architecture
From pilot setups to full production lines
Future-ready
Combines 3D metrology with AI-based defect detection
Laser-based 3D camera inspection represents a major leap forward in gear metrology. By capturing the complete geometry of a gear as a precise point cloud, manufacturers can accurately measure measurement over rollers, tooth thickness, tooth depth, outside diameter, and many other checkpoints—all without physical contact and at production speed.
With Intelgic’s AI-driven machine vision systems, gear inspection becomes faster, more reliable, and fully digital, enabling manufacturers to achieve higher quality, lower scrap, and greater confidence in every gear they produce.
