Integrated Framework for Inspection, Functional Modeling, and Wear Compensation of Gears in Circular Production

Gears are among the most challenging components to reuse in circular production, since their load-bearing function demands high precision while their geometries inevitably deviate from original tolerances after service. In industrial practice, these deviations typically lead to rejection, as inspection criteria are often identical to those used for new parts. This rigid, tolerance-driven approach discards many components that may still function acceptably, highlighting the need for methods that assess gears on the basis of performance rather than dimensional conformity. This paper presents a function-oriented framework for gear wear compensation that combines high-precision metrology, functional modeling, and adaptive tolerance management. The methodology predicts gearbox performance directly from geometry measurements and restores functionality through selective pairing, adaptive manufacturing of complementary gears, or reprocessing of the worn gear itself. Functional testing in a virtual environment validates predicted outcomes prior to physical implementation. By prioritizing functional fulfillment over strict adherence to original tolerances, the proposed framework extends the usable life of gears and reduces material waste enabling circular production for complex gear systems.