Guideway and slide tightness adjustment of the whole strategy: from inspection to commissioning
First, the basic preparation before adjustment: cleaning and installation calibration
In the adjustment of the guide rail and the slider before the tightness, need to do two basic work:
Thoroughly clean the guide rail system
Use anhydrous alcohol or special cleaner, with a dust-free cloth to wipe the surface of the guide rail, the inside of the slider and the raceway, to ensure that there is no oil, dust or metal debris residue. Pay special attention to the grooves of the ball guide and the oil film area of the sliding guide to avoid impurities affecting the adjustment accuracy.
Calibrate the installation accuracy of the guide rail
Use a level meter to check the level of the guide rail, to ensure that the single guide rail is smooth throughout the whole process without obvious tilt.
For double guide rail system, you need to use a micrometer to measure the parallelism of the two guide rails to ensure that the direction of movement is the same.
Check the coaxiality of the installation of the slider and guide rail, manually push the slider, to confirm that there is no obvious stagnation or offset.
Second, the core steps of ball guide tension adjustment
Ball guide is commonly used in high-precision, high-speed scenes, the focus of the adjustment is to control the preload and clearance:
(1) according to the use of demand adjustment of preload force
Precision positioning scene (zero clearance):
Loosen the slider fixing screws (retaining a slight preload), and slowly apply pressure in the direction of the guide rail with a wedge or a special tool.
At the same time, use a micrometer to monitor the displacement of the slide. When the needle oscillation is controlled to a very small range (e.g. no visible wobble), tighten the screws according to the manufacturer's specified torque (e.g. M8 screws usually require a force of 12-15 Nm).
Push the slider manually and you should feel an even resistance without any obvious stuttering.
High-speed movement scenario (slight clearance):
If you need the slider to move more flexibly, you can add or subtract thin shims (thickness 0.01 mm / piece) between the slider and the mounting surface, retaining a gap of 0.01-0.03 mm, and prioritize the adjustment of the non-driven side of the guide rail to balance the load.
(2) Synchronized adjustment of multi-slider system
For the structure of multiple sliders connected in series or parallel, the adjustment should be carried out sequentially from the middle to the ends, or use a torque wrench to synchronize the tightening of the screws to ensure that the slider force is consistent, to avoid deformation of the guide rail due to uneven force.
(3) abnormal problem handling
If the slider moves suddenly stagnation, need to check the raceway whether there are foreign objects, ball wear or partial deformation of the guide rail, if necessary, disassemble and clean or replace parts.
If the slider shaking obviously, may be insufficient preload, can be replaced with a higher preload level slider (such as upgrading from medium preload to high preload).
Third, the sliding guide tension adjustment points
Sliding guide (such as plastic guide, static pressure guide) adjustment focuses on the gap and oil film control:
(A) liquid hydrostatic guide oil film adjustment
Through the hydraulic system to adjust the oil supply pressure, so that the guide and the slider between the formation of a stable oil film (thickness usually 5-10 microns). If the amount of return oil increases abnormally, it may be that the gap is too large, you need to fine-tune the guide and the slider with the spacing, to ensure that the oil film is uniformly loaded.
(B) the mechanical gap adjustment of the molded guide rail
Wedge iron adjustment method:
Loosen the wedge iron fixing screw, with a ruler to measure the guide rail and slider gap (target value 0.02-0.04 mm).
Slowly rotate the wedge iron adjusting screw (each rotation should not be too large), until the plug ruler to feel a slight resistance when pumping, and then lock the screw.
Wear-resistant sheet maintenance: If the paste plastic layer is seriously worn (more than 0.1 mm), it is necessary to re-paste the PTFE wear-resistant sheet and grind it to the fitting precision.
Test run and performance verification after adjustment.
After completing the adjustment, it is necessary to check the effect through actual operation:
Manual test: slowly push the slider, feel whether the movement is smooth and even, no "crawling" or "jumping" feeling.
Noise check: listen to the operation of whether there is abnormal sound (such as ball noise, friction noise), under normal circumstances, the ball guide noise should be lower, the sliding guide should be quieter.
Precision recalibration:
Use a micrometer to detect the straightness of the slider movement, the whole error should be controlled in a small range (such as every 500 mm error ≤ 0.01 mm).
For high-precision equipment, laser interferometer can be used to test the repetitive positioning accuracy to ensure that it meets the process requirements.
Lubrication supplement: add grease or lubricant (lithium grease for ball guide, lubricant for sliding guide) to the guide in time after adjustment to ensure adequate lubrication and reduce friction and wear.
Fifth, common problems and solution ideas
Slider jamming: may be too much preload or raceway with foreign objects, need to reduce preload or re-clean the guideway.
High-speed vibration: may be too large a gap or guide rail parallelism deviation, need to increase the preload or recalibrate the guide rail installation.
Inaccurate positioning: check whether the mounting screws are loose, whether the guide rail is deformed, according to the standard torque to tighten or straighten the guide rail.
Operation Precautions
Before adjustment, be sure to cut off the power supply of the equipment and fix the mechanical parts to avoid the danger caused by accidental contact.
Adjustment details of different brands of guide rails may be different, it is recommended to refer to the manufacturer's manual (e.g., THK, HIWIN and other brand guidelines).
Regular maintenance (e.g., inspection every 500 hours of operation) can detect gap changes in time and extend the service life of the guideway system.
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