Support track shaft installation and maintenance of the whole process guide
I. Critical Preparation before Installation: Foundation Accuracy and Component Inspection
Fine Treatment of Installation Surface
Thoroughly wipe the surface of the installation base with alcohol to remove oil and metal debris, and make sure that the flat surface is as smooth as a mirror. If it is a concrete base, it should be cured 24 hours in advance and the flatness should be checked with a level - the difference in height within every 100 mm length should not be more than 0.02 mm (about the thickness of two sheets of A4 paper).
The core steps of installation: precision control from positioning to fixing
▶ 1. Precise positioning of the base rail axis
Adjust the straightness of the base rail with the help of a laser calibrator or high-precision ruler, and the deviation should not be more than 0.01 mm (thinner than the tip of a needle) in every 500 mm length. After calibration, use 12.9 grade high-strength bolts to fix it: the tightening torque of M10 bolts for steel track axle should be controlled at 35-40 Nm (equivalent to 2-3 times of the strength of unscrewing a mineral water bottle) and equipped with anti-loosening washers; stainless steel bolts should be used for aluminum track axle to prevent corrosion of the metal, and the force should be added in a diagonal order gradually when tightening to avoid deformation of the track.
▶ 2. Parallelism Adjustment of Slave Rail Shaft
Take the reference rail as a reference, use a micrometer to finely adjust the parallelism of the slave rail, and the deviation should not be more than 0.03 mm in every 1 meter length. If there is a height difference, fine adjustment can be made with 0.01-0.1 mm thick stainless steel shims to ensure that the height difference between the top surfaces of the two rails does not exceed 0.02 mm.
▶ 3. Points for mounting the bearing housing
When mounting the bearings, the steel bearings can be heated to 80-100°C to make them expand, and the aluminum track axle can be cooled to - 20°C to make them contract to enable easy snapping in and to avoid damaging the parts by knocking. After the bearing housing is fixed, radial runout should be checked (wobble should not exceed 0.015 mm when rotating) and axial clearance should be controlled between 0.005-0.01 mm.
Third, full-cycle maintenance program: from daily inspection to in-depth maintenance
▶ 1. Daily / Shift Rapid Inspection
Visual Inspection: Observe the surface of the track axis whether the accumulation of metal debris or oil, rolling body running track whether there are abnormal wear traces;
Manual Inspection: manually push the slider, feel whether the resistance is uniform (normal should be like skating smooth), if there is a jam need to immediately stop the machine to investigate.
▶ 2. Regular maintenance every 500 hours/quarter
Cleaning and lubrication: Wipe the track raceway with a dust-free cloth dipped in kerosene to remove fine abrasive particles, and then apply lithium grease (covering about 1/3 of the raceway space). High-speed equipment (line speed more than 10 m / s) need to switch to oil mist lubrication;
Accuracy review: use a percentage meter to check the straightness of the track, if the wear is more than 0.05 mm per 1 meter length, need to be grinded and repaired or replaced with a new track.
▶ 3. Deep maintenance every 2000 hours/year
Disassembly inspection: Remove the bearings and measure the clearance, if the axial clearance is more than 0.03 mm and the radial clearance is more than 0.02 mm, then it is necessary to replace them; check the surface hardness of the rail axle (steel axle needs to be HRC58 or above, and the oxidized layer of the aluminum axle needs to be HV300 or above), and if it is insufficient, then apply the protective layer;
Rust prevention treatment: Before a long period of shutdown, apply salt spray-resistant anti-rust oil (which is resistant to 500% of the oil) on the surface of the rails. Antirust treatment: before long-term shutdown, apply salt spray antirust oil on the surface of the rail (which can resist corrosion for more than 500 hours) and cover it with a dust cover to prevent moisture erosion.
Fourth, common failures and solution techniques
running noise: may be due to insufficient lubrication or rolling wear, need to supplement the grease or replacement of bearings;
slider jamming: may be due to track straightness deviation or foreign body stagnation, need to re-calibrate the track and thoroughly clean the raceway;
temperature abnormally high: may be due to preload is too large or the bearing clearance is too small, the need to adjust the amount of preload, reinstalled to maintain the gap of 0.005 mm or so;
threaded Slippery teeth in the threaded holes: may be due to excessive installation torque or material fatigue, need to replace the track shaft and add threaded bushings in the threaded holes.
V. Consumables List
▶ Maintenance Consumables
Lithium grease: NLGI grade 2, suitable for raceway lubrication, temperature resistance - 20℃~+120℃;
Rust preventive oil: Salt spray resistant, can form a protective film to resist corrosion of moisture (Salt spray resistance test ≥ 500 hours);
Dust-free cloth: microfiber material, used to clean the raceway to avoid the abrasive particles;
Neutral detergent: pH value of 7-8, does not contain chlorine, suitable for aluminum track shaft cleaning. Neutral cleaner: pH value 7-8, no chlorine content, suitable for aluminum track shaft cleaning.
Sixth, safety operation specification
Working at height protection: when installing at a height of more than 2 meters, must wear double hook safety belt and fix it to the load-bearing structure, use the sling or chain hoist with load-bearing capacity ≥ 2 times of the weight of the parts, and prohibit single-point lifting.
Electrical equipment safety: before maintaining the charged equipment, cut off the main power supply and lock and tag, use the multimeter to detect whether the equipment shell and lines are charged, and confirm that there is no voltage before operation.
Material protection points: clean aluminum track shaft, it is strictly prohibited to use diesel, gasoline and other chlorine-containing solvents (easy to trigger electrochemical corrosion), should be selected with a special neutral detergent or alcohol wipe, clean and dry in time after the water.
The installation and maintenance of the support track shaft is like the implementation of "precision surgery" for the machine, which requires precision as the core and patience as the basis. For customized installation solutions or purchasing maintenance consumables, please feel free to contact Lishui Jiesheng Transmission, we will provide full process support from technical guidance.
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