Guideway level adjustment: key points and practical methods
In machinery manufacturing, automated production lines, CNC machine tools and other equipment, the horizontal state of the guideway directly affects the operating accuracy, stability and service life of the equipment. Improperly adjusted guideway level will lead to problems such as table movement jamming, machining size deviation, and increased equipment vibration. Mastery of the main points of the guide rail level adjustment and practical methods, is to protect the key to efficient operation of the equipment.
First, the core points of the guide rail level adjustment
(1) the selection of the reference surface and processing of the guide
rail installation of the reference surface is to ensure that the level of adjustment of the accuracy of the foundation. The datum surface needs to have a high degree of flatness and surface roughness, usually required to control the flatness error within 0.01mm/m, surface roughness Ra ≤ 1.6μm. in the installation of the guide rail, the datum surface needs to be strictly inspected, if there is a bulge, depression, or impurities, need to be repaired by grinding, milling and other ways, or the use of a dust-free cloth, compressed air to thoroughly clean, to avoid the datum surface is not flat, resulting in a twisted, tilted guide rail after installation. Guide rail installation after distortion, tilt. For example, when installing the guide rail in the bed of CNC machine tools, it is necessary to carry out high-precision grinding on the surface of the bed to ensure that its flatness meets the requirements, and lay a good foundation for the subsequent installation of the guide rail.
(2)Measuring tools accuracy of high-precision
measuring tools is to realize the premise of accurate level adjustment. Commonly used measuring tools include level meter, laser interferometer, electronic level meter, etc. Different tools are suitable for different precision requirements and scenarios. Level meter is relatively inexpensive, applicable to the initial measurement of general precision equipment, its accuracy is usually 0.02mm/m; laser interferometer precision is extremely high, up to the nanometer level, commonly used in high-precision machine tools, semiconductor equipment, and other occasions on the level of the guide rail demanding; electronic level meter combines the advantages of high-precision and digital display, easy to operate, intuitive measurement results. In the choice of measuring tools, need to be based on the precision requirements of the equipment and budget reasonable selection, while ensuring that the measuring tool after regular calibration to ensure the reliability of the measurement data.
(3) Adjustment order and force balance
The level adjustment of the guideway should follow a scientific order, generally the first coarse adjustment, and then fine adjustment. Coarse adjustment, can be adjusted by adjusting the degree of tightness of the guide rail mounting bolts, roughly the level of the guide rail adjusted to a value close to the target; fine-tuning with the help of measuring tools, step by step fine-tuning, until the precision requirements. In the adjustment process, we should pay attention to the force balance, to avoid deformation of the guide rail due to the local force is too large or too small. For example, when tightening the guide rail mounting bolts, diagonal tightening method should be used, and gradually tighten it for many times, each time the tightening torque needs to be uniform and consistent, to ensure that the guide rail in the installation process to maintain a smooth, to prevent distortion and deformation.
( 4) the impact of environmental factors control environmental
factors have an important impact on the results of the guide rail level adjustment. Temperature changes will lead to thermal expansion and contraction of the guide rail and equipment base, thus affecting the level. Therefore, the adjustment work should be carried out in a constant temperature environment as far as possible, and if it is not possible to realize constant temperature, the temperature change needs to be monitored and compensated. In addition, vibration, airflow and other factors may also interfere with the measurement and adjustment process, should be selected less vibration, airflow stability of the site for operation, if necessary, isolation measures can be taken, such as laying vibration damping pads under the equipment, to reduce the impact of external vibration on the adjustment work.
Second, the guide rail level adjustment of practical methods
(1 ) level meter adjustment method
steps will be
placed in the guide rail at the beginning of the level meter, along the length of the guide rail every certain distance ( such as 300mm or 500mm ) for a measurement, and record the level meter readings. According to the measured data, analyze the level deviation of the rail. If the bubble of the level meter is biased to one side, it means that the side of the guide rail is high, and it is necessary to reduce the height of the side by adjusting the shims or adjusting bolts under the guide rail; on the contrary, it is necessary to raise the height of the side. After adjustment, use the level meter to measure again and repeat the above steps until the leveling error of the guide rail in the whole length range meets the requirements. Generally speaking, for ordinary precision equipment, the leveling error can be controlled within 0.05mm/m; for high precision equipment, the error should be controlled within 0.01mm/m. Application Scenario: The level meter adjustment method is easy to operate, low cost, and is suitable for the level adjustment of common mechanical equipments that do not require high precision, such as small machine tools, conveyor rails of automated production lines, and so on.
( 2) Laser Interferometer Adjustment Method Operation
Procedure
Fix the transmitter of the laser interferometer on a stable base, so that the laser beam emitted by it is parallel to the ideal axis direction of the guide rail; the receiver is mounted on the slider of the guide rail or on the working table, to ensure that it can accurately receive the laser signals. Start the laser interferometer, move the receiver along the length of the guideway, perform segmented measurements, and record the horizontal deviation data at each measurement point. The laser interferometer is able to display the measurement results in real time and present the leveling curve of the guideway in graphical or numerical form. Based on the measurement data, the guideway is precisely fine-tuned by adjusting the guideway's mounting bolts, shims or supports. During the adjustment process, the measurement data from the laser interferometer is continuously monitored until the level of the guideway reaches the accuracy standard required by the equipment. Application Scenario: The laser interferometer adjustment method is extremely accurate and suitable for high-precision machine tools (such as five-axis machining centers, coordinate boring machines), semiconductor manufacturing equipment (such as photolithography machines, wafer cutters) and other occasions with stringent requirements for the level of the guideway, and can meet the demand for nanometer-level precision adjustment.
(3) electronic level meter with the adjustment tooling method operation
steps will be
installed in the electronic level meter on the special adjustment tooling, adjustment tooling can be fixed in the guideway of the slider or the table, to ensure that the electronic level meter and the guideway to maintain parallel. Turn on the electronic level meter and set the measurement parameters, such as measurement distance, precision unit and so on. Move the adjusting tooling along the length of the guideway, the electronic level meter automatically collects and records the level data of each measuring point, and shows it in real time through the display. According to the measurement data of the electronic level meter, use the adjusting mechanism of the guideway (such as adjusting bolt, wedge block, etc.) to make adjustment. When adjusting, refer to the real-time feedback of the electronic level meter and fine-tune gradually until the levelness reaches the target value. The electronic level meter can also export the measured data for further processing and analyzing through the data analysis software, so as to have a more comprehensive understanding of the horizontal status of the guide rail. Application Scenario: The electronic level meter with the adjustment tooling method combines the high precision and digital advantages of the electronic level meter and the convenience of the adjustment tooling, which is suitable for all kinds of machinery and equipment to adjust the level of the guide rail, especially in the need for frequent adjustments or detailed analysis of the measurement data has obvious advantages.
Third, the core precautions in the adjustment process
( 1 ) safety regulations
before the operation of
the adjustment must cut off the power supply of the equipment, and in the power distribution cabinet hanging "prohibit closing the gate" warning signs. Operators need to wear anti-smash shoes, goggles and other protective equipment, demolition of heavy-duty rails to be assisted by hydraulic jacks, tightening bolts need to use torque wrenches operated in accordance with the standard torque, and at the same time set up a cordon to prevent unrelated personnel from entering.
( 2) data integrity record of
measurement data should be accurate to three decimal places, and label the temperature and humidity at the time of measurement. It is recommended to record the key steps such as gasket increase and decrease, bolt tightening, etc. by taking photos or videos, and establish an electronic archive to classify and store the data, so that it is easy to analyze the trend of changes in the level of the guide rail.
(3) dynamic monitoring and maintenance
to establish a "regular testing + real-time monitoring" mechanism, quarterly laser interferometer comprehensive testing, set 0.005mm/m level change warning threshold. High-temperature environment needs to be detected every month, high vibration conditions can be installed anti-loosening nut to ensure that the guide rail continues to operate stably.
Mastering the key points and practical methods of guide rail level adjustment can effectively improve the installation and maintenance level of equipment, and ensure the high precision and stable operation of mechanical equipment. In actual operation, according to the characteristics of the equipment, precision requirements and site conditions, choose the appropriate adjustment methods and tools, and strictly follow the operating specifications, in order to achieve the best adjustment results.
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