1. Prepare
(1) operation data before operation: including general assembly drawing, component assembly drawing, part drawing, material BOM table, etc. Until the end of the project, the integrity and neatness of drawings and the integrity of process information records must be guaranteed.
(2) Workplace: Parts placement and assembly must be carried out in the specified workplace, and the place where the whole machine is placed and assembled must be clearly planned. Until the end of the whole project, all workplaces must be kept neat, standardized and orderly.
(3) Assembly materials: Before the operation, the assembly materials specified in the assembly process must be in place on time. If some non-decisive materials are not in place, the operation sequence can be changed, and then a material reminder sheet can be filled out and submitted to the purchasing department.
(4) understand the structure, assembly technology and process requirements of the equipment before assembly.
2. Basic specifications
(1) Mechanical assembly shall be carried out in strict accordance with the assembly drawings and process requirements provided by the design department, and it is strictly forbidden to modify the operation content without permission or change the parts in an abnormal way.
(2) The assembled parts must be qualified by the Quality Inspection Department. If any unqualified parts are found in the assembly process, they should be reported in time.
(3) The assembly environment shall be clean and free from dust or other pollution, and the parts shall be stored in a dry, dust-free place with protective pads.
(4) During the assembly process, the parts shall not be bumped or cut, the surface of the parts shall not be damaged, or the parts shall be obviously bent, twisted or deformed, and the mating surface of the parts shall not be damaged.
(5) Lubricating oil (grease) should be added between the contact surfaces of parts moving relatively.
(6) The matching dimensions of matching parts should be accurate.
(7) During assembly, parts and tools should have special storage facilities. In principle, parts and tools are not allowed to be placed on the machine or directly on the ground. If necessary, protective mats or carpets should be laid at the storage places.
(8) In principle, it is not allowed to trample the machine during assembly. If it is necessary to trample, a protective pad or carpet must be laid on the machine. It is forbidden to trample important parts and parts with low nonmetallic strength.
3. Connection method
(1) Bolt connection
A. When fastening bolts, adjustable wrench shall not be used, and more than one identical washer shall not be used under each nut. After countersunk screws are tightened, the nail head shall be embedded in the machine part and shall not be exposed.
B. under normal circumstances, the threaded connection should be provided with lock spring washers, and the symmetrical multiple bolts should be tightened step by step in symmetrical order, and the strip connectors should be tightened symmetrically from the middle to two directions.
C. After the bolt and nut are tightened, the bolt should expose the nut by 1-2 pitches; When fastening the moving device or maintaining the screws, it is not necessary to disassemble the parts. Before assembly, the screws should be coated with thread glue.
D. Fasteners with specified tightening torque requirements shall be tightened with a torque wrench. For bolts with no specified tightening torque, the tightening torque can refer to the Schedule.
(2) Pin connection
A. Generally, the end face of the locating pin should be slightly higher than the surface of the part, and the big end of the taper pin with screw tail should sink into the hole after it is installed in the relevant part.
B. after the cotter pin is installed in the relevant parts, its tail should be separated by 6-9.
(3) Key connection
A. The Ping Jian and the two sides of the keyway of the fixed key should be in uniform contact, and there should be no gap between their mating surfaces.
B. after the key (or spline) with clearance fit is assembled, there shall be no uneven tightness when the relative moving parts move along the axial direction.
C. The contact area of hook key and wedge key after assembly shall not be less than 7% of the working area, and the non-contact parts shall not be concentrated in one place; The length of the exposed part should be 1%-15% of the length of the inclined plane.
(4) riveting
a. The riveting materials, specifications and dimensions must meet the design requirements, and the processing of rivet holes should comply with relevant standards.
B. during riveting, the surface of the riveted parts shall not be damaged or deformed.
C. generally, there shall be no looseness after riveting, and the head of the rivet must be in close contact with the riveted parts, and should be smooth and round.
(5) expansion sleeve connection
expansion sleeve assembly: coat the expansion sleeve with lubricating grease, put the expansion sleeve into the assembled hub hole, insert it into the mounting shaft, adjust the assembly position, and then tighten the bolts. The tightening sequence is bounded by the slit, and the left and right cross symmetry are tightened in turn to ensure that the rated torque value is reached.
(6) Tightening connection
The taper end and hole of the taper end tightening screw should be 9, and the tightening screw should be tightened to the aligned hole.
4. Assembly of rolling bearings
(1) Before the bearing is assembled, there must be no dirt on the bearing position.
(2) When the bearing is assembled, a layer of lubricating oil should be coated on the surface of the mating parts, and the end of the bearing without model should face inward, that is, in the direction of the shaft shoulder.
(3) When assembling the bearing, a special press should be used, and it is strictly forbidden to assemble by direct hitting. When assembling the bearing, the magnitude, direction and position of the applied force should be appropriate, and the force should not be exerted on the protective frame or the rolling body, and should be evenly and symmetrically, so as to ensure that the end face is perpendicular to the shaft
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(4) generally, the end face of the inner ring of the bearing should be close to the shaft shoulder (shaft clamp). After the outer ring of the bearing is assembled, the contact between the bearing cover at the positioning end and the washer or the outer ring should be uniform.
(5) After the rolling bearing is installed, the rotation of the relative moving parts should be flexible and light. If there is a sticking phenomenon, check and analyze the cause of the problem and deal with it accordingly.
(6) In the process of bearing assembly, if the hole or shaft is found to be too loose, check the tolerance; When it is too tight, it is not allowed to assemble it violently. All of them should check and analyze the causes of the problems and deal with them accordingly.
(7) The axial clearance of single-row tapered roller bearing, thrust angular contact bearing and bidirectional thrust ball bearing shall meet the requirements of drawings and technology during assembly.
(8) A proper amount of grease should be injected into the bearing and its matching surface after assembly. For bearings whose working temperature does not exceed 65℃, ZG-5 grease can be used according to GB491 Calcium-based Grease. For bearings with working temperature higher than 65℃, ZN-2 and ZN-3 grease can be used according to GB492 "Calcium-based Grease".
(9) The temperature rise of ordinary bearings during normal operation should not exceed 35℃, and the maximum temperature during operation should not exceed 7℃.
5. Assembly of linear bearing
(1) Before assembly, the bearing should be coated with grease.
(2) When the bearing is pressed into the bearing seat, a special installation tool should be used to press against the end face of the outer ring. It is not allowed to directly beat the bearing to avoid deformation.
(3) The fit between the bearing and the bearing seat must meet the tolerance requirements. If it is too tight, the guide shaft and the bearing will be in interference fit, which will damage the bearing; Too loose will make the bearing unable to be fixed in the bearing seat.
(4) When the guide shaft is loaded into the bearing, it should be inserted into the alignment center gently. If it is inserted askew, the ball will fall off and the cage will be deformed.
(5) When the bearing is installed in the bearing seat, it is not allowed to rotate. Forcing it to rotate will damage the bearing.
(6) it is not allowed to directly fasten the bearing outer ring with the fastening screw, otherwise deformation will occur.
6. Assembly of linear guide rail
(1) The installation part of the guide rail shall not be contaminated, and the flatness of the installation surface must meet the requirements.
(2) When there is a reference edge on the side of the guide rail, it should be installed close to the reference edge. If there is no reference edge, the sliding direction of the guide rail should be consistent with the design requirements. After the guide rail fixing screw is tightened, check whether there is any deviation in the sliding direction of the slider, otherwise it must be adjusted.
(3) If the slider is driven by a belt, the belt must not be pulled obliquely after the belt and the slider are fixed and tensioned, otherwise the pulley must be adjusted to make the driving direction of the belt parallel to the guide rail.
7. Assembly of sprocket chain
(1) The cooperation between sprocket and shaft must meet the design requirements.
(2) The geometric center planes of the teeth of the driving sprocket and the driven sprocket should coincide, and the offset should not exceed the design requirements. If not specified in the design, it should generally be less than or equal to 2‰ of the center distance between two wheels.
(3) When the chain engages with the sprocket, the working edge must be tightened to ensure smooth engagement.
(4) The sag of the non-working side of the chain should meet the design requirements. If it is not specified in the design, it should be adjusted by 1% ~ 2% of the center distance between two sprockets.
8. Assembly of gears
(1) After the gears engaged with each other are assembled, when the width of the gear rim is less than or equal to 2mm, the axial dislocation shall not be greater than 1 mm; When the gear rim width is greater than 2mm, the axial dislocation shall not exceed 5% of the rim width.
(2) The installation accuracy requirements of cylindrical gear, bevel gear and worm drive shall be specified in JB179-83 Accuracy of Involute Cylindrical Gear, JB18-6 Transmission Tolerance of Bevel Gear
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and JB162-6 respectively according to the accuracy and specifications of the transmission parts.
(3) The gear meshing surface should be lubricated normally according to the technical requirements, and the gear box should be filled with lubricating oil to the oil level line according to the technical requirements.
(4) The noise of gear box under full load operation shall not be greater than 8dB.
9. Assembly of synchronous belt wheel
(1) Axles of driving and driving synchronous belts must be parallel to each other, and there is no skew or swing, and the inclination error should not exceed 2‰.
(2) when the width of two pulleys is the same, their end faces should be on the same plane, and the axial misalignment of the two pulleys should not exceed 5% of the width of the rim.
(3) When assembling the synchronous belt, it is not allowed to pry into the pulleys forcibly, and the belt should be assembled by shortening the center distance between the two pulleys, otherwise the tensile layer of the synchronous belt may be damaged.
(4) The timing belt tensioner should be installed on the loose side for tensioning, and two fastening bolts should be fixed.
1. Assembly of flat belt
(1) Before installation, all conveying planes should be leveled.
(2) The connecting line between the center points of pulleys should be adjusted to the same vertical plane, and the axes should be parallel to each other.
(3) The conveying direction of the flat belt should be installed in the direction of the arrow marked on the belt, otherwise its service life will be affected.
11. Assembly of motor and reducer
(1) Check whether the motor model is correct and the reducer model is correct.
(2) Before assembly, clean the connecting part between the motor shaft and the reducer.
(3) Before tightening the motor flange screw, rotate the motor to correct the concentricity between the motor shaft and the reducer coupling, then connect the motor flange with the reducer and tighten the fixing bolts diagonally.
(4) During the assembly of the servo motor, the encoder at the rear of the motor should be guaranteed to be free from external force, and it is forbidden to knock the servo motor shaft.
(5) Installation of the servo reducer:
A. Move the sealing screw on the outside of the reducer flange to facilitate adjustment of the clamping screw.
B. unscrew the clamping screw, connect the motor flange with the reducer, and tighten the positioning bolt diagonally.
C. tighten the clamping ring with proper torque, and then tighten the sealing screw.
D twist the motor flange bolt until it is loose, jog the servo motor shaft or rotate the motor shaft by hand for several turns to correct the concentricity between the motor shaft and the reducer coupling.
e. finally, connect the motor flange with the reducer and tighten the positioning bolt diagonally.
12. Adjustment and connection of racks
(1) The height of racks in different sections shall be adjusted to the same height according to the same datum point.
(2) The wallboard of all racks shall be adjusted to the same vertical plane.
(3) After all the racks are adjusted in place and meet the requirements, fixed connecting plates shall be installed between them.
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13. Assembly of pneumatic components
(1) The configuration of each pneumatic drive device must be connected in strict accordance with the gas circuit diagram provided by the design department, and the valve body, pipe joint, cylinder and so on must be checked correctly.
(2) The inlet and outlet of the main air inlet relief valve shall be connected in the direction of arrow, and the water cup and oil cup of the air filter and oil mist sprayer must be installed vertically downward.
(3) Before piping, the cutting powder and dust in the pipe should be fully blown out.
(4) The pipe joint is screwed in. If the pipe thread does not have thread glue, it should be wound with raw tape, and the winding direction should be clockwise when viewed from the front. The raw tape should not be mixed into the valve. When the raw tape is wound, a screw thread should be reserved.
(5) The trachea should be arranged neatly and beautifully, and try not to cross it. A 9 elbow should be used at the corner, and the joint should not be subjected to extra stress when the trachea is fixed, otherwise it will cause air leakage.
(6) When the solenoid valve is connected, pay attention to the function of each port number on the valve: p: total air intake; A: outgassing 1; B: outgassing 2; R(EA): exhaust gas corresponding to a; S(EB): exhaust gas corresponding to B.
(7) When assembling the cylinder, the axis of the piston rod should be consistent with the moving direction of the load.
(8) When using linear bearing guide, after the front end of the piston rod of the cylinder is connected with the load, there must be no extra force in the whole stroke, otherwise the cylinder will be damaged.
(9) When using the throttle valve, attention should be paid to the type of throttle valve. Generally speaking, it is distinguished by the big arrow marked on the valve body, and the big arrow pointing to the threaded end is used for the cylinder; The big arrow pointing to the pipe end is used for solenoid valve.
14. Assembly inspection work
(1) Every time a component is assembled, it should be inspected according to the following items. If any assembly problem is found, it should be analyzed and handled in time.
a. integrity of assembly work, check assembly drawings and check whether there are any missing parts.
B. the accuracy of the installation positions of all parts shall be checked by checking the assembly drawings or as required in the above specifications.
C. the reliability of each connecting part, whether the fastening screws meet the torque required for assembly, and whether the special fasteners meet the requirements for preventing loosening.
D. the flexibility of moving parts, such as whether the conveying roller, pulley and guide rail are stuck or not, eccentric or bent when rotating or moving manually.
(2) after the final assembly, the connection between the assembled parts is mainly checked, and the inspection content is measured by the "four characteristics" specified in (1).
(3) After the final assembly, all parts of the machine should be cleaned of iron filings, sundries, dust, etc. to ensure that there are no obstacles in all transmission parts.
(4) When commissioning the machine, carefully monitor the startup process. After the machine starts, immediately observe whether the main working parameters and moving parts are moving normally.
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