The following are the key adjustment tips and steps for the installation of the cutter reducer:
1. Core adjustment skills
1. Give priority to elastic couplings
It is strictly prohibited to use rigid couplings in the connection between the motor and the reducer, or the reducer and the load (such as screw, gear rack). Flexible couplings such as plum blossom couplings, diaphragm couplings or bellows couplings should be preferred. Elastic couplings can compensate for slight installation deviations and thermal expansion during operation, effectively absorb vibration and impact, and are the first line of defense to ensure coaxiality.
2. Follow the cycle principle of "loose-tune-tight-restore"
This is the key to avoiding "false alignment". Tightening the bolts alone will cause a slight shift in the position of the reducer.
Loosen: Completely loosen all fixing bolts, leaving the reducer in a free state.
Adjustment: Use a dial indicator or laser alignment tool for precise measurements and adjustments.
Tightening: Gradually tighten to the specified torque in 2-3 times in diagonal order.
Reply: After tightening, you must re-measure to confirm that the coaxiality and parallelism are still within the qualified range. If it is out of tolerance, loosen the bolts and readjust until the data still reaches the standard after tightening.
3. Radial and end face deviations need to be corrected simultaneously
When adjusting, you cannot only focus on radial coaxiality and ignore end face parallelism.
Radial runout: reflects the offset of the center lines of the two axes.
End runout: reflects the parallelism of the flange surfaces of the two axes. Non-parallel end faces will generate huge axial forces, leading to seal failure and abnormal bearing wear.
Both dimensions must be measured and adjusted simultaneously using a dial indicator or laser alignment tool to ensure that both meet standards.
4. Use precision gaskets for fine adjustment
When the deviation exceeds the standard, adjust the height and horizontal position by adding or subtracting thin metal gaskets (such as copper sheets or stainless steel sheets, thickness 0.1-0.5mm) between the reducer mounting feet and the base.
It is strictly prohibited to use non-metallic or elastic materials such as paper and rubber blocks as gaskets. They will deform after being stressed, resulting in rapid loss of accuracy.
The gasket should be flat and without burrs, and the depth of the gasket should not exceed 1/3 of the width of the mating surface.
2. Adjustment accuracy reference standard
Different connection methods and equipment have different accuracy requirements. The following are general reference values.
3. Adjusted verification steps
After the adjustment is completed, the following three-step verification must be passed to confirm that the installation is qualified:
1. Manual turning: Turn the input shaft or coupling by hand. The whole process should be flexible and smooth, without any feeling of sticking or tightening and loosening. If there is resistance, it means there are still internal differences and readjustments are necessary.
With the load off, run at low speed with no load for 30 minutes to 1 hour. Monitor the running sound, which should be smooth gear meshing sound, without periodic "clicking" sounds, sharp whistling or abnormal vibrations.
3. Temperature rise monitoring: Use an infrared thermometer to monitor the temperature of the reducer bearing seat and shell. After the no-load operation is stable, the temperature rise should not exceed 40°C, and the maximum surface temperature should not exceed 70-85°C. Excessive temperature rise is a typical symptom of bearings being subjected to additional loads due to poor alignment.
