In view of the shafting alignment and connection errors that may occur in the actual operation of the ZQ750-48.57-1 reducer, it is recommended to follow the standardized operation process of "first correct the alignment deviation, then solve the connection problem, and finally verify the operation effect." The specific correction and processing methods are as follows:
1. Precise correction of shaft alignment deviations
Shaft alignment errors mainly manifest as radial, angular and comprehensive deviations, and the correction process needs to be strictly standardized:
Early preparation and rough adjustment: First clean the oil dirt and impurities on the surface of the coupling, and check whether the shaft body is bent. If the radial runout of the shaft exceeds 0.05mm, it must be straightened or replaced first. Then, use a ruler or feeler gauge to perform rough alignment and initially align the two halves of the coupling to avoid excessive deviation during subsequent fine adjustments. At the same time, it is necessary to use a feeler gauge to check the equipment base to completely eliminate the "soft foot" problem of poor contact between the base and the bottom plate. In terms of measurement tools, laser alignment instruments are preferred, and dial indicators can also be used in regular scenarios.
Radial deviation correction: For radial deviations where the two axes are parallel but not concentric, the dial indicator can be adsorbed on the flange on one side of the coupling, and the indicator head is pressed against the outer circumferential surface of the flange on the other side. Slowly rotate the two axes and record the maximum and minimum readings. Half of the difference is the radial deviation. If the deviation exceeds the standard, it can be adjusted by adding a thinned steel gasket to the base of the motor or reducer. The thickness of a single adjustment should not exceed 0.5mm. If a laser alignment instrument is used, the equipment can be moved laterally by horizontally adjusting the bolts based on real-time data until the radial deviation is controlled within the standard range of ≤0.05mm.
Angular deviation correction: For the angular deviation where the center lines of the two axes intersect at a certain angle, the dial indicator head can be pressed against the flange end face on one side of the coupling, and the difference in readings can be recorded by rotating the two axes. When adjusting, it is necessary to add or subtract gaskets from one side of the equipment base (for example, if the left side is higher, add a gasket to the left base). The thickness of each pad should be controlled to ≤0.1mm. When using the laser alignment tool, you can adjust the front and rear anchor bolts of the equipment according to the system prompts to correct the angle until the angular deviation is ≤0.05mm/m.
Comprehensive deviation correction: When two deviations exist at the same time, the principle of "first adjusting the angular direction, then adjusting the radial direction" must be followed to avoid "false deviation" interference caused by angular deviation on radial detection. After adjustment, the coupling needs to be rotated for one week for retesting and repeated fine-tuning until both indicators meet the standards. Subsequently, tighten the fixing bolts according to the diagonal and even principle, and check again after tightening to prevent trace displacement caused by bolt tightening.
2. Troubleshooting and repair of shaft connection errors
Connection errors are often reflected in the coupling fit and keyway assembly, and need to be dealt with accordingly:
Coupling assembly correction: If the coupling and shaft fit too loosely, causing shaking during operation, the coupling should be replaced with an adapted coupling or reinforced with an expansion sleeve; if the fit is too tight, it is strictly prohibited to use tools such as a hammer to hit it to avoid damage to the bearings and gears due to excessive axial or radial force. You can lightly polish the shaft surface or the inner hole of the coupling with sandpaper to ensure a transition fit clearance of 0.01-0.03mm. In addition, if a rigid coupling is misused, it is recommended to replace it with a flexible coupling to reserve space for deviation compensation and reduce the impact of alignment deviation.
Correction of the fit between the keyway and the flat key: If the fit between the flat key and the keyway is too tight, you can use a file to slightly trim the inner wall of the keyway. After trimming, be sure to clean up the iron filings to ensure smooth assembly; if the fit is too loose, you need to replace the matching flat key, or add a thin copper sheet to the key side to fill the gap to prevent transmission slippage. During assembly, it is necessary to ensure that the flat key and the keyway fit closely and are installed in place to avoid displacement during operation and damage to the shaft and coupling.
3. Later verification and long-term maintenance and consolidation
After physical correction is completed, dynamic verification and regular maintenance are required to consolidate the effect:
Trial run verification: First start the equipment at low speed without load and run for 10-15 minutes. During this period, use a vibration detector to monitor to ensure that the amplitude is ≤0.1mm/s, and use a stethoscope to check whether there are any abnormal noises. After confirmation, gradually load to the rated load and run for 1-2 hours, and check the vibration value and bearing temperature again. If an abnormality occurs during operation, the machine needs to be stopped immediately and rechecked and adjusted.
Later maintenance and consolidation: After the equipment is running for 30 minutes, the anchor bolts need to be re-tightened to prevent loosening due to thermal expansion and contraction; after 100 hours of subsequent operation, the bolt status needs to be inspected again. In addition, it is recommended to comprehensively review the alignment and connection status at least once a year to avoid new deviations and looseness problems caused by vibration or aging during long-term operation of the equipment.
