The first step: benchmark alignment and basic pre-adjustment
1. Core principle: Use the reducer body as a fixed benchmark, give priority to stabilizing the base of the reducer, and then adjust the position of the motor or load end.
2. Basic calibration: Use a frame level with an accuracy of 0.02mm/m to measure the flat surface of the reducer box and the end face of the input/output shaft flange. First adjust the longitudinal level (along the axis direction), and then adjust the transverse level to ensure that the level errors in both vertical and horizontal directions are ≤0.1mm/m.
3. Coarse adjustment and alignment: You can use the ruler method to hang a ruler on the shaft end to initially observe the parallelism, or check the flange fitting surface gap visually or with a feeler gauge (check with a 0.05mm feeler gauge, and the insertion depth should not exceed 1/3 of the width of the fitting surface).
Step 2: Precision measurement and deviation calculation
1. Tool selection: It is recommended to use the 'double meter method' (dial indicator + magnetic meter base) in general scenarios; for high-precision or high-power transmission systems (such as power > 200kW), it is recommended to use a laser alignment instrument.
2. Double-meter method operation: Fix the magnetic meter base on the input/output flange of the reducer. One meter is pressed against the outer circle of the mating shaft (motor shaft or load shaft) to detect the radial deviation, and the other meter is pressed against the end face of the flange to detect the angular (end face) deviation. Rotate the shaft system 360° synchronously and slowly, and record readings at four positions: 0°, 90°, 180°, and 270°.
3. Deviation calculation:
Radial deviation = (maximum reading - minimum reading) / 2
Angular deviation = Maximum difference between end faces ÷ Measured diameter (or flange diameter)
Step Three: Fine-tuning Correction and Dynamic Verification
1. Fine-tuning operation: According to the measurement data, adjust the radial deviation in the horizontal direction by moving the motor or load equipment, and adjust the height in the vertical direction by adding or removing stainless steel gaskets (the number of layers of the same foot gasket is ≤ 3, and the total thickness is ≤ 5mm). It is recommended that each adjustment amount is ≤0.05mm, and follow the 'measurement-analysis-adjustment' cycle until the deviation value is controlled within the allowable range.
2. Tightening retest: After the adjustment reaches the standard, gradually tighten the anchor bolts 2-3 times in a diagonal sequence (to avoid tightening them all at once and causing base deformation). After tightening, the coaxiality needs to be retested again to prevent position deviation during the tightening process.
3. Trial run verification: First, manually turn the machine to confirm that the whole process is smooth and without jamming; then conduct a no-load trial run for 10-30 minutes to check that there is no periodic vibration, abnormal sound and abnormal temperature rise; after running with load, it is recommended to stop the machine and retest the coaxiality again. If there is no thermal rebound (deviation change ≤ 0.02mm), it is qualified.
