R0015028D ZX5 Hepco Beam Alignment Module C

Instructions for mounting and aligning hepco x axis beam

Difficulté

Very hard Très difficile

Durée

8 hour(s) heure(s)

R0015028D_ZX5_Hepco_Beam_Alignment_Module_C_Screenshot_2023-06-29_143013.png

Introduction

Tools Required

Engineers level

Hepco flat spanner

Hepco Box spanner

Standard hex key set

Incremental shim pack

Parts Required

B0000046 Slide Base Bearing Block (Straight Grease Nipple) x 6

B0000184 Journal Cap Seal 34 x 4

B0000185 Double Row Long Stud Journal Eccentric x 2

B0000186 Double Row Long Stud Journal Concentric x 2

B0000234 Straight Grease Nipple M6 ST/ST x 6

B0001006 Linear rail 25mm x 820mm x 6

B0001102 Double edge spacer slide and beam 7600mm x 1

D0015072 Carriage Plate x 1

D0015492 Vertical Beam Adjustment Plate x 5

D0015493 Lateral Beam Adjustment Plate x 5

P0000200 Elbow Adaptor 6mm - M5 x 1

Étape 1 - Unless otherwise stated

Use Loctite 243 on all fasteners

Use Loctite 570 on all threaded pneumatic connections

Pen mark all bolts once finalised

Étape 2 - Additional spacer

Ensure additional spacer is removed from jigs when using for alignment on module C

Étape 3 - Attach Setting jigs

Mount setting jigs to channel section in positions shown using M8 cap head bolts and heavy washers

Position one shown will require fixing points drilling to channel section . Drill M8 and position to measurement shown of 430mm

Étape 4 - Level Setting Jigs

....The correct setting of these jigs is vital to correct installation of the hepco drive system. Accurate positioning of these will enable quality checks to be performed on the supplied hepco rail

Use an engineers level to individually adjust each jig to be level on both axis

...Always ensure when levelling that the jig remains in contact with the blue support bar on at least one point . The distance between the top face and the blue mounting section is vital to the correct set up

Étape 5 - Level x axis between jigs

Using a 2 meter straight edge , the jigs should be levelled to each other as shown.

Identify which Jig is the lowest point by using the straight edge and level . Adjust the lower height jigs to match the highest point one. This is to ensure that the height is maintained as much as possible between blue mounting bar and jig top face

When a jig is adjusted for height, i will need rechecking to see if the other previous levelled plains have moved. If so, re adjust to bring jig level in all axis

Étape 6 - Wire line for setting straightness

A wire line should be used for setting the straightness of the jigs along the x axis

Use dokit Alignment guide using wire line for correct process to set up

Étape 7 - Quality Check

Qc Double check required at this point from Supervisor that all alignment is correct.

Étape 8 - Position Hepco double edge slide

B0001102 can now be assembled on jigs .

These beams are paired so check you have been issued a set correctly

Pairs can be identified as follows

1 and 1

2 and 2

A and A

B and B

Étape 9 - Mechanically join Hepco beam

1 Use jig shown to ensure correct pitching of 2 sections of drive rail when coupled together

2 Use v blocks to ensure alignment of V's on hepco rail are correct when mating the two parts

3 Position and tighten the joining bars between the two sections (picture required)

Étape 10 - Set beam position

Hepco slide rail should be positioned as drawing

Étape 11 - Assemble carriage

D0015072 Carriage Plate x 1

B0000185 Double Row Long Stud Journal Eccentric x 2

B0000186 Double Row Long Stud Journal Concentric x2

1 Remove nuts and washers from journals

2 Insert into carriage plate in positions shown

3 Add washer and nut to top face with no adhesive

Étape 12 - Set journals

Fit assembled carriage plate to hepco slide ,orientated as shown

Set Tension on eccentric journals using hepco flat spanner and box wrench

Correct tension is

....When the carriage is pushed by hand , it must be just possible to skid the journal on the v rail when held Journal must have enough contact to be turned when the carriage plate is pushed

...Caution must be used when tension is applied when setting. To much can caused damage to journal and rail. Gradually increase tension checking at each point t confirm

The journal setting must be checked at several points across the hepco rail .Journals should be adjusted to give the best contact overall along the entire travel of the carriage plate

Étape 13 - Fit wipers and finalise

Remove carriage plate

1 Fit B0000184 x 4 cap seals with adjustable inserts (supplied with cap) Adjust so journal is not in contact with cap seal but close as possible

2 Dispose of fixed variant

3 Add Loctite 290 to finalised journal nuts

Étape 14 - Refit carriage plate

Refit carriage plate to hepco rail and check travel along the entire length to confirm correct position of cap seals. If it has become hard to push cap seals are not positioned correctly

Étape 15 - Check level of carriage plate

Inspect Level of hepco beam as shown . These levels should be checked at every 300mm along the entire length of the beam. This will give an indication of what is required for adjustment .

...

Étape 16 - 1st stage levelling

1 The first stage of levelling any discrepancy from the rail is to add bias shims to the setting jigs that the hepco rails is sitting on . This will only give slight adjustment in one direction . Image shows where shims can be added to adjust level indicated. Never add shims to both sides (hepco beam is removed for clarity of shim location )

2 Levelling in this direction is not likely, if setting jigs are set up correctly then this level will be correct

If this process corrects any discrepancies on level move to mounting bracket stage . If more adjustment is required continue to step 17

Étape 17 - 2nd stage levelling if required

In extreme cases additional adjustment may be required for correct positioning

Shims can be placed between the main hepco slide and extruded mounting section. This step should only be undertaken with supervisor authorisation

...If shimming is required at these points ,care must be taken to add shims incrementally on size to avoid the straightness of the rail being compromised

Étape 18 - Laser checks

Once the hepco rail has been positioned and levelled correctly, a laser check must be performed to ensure straightness of hepco rail

(photos required)

Étape 19 - Quality Check

Sign off is required at this point to double check and ensure quality . Supervisor approval required

Étape 20 - Fit linear rails

Fit 6 off B0001006 linear rails to hepco beam as shown

Use data for position of each rail

Fix with m6 plate washers and m6 socket caps (size)

only apply light pressure to 2 off fixings per rail

en none 0 Draft