Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released Drive Systems Rack and Pinion Drives MPZ_001_engl.doc 1 01.06.05 01.06.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 2 01.06.05 01.06.05 24 Schell Lorch Table of Contents Company address ……………………………………………………………….….2 Safety notes ….............................……………………………………………….….3 Signs and symbols ………………………………………………………………..….3 Safety ………………………………………………….……………………………..…3 Item number …………………………………………………………………………...
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 3 01.06.05 01.06.05 24 Schell Lorch CAUTION! The observance of the instructions in this documented procedure is prerequisite for the undisturbed operation and the contingent acceptance of liability on account of possible defects. Therefore study the operating instructions before starting the assembly.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure 4100-001-06.05 Page Name released Assembly Plan – Toothed Racks Servo Line 4 01.06.05 01.06.05 24 Schell Lorch person should be called in or a crane be used, if the weight exceeds 8 kg. Always have a second person lend a hand, if the length exceeds 1000 mm in order to prevent bending and injury due to false posture. The crane must always be operated by a crane driver.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 5 01.06.05 01.06.05 24 Schell Lorch mounting bench would be needed if mechanics of different height were to work at the same bench. Suitable supports or trestles must be provided in order to prevent hand or fingers from being squeezed and bruised when depositing the unit onto the bench or on a table.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 quality and precision Procedure Assembly Plan – Toothed Racks Servo Line module 4100-001-06.05 Page Name released with bores 6 01.06.05 01.06.05 24 Schell Lorch length of rack Identification ☞ The rack is identified by item number and order code as well as the manufacturer’s logo. This identification also ensures the retraceablitiy of the manufacturing process.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 7 01.06.05 01.06.05 24 Schell Lorch of contact the peripheral speed of both operating pitch circles is identical. Racks are available in different designs to be chosen by the customer to suit the intended use. Proper use Toothed racks are used in applications where rotary motions are to be converted into linear motions.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 8 01.06.05 01.06.05 24 Schell Lorch Transport and handling ☞ Observe all safety regulations applying to transport and handling with lifting gear. ☞ Make sure that the load is handled and set down slowly and carefully. ☞ Especially when transporting and handling long racks (≥ 2000 mm), avoid any leverage upon the rack.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 9 01.06.05 01.06.05 24 Schell Lorch ☞ Avoid any unfavourable leverage on the rack during storage (for lever ratios see paragraph “Transport and handling”). ☞ Protect the rack against dust or other pollution. ☞ Do not damage the teeth or the supporting/contact surfaces.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 10 01.06.05 01.06.05 24 Schell Lorch Mounting instructions Contact surface The machine bed should enable easy installation and grease-free mounting of the rack. 1. Position the first rack on the machine bed, adjust it concentrically, and clamp it to the contact surface with a screw clamp.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 11 01.06.05 01.06.05 24 Schell Lorch ☺ Mounting example on the machine bed 3. Remove the mating companion piece and the auxiliary contact surface. 4.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure 4100-001-06.05 Page Name released Assembly Plan – Toothed Racks Servo Line 12 01.06.05 01.06.05 24 Schell Lorch 6. Plug the displacement unit into the pinholes at the joint of the two racks. One measuring roll is laid into the tooth gap at the joint and the other two in a tooth gap left and right of the joint.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 13 01.06.05 01.06.05 24 Schell Lorch 8. Slightly tighten the hexagon socket screws on the not yet fully fixed rack and loosen the set-screws at the displacement unit. Remove the displacement unit from the pinholes of the racks. 9.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 14 01.06.05 01.06.05 24 Schell Lorch ☞ Now fix the racks permanently with the straight pins. For this purpose we recommend to use hardened straight pins according to DIN EN ISO 8734. ☞ All racks must be pinned in addition to being fastened with fixing screws in order to prevent micro-sliding.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 15 01.06.05 01.06.05 24 Schell Lorch 3. Tighten the hexagon socket screws of the second rack in such a way that adjustment is still possible. Then remove the companion piece.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 16 01.06.05 01.06.05 24 Schell Lorch ☞ Now secure the rack permanently with straight pins. We recommend to us hardened straight pins acc. to DIN EN ISO 8734. ☞ All racks must be pinned in addition to being fastened with fixing screws in order to prevent micro-sliding.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 17 01.06.05 01.06.05 24 Schell Lorch Engaging the gear unit ☞ Push the adjusting unit, consisting for example of the gear unit and two lateral angle irons, manually into the gearing until the pinion meshes with only little backlash with the rack. Then slightly fix the adjusting unit with the screws.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 18 01.06.05 01.06.05 24 Schell Lorch ☺ In order to ensure a traversing movement free from play over the whole travelling length we recommend to replace the pinion shaft inside the gearbox by a pre-load pinion shaft.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 19 01.06.05 01.06.05 24 Schell Lorch s ao The center distance "ao" pinion and rack is set as a function of the tooth-flank backlash "s": s = min. 0.03 / max. 0.3 For module 1 to 2,5: s = max. 0,1 mm For module 3 to 4: s = max. 0,2 mm For module 5 to 12: s = max. 0,3 mm This value may be doubled for lifting axles.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 20 01.06.05 01.06.05 24 Schell Lorch the attachment of the mounting axle with the felt gearwheel and the supply of the lubricant from the grease cup by means of the set of connecting hoses must be adapted to the existing mounting conditions.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 21 01.06.05 01.06.05 24 Schell Lorch Visual check ☞ The entire drive system must be visually checked for external damage and leakage. ☞ Any defective or leaking components are to be repaired immediately.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 22 01.06.05 01.06.05 24 Schell Lorch Error list (troubleshooting) ☞ React immediately whenever you detect unusual loss of lubricant, increased running noises, or unusually high gear temperatures.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 23 01.06.05 01.06.05 24 Schell Lorch Disassembling the rack ☞ All fixing screws must be loosened before the rack can be removed from the pinned fastening with the aid of suitable tools. ☞ Remove the racks carefully in order to avoid damage to the drive system and adjoining components. ☞ Use only original spare parts.
Documented ProcedureBPA MPZ 001 Documented Department Rev. Index Date TB / Schell D 3.05.2011 Procedure Assembly Plan – Toothed Racks Servo Line 4100-001-06.05 Page Name released 24 01.06.05 01.06.05 Disposal Lubricants Environmental hazard Lubricants are hazardous substances susceptible to pollute soil and water. ☞ Dispose of the lubricants as required by national regulations. ☞ Never mix polyglycolic substances with mineral oils which are intended for recycling.
