What should be paid attention to during the installation and debugging of vertical machining center machine?

The installation and debugging of the vertical machining center machine directly affects the precision, stability and service life of the equipment. The core precautions are carried out around four core links: basic preparation, installation specification, precision calibration and trial operation verification, as follows:

First, the foundation preparation before installation

Site conditions should meet the standards: the ground should be solidified with concrete, and the bearing capacity should be ≥5t/㎡, so as to avoid the settlement of equipment during operation. The ambient temperature is controlled at 15-30℃ and the humidity is 40%-75%, away from dust, vibration sources (such as punching machines) and strong electromagnetic interference.

Supporting facilities should be ready in advance: the power supply system should meet the rated voltage of the equipment (usually 380 V 10%), and be equipped with independent grounding (grounding resistance ≤4Ω) and voltage stabilizer to prevent voltage fluctuation from damaging electrical components. At the same time, the installation space and interface of cooling system and chip removal device are reserved.

Unpacking inspection of the equipment: check whether the models and quantities of the main engine, accessories and tools match, check whether the appearance of the equipment is damaged by transportation, whether the key components (such as spindle and guide rail) are corroded or deformed, and confirm that the accompanying technical documents (specifications and precision test reports) are complete.

Second, the installation process core specification

Accurate level adjustment: use a level with an accuracy of ≥0.02mm/m to carry out multipoint measurement at different positions on the x and y axes of the workbench. By adjusting the anchor bolt, the horizontal error is controlled within 0.02mm/m, so as to ensure the uniform stress of the machine tool and avoid the precision drift caused by long-term operation.

Components shall be assembled according to the process: the connecting bolts of key components such as spindle, tool magazine and column shall be tightened according to the specified torque (refer to the values in the equipment manual) to avoid vibration caused by looseness. Before connecting hydraulic and pneumatic pipelines, it is necessary to clean up the impurities at the interface to prevent blockage. After connecting, carry out pressure test (usually 0.3-0.5MPa for hydraulic system) to ensure no leakage.

Safety wiring of electrical system: wiring shall be conducted in strict accordance with the electrical schematic diagram, and the wiring shall be arranged neatly and fixed firmly to avoid interference with moving parts. After the wiring is completed, check the insulation performance, and measure the insulation resistance between phases and ground with a megger ≥1MΩ to prevent short circuit fault.

Third, the key steps of precision calibration

Geometric accuracy detection: use laser interferometer to detect the positioning accuracy and repetitive positioning accuracy of X, Y and Z axes, so as to ensure that it meets the factory standards of equipment (usually, the positioning accuracy is ≤0.015mm and the repetitive positioning accuracy is ≤0.008mm). The dynamic accuracy of the machine tool is detected by the club instrument, and the matching error of the servo system and the ball screw is checked.

Accuracy calibration of spindle: measure the end-face circular runout and radial circular runout of spindle with a dial indicator, and the error shall be ≤ 0.003mm.. Test the stability of the spindle at different speeds, and check whether the lubrication system supplies oil normally, so as to avoid the overheating of the spindle from affecting the machining accuracy.

Verification of tool magazine and tool changing accuracy: Test the tool changing action for many times in manual and automatic modes to ensure accurate positioning of tool magazine, smooth tool changing and firm tool clamping. Check the concentricity between the tool tip and the spindle center line, and control the error within 0.01mm to prevent machining error caused by tool change deviation.

IV. Commissioning and debugging verification

No-load test run: after the power supply is connected, manually move each shaft to check whether the movement is stable and free from jamming. Then start the no-load running program, let the equipment run continuously for 2-4 hours within the full stroke range of each shaft, and monitor the parameters such as spindle temperature, motor load and pressure of hydraulic/pneumatic system to ensure that there is no abnormal alarm.

Load test and parameter optimization: install standard trial cut pieces (such as No.45 steel block), perform typical machining operations such as milling and drilling, and check whether the machining accuracy (dimensional tolerance and surface roughness) is up to standard. Adjust the servo parameters, spindle speed and feed speed according to the trial cutting results to optimize the machining stability.

Safety function verification: test the sensitivity of emergency stop button, travel limit, overload protection and other safety devices to ensure that the equipment can stop quickly under abnormal conditions. Check the working effect of cooling system and chip removal device to avoid cutting fluid leakage or poor chip removal affecting production.

V. Follow-up Closing and Maintenance

Filing of debugging records: record all parameters (levelness, accuracy test results and parameter settings) in the process of installation and debugging in detail, and organize them into technical files for subsequent maintenance and reference.

Operator training: explain the equipment operation rules, daily maintenance points (such as rail lubrication and filter element replacement) and common fault handling methods to users to avoid equipment damage caused by misoperation.

Initial maintenance follow-up: within 1-3 months after commissioning, pay a regular return visit to the running state of the equipment, check the fastening situation and accuracy change of key components, and deal with potential problems in time.