Guidelines for mounting of monorail guidance systems
The guidance systems can only achieve their function and maximum operating life if they are correctly mounted and maintained, see link.
Guidelines
General
Use only the appropriate tools and fitting aids.
Always carry out the operations in the specified sequence.
Do not carry out “prestrung mounting” – do not slide carriages already mounted on the machine table onto guideways that are also already mounted.
Hands should be kept clean and dry, wear cotton gloves if necessary.
Perspiration can lead to corrosion on monorail guidance systems with a dry preservative.
Transport, storage and fitting area
Monorail guidance systems should only be transported and stored in their original packaging.
Guideways longer than 1,5 m must be supported at a minimum of 3 points.
Monorail guidance systems should only be removed from their original packaging once they are at the assembly area and immediately before mounting.
Monorail guidance systems should not be mounted in the vicinity of machines or equipment that generate swarf or dust.
Do not transmit electrical currents, for example during welding, through the monorail guidance systems.
ACHTUNG
Observe the specifications and regulations in accordance with the table.
The mounting guidelines are structured such that they can be used as a basis for creating individual mounting manuals as easily as possible.
Mounting manuals can be called up on the Internet http://www.schaeffler.de/std/1D51.
Mounting manuals available from Schaeffler in the field of monorail guidance systems:
RUE: MON 30, MON 40, MON 41, MON 42
KUSE: MON 22
KUVE: MON 38, MON 45, MON 46
accessories: MON 01, MON 07, MON 21, MON 65
HLE: MON 50.
ACHTUNG
Risk of injury. In your handling or mounting manuals, please draw attention to the sharp edges caused by the design on guideways, holes and covering strips.
Risk of injury. Draw attention in your handling or mounting manuals to the normal hazards that are generally present in the mounting of machines and when working with lifting gear and tools.
Fixing screws for carriages and guideways
Monorail guidance systems must only be located using the specified screws.
It is vital to follow the information:
in this catalogue
in the technical proposal letter
in the assembly drawing – if contained therein.
ACHTUNG
The screw specifications and tightening torques must be observed.
Any deviations will influence the performance of the screw connections as well as the function and operating life of the guidance systems.
Only fixing screws of the specified grades must be used.
If there is a possibility of settling, the fixing screws should be secured against rotation.
Ensure that the adjacent construction is of adequate strength.
The technical performance capability can only be achieved through the use of:
all threaded fixing holes
the specified screw grade
the specified tightening torques for screws.
Delivered condition
Monorail guidance systems are supplied with a preservative, basic greasing or initial greasing, see table.
The preservative is compatible with oils and greases having a mineral oil base.
Delivered condition
Designation
Delivered condition
Lubrication
Mounting
coated with preservative
with initial greasing
with basic greasing
preassembled as unit
guideway and carriage separate
RUE..-E
●
❍
‒
●
❍
KUSE
●
❍
‒
●
❍
KUVE..-B
❍
❍
●
●
❍
KUVE25-B..-HS
❍
●
‒
●
❍
KUVE..-W
❍
❍
●
●
❍
KUVS
❍
●
‒
‒
●
●
Standard.
❍
Optional.
Protection of wipers
The sharp-edged counterbores of the holes in the guideways are covered by an adhesive strip, ➤ Figure.
ACHTUNG
The adhesive strip protects the seal lips on the wipers of the carriages. The adhesive strip should not be removed until immediately before the guidance system is mounted.
The counterbores may cause injury.
Holes covered by adhesive strip
RUE..-E
Adhesive strip
Marking of locating face and marked face
The locating face is always on the opposing side to the marked face. The locating face of the guideway and the locating face of the carriage are on the same side when supplied, ➤ Figure. If the locating faces shall not be on the same side, the position of the locating faces must be indicated when ordering. If the carriage is separated from the guideway for mounting, it must be ensured that the position of the locating faces corresponds to the initial situation, when joining the carriage and the guideway.
The locating heights and corner radii in the table must be observed, see the section for the specific series.
Position of locating face and marked face
Locating face · Marked face · Vee strip
Dismounting and mounting of carriages
Observe and if necessary note the mounting position of the carriages (locating face).
ACHTUNG
Only remove carriages from the guideway if necessary.
Dismounting of carriages
Locate the dummy guideway
on one end face of the guideway and slide the carriage carefully onto the dummy guideway , ➤ Figure.
ACHTUNG
Do not move carriages over the counterbores of fixing holes that have not been closed off. Ensure that the seal lips of the wipers are protected if carriages are moved.
Do not remove the dummy guideway from the carriage. Protect the rolling element set against contamination and damage.
Mounting of carriages
Locate the dummy guideway
with the carriage on one end face of the guideway , ➤ Figure.
Slide the carriage
carefully onto the guideway, taking care not to damage the seal lips.
Dismounting and mounting of carriages
Dummy guideway · End face of guideway · Carriage
Location of carriages
ACHTUNG
The tightening torques MA in the dimension tables are valid for screws coated with preservative. If there is a possibility of settling, the fixing screws should be secured against rotation.
Observe the tightening torques MA for the fixing screws.
If the carriages are not connected to a central lubrication system, grease the carriages using the initial grease quantity.
The guideways and carriages must be protected before and during mounting against solid and fluid contaminants.
Series RUE and KUSE
ACHTUNG
Before the carriages are screw mounted to the adjacent construction, check the seat of the O rings.
Location of guideways
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
The tightening torques MA in the dimension tables are valid for screws coated with preservative.
Tightening scheme
Tighten the fixing screws in accordance with the scheme, ➤ Figure:
Tighten all the screws to 0,4×MA.
Tighten the screws marked in red to 0,7×MA.
Tighten the screws marked in black to 0,7×MA.
Tighten the screws marked in red to MA.
Tighten the screws marked in black to MA.
Tightening scheme for guideways
Multi-piece guideways
The end faces of the guideways are abutted against each other and the carriages are moved over the joint – this gives almost ideal alignment of the guideways.
ACHTUNG
In the case of multi-piece guideways, the gap at the end faces between two segments must be < 0,05 mm.
Screw mount the guideways in accordance with the tightening scheme, ➤ Figure. Leave the carriages located at the joint. Then check the joints again.
ACHTUNG
The guideway segments are marked with numbers and letters, ➤ Figure.
During mounting, the numbers and letters of the ends at each joint must match.
Butt joints on multi-piece guideways
Butt joints: · 1A – 1A · 1B – 1B · 2A – 2A
Fitting of closing plugs
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
Before mounting, guideways must be located using the tightening torque MA.
Do not move carriages over the counterbores of fixing holes that have not been closed off. Ensure that the seal lips of the wipers are protected if carriages are moved.
Depending on the environment and operating conditions, the counterbores are closed off using plastic or brass closing plugs. A fitting device for brass closing plugs is available, see link.
Position the fitting device over the closing plug until the pawl contacts the next closing plug that has not yet been pressed in; for the last closing plug, carry out this alignment visually .
Press in the closing plug using a maximum of 300 bar.
Unroll a portion of the covering strip and place with the adhesive film side face down in the slot – the covering strip should finish approx. 2 mm from the end of the guideway.
Peel off the protective film over a length of approx. 30 mm and fold it out at an angle to one side.
Align the covering strip in the slot and stick it down by applying pressure – for example by means of a pressure roller . The strength of the bond will depend on the pressure used.
Remove the protective film and finish fitting the covering strip.
The final adhesive force is achieved at room temperature after approx. 72 hours.
ACHTUNG
Check the storage life of the adhesive tape, see printed information on packaging.
Sticking down the covering strip
Protective film · Pressure roller
Fitting of clip fit covering strip
ACHTUNG
Risk of injury. The slot in the guideway and the ends of the covering strip have sharp edges.
Do not use the covering strip ADK if using the damping carriageRUDS.
Fit the covering strip only if it is free from creases and damage. Protect the covering strip and slot against contamination during fitting. Handle the covering strip with great care, avoiding alignment. Do not reuse the covering strip.
Clean the covering strip and guideway slot using a lint-free cloth .
Inspecting and cleaning the covering strip and guideway slot
Covering strip · Slot in guideway · Lint-free cloth
ACHTUNG
The covering strip may spring out of the slot if retaining plates are not used, so it must always be secured.
Insert and roll out the covering strip, ➤ Figure :
Insert the covering strip with the convex side upwards in the slot .
Unroll the covering strip by at least 200 mm. Leave the strip protruding by 10 mm to 20 mm. Bend the protruding length downwards by approx. 45° for fixing.
Unroll the covering strip completely and position it in the slot .
Secure the covering strip by means of retaining plates .
Placing the covering strip in the slot
ACHTUNG
The covering strip must be completely inserted in the slot before it is rolled in.
Always observe the travel direction of the rolling-in device. Do not tilt or reverse the rolling-in device.
Fit the closing plugs flush with the guideway surface , , see link.
Clean the surface (not in the case of plastic closing plugs).
Fitting of the closing plugs
Closing plugs · Rubber hammer · Oilstone
Commissioning the guidance system
Oil lubrication
ACHTUNG
Ensure that the guideways show a visible oil film.
Supply the guidance system with oil:
In order to ensure cleanliness and prevent corrosion, flush and fill all lubrication point supply pipes and lubrication holes immediately after connection.
At the time of commissioning, monorail guidance systems should be oiled with the minimum oil quantity Qmin, moving the carriage four times the carriage length during this process.
Damping carriage
Connect the damping carriage RUDS to the unpressurised lubricant supply system.
Grease lubrication
ACHTUNG
Ensure that the guideways show a visible grease film.
Linear recirculating ball bearing and guideway assemblies KUVE..-B have a basic greasing.
Supply the guidance system with grease:
Fill a clean grease gun or other lubrication device with fresh grease.
Clean the lubrication connector and its immediate environment.
Lightly grease the cleaned guideways.
Fill the carriages with the initial grease quantity, moving the carriages four times their length during this process.
Influence of grease
During commissioning and relubrication, the coefficient of friction increases temporarily due to the fresh grease. After a short running-in period, however, the coefficient of friction returns to its original lower value.
The friction behaviour is determined significantly by the characteristics of the grease used. The consistency and base oil viscosity serve as approximate guide values.