The safe and flawless assembly and disassembly of machines and systems for industry only works if everyone involved knows exactly what needs to be done – and has the right equipment for their respective tasks. This involves much more than just loosening a few screws, unplugging connectors and positioning them correctly with lifting tools. Extreme precision is required in all areas to prevent damage and ensure efficient processes.
MACHINE ASSEMBLY AND DISASSEMBLY: A TASK FOR MANY TRADES
When machines or systems from industrial production are to be assembled or disassembled, it is a complex undertaking. It requires comprehensive planning because many aspects have to be taken into account.
The most important factor is time. Machine assembly or disassembly always means changes to the usual production processes. They may mean that some production lines only function to a limited extent or have to come to a complete standstill.
Efficiency during assembly and disassembly
Maximum efficiency is required in order to avoid or at least minimize production downtime and thus financial losses. Preparation is crucial because it is necessary to coordinate various trades that may be required for the assembly or disassembly of the machines.
Depending on the system, the areas of responsibility include pipeline construction, sealing technology, plastics construction, steel construction, sheet metal processing and heavy assembly. In addition, there are electrical installations, electrical assembly, the assembly of robot systems and the entire logistics area, from lifting the machines to transportation.
Precision assembly and disassembly
In order to ensure efficient processes and rapid assembly and disassembly, the individual work steps require precision above all else. This is why particularly suitable tools and other equipment, such as special forklifts or cranes, are used in such cases.
These not only guarantee that assembly processes are completed quickly. They also help to prevent damage during the work. The range of special tools and solutions for machine assembly is very extensive. Below we provide a brief overview, which cannot claim to be exhaustive – because the selection for the various areas of application is too large for that.
ASSEMBLY AND DISASSEMBLY: TOOLS FOR VARIOUS APPLICATIONS
The assembly and disassembly of machines and machine parts usually requires a wide range of different tools in order to be able to carry out the installation of all elements quickly and professionally.
Many of these assembly tools are also familiar from other trades: However, screwdriver bits, bit holders, extensions and adapters, socket wrench inserts and universal wrenches must meet the highest standards of precision and efficiency for industrial assembly.
Assembly and screwdriving technology for machine assembly
In machine assembly, the dimensions range from very small screw connections for electrical installations to massive threaded bolts. The requirements for the possible torques or the tensile force that the tools should – or must – achieve vary accordingly.
The assembly and screwdriving technology used in the industrial sector includes, among other things:
- Mechanical, mechatronic and digital torque wrenches
- Compressed air assembly tools such as impact wrenches, rotary screwdrivers, direct screwdrivers and similar
- Micro and small screwdrivers such as electric screwdrivers or shut-off screwdrivers
- Impulse screwdriver
- Cordless screwdriver
- EC screwdriver
- Screwdriver
- Hydraulic screwdriver
- High-torque screwdrivers and hydraulic tools for high torques
- Preload cylinder
- Servo presses, for example electric presses, screw presses or force-displacement presses
Suitable pullers are used to remove ball bearings, pole wheels, plain bearings, roller bearings and similar machine parts. These are available either as mechanical versions or as hydraulic versions.
Heating devices are used to be able to install and remove cylindrical roller bearings safely, quickly and without damage. The heat is generated using induction technology or medium frequency technology, for example.
Tools for material processing during machine assembly
Sometimes it is necessary to process the material of the machines or machine parts yourself during assembly or disassembly. The tools used for this are, for example
- Grinding machines such as turbine, flap, orbital, eccentric, angle, polishing or belt grinders, emerizing machines and similar devices,
- Drilling machines, such as cordless or pneumatic angle, rod or gun drills,
- Riveting tools such as riveting hammers and counter holders,
- Chipping hammers,
- Chamfering machines and milling tools,
- Pneumatic saws and circular saws,
- Welding machines for various welding processes.
Tools for testing and inspection during machine assembly
Quality assurance not only plays a central role in ongoing operations, it is also an essential component of (initial) assembly and disassembly. This is why aids and tools for checking and analyzing the machines concerned are also part of the equipment for machine assembly.
Tools in this area are becoming increasingly intelligent in order to obtain more precise information about the condition of the systems and system components. For example, digital test keys are used to track the entire tightening process. This allows the torque, angle of rotation and yield point to be precisely adjusted and assessed.
Transducers and analyzers complete the range of technical options for checking the quality of assembly.
TOOLS FOR THE ALIGNMENT OF MACHINES
Machines and systems are often installed horizontally in all areas of industry. For this reason, it is extremely important that the horizontal reference planes are correctly determined before installation. Otherwise, incorrect leveling can lead to faulty processes. This in turn leads to faulty products that do not meet quality standards.
When relocating a machine, it is important that the system in question is brought back into balance. This is not possible without precise and strict measurement. This can lead to considerable problems, especially when using stands and underframes.
Levels are instruments that can be used to check whether planes and lines are horizontal, vertical or at a 45-degree angle. Different types of leveling devices are used depending on the required measuring accuracy or the elements to be measured.
Simple leveling devices
The spirit level is one of the typical leveling devices used in everyday life. For the most accurate measurement results possible, digital versions are used that can not only determine vertical and horizontal levels, but also different angles.
Laser leveling devices
Laser levelling devices project reference lines onto a measurement object and thus help to determine the exact positions for alignment and positioning. For this reason, they are used in the installation of industrial systems, for example.
Mobile 3D coordinate measuring machines (CMMs) use lasers to scan various measuring points. This allows parallelism, height and distances between elements to be measured. One of the advantages is that a single person can carry out these measurements – and without varying measured values.
MEASUREMENTS FOR LEVELING
Various measurements are carried out to ensure that machines and systems are leveled and the permissible tolerances are adhered to.
The alignment is adjusted while the machine is mounted on a mounting plate. As the alignment is set at room temperature, changes during operation must be taken into account. This is because mechanical torques, vibrations and thermal expansion can affect the alignment. Alignment adjustment also includes shaft centering and positioning of the measurement objects.
Level adjustment is important for the installation of equipment stands and base frames. For this purpose, the floor level is measured to detect height differences in the ground. If necessary, leveling plates or adjusting screws are used to achieve a horizontal position. If available, conveyor lines are then aligned.
Strain measurement is necessary because many machines and machine parts are installed parallel or at right angles to their base frames or equipment stands, but without the loads that occur during operation. By measuring the strain, the load on the equipment stands and base frames as well as the flatness of machine parts and installation surfaces can be precisely determined.
Shaft alignment devices
In shaft alignment, two or more machines or machine parts are arranged in relation to each other so that the axes of rotation of all connected shafts are aligned as precisely as possible. Shaft alignment devices also work with laser technology and are used to achieve the most precise shaft alignment possible.
This reduces load change reactions and excessive wear on clutches, bearings, shaft seals and other machine parts.
Other alignment devices
Belt tension measuring devices, which are used to check the recommended pre-tension of drive belts, also fall under the heading of alignment devices. For this purpose, the vibration frequency of the belt is determined when stationary. The pulleys are also aligned in the same way. Laser-assisted alignment systems are now also used here to ensure the greatest possible precision.
LIFTING AND TRANSPORTING MACHINES FOR ASSEMBLY AND DISASSEMBLY
Regardless of whether a machine is being assembled for the first time or is to be dismantled for a plant relocation, for example – goods of this size and weight class require special equipment in order to be able to move them to the intended positions.
Vehicle fleet for the assembly and disassembly of machines
Due to their dimensions, machines, machine parts and systems can only be moved with vehicles and equipment specially equipped for such tasks. This applies to maneuvering within production facilities as well as transport.
Because each machine and its environment have very different lifting and transportation requirements, a comprehensive fleet of vehicles is needed. This includes
- Forklift trucks in various designs from industrial forklifts to telescopic forklifts
- High push trolley
- Working platforms
- Cranes
- Trucks and trailers
Lifting systems and similar aids
Lifting systems and transport rollers are used to lift and move bulky and heavy loads, depending on the conditions on site. The range extends from hydraulic systems to air systems, which are operated either manually or by power unit. Transport rollers are available in various designs. They are particularly suitable on stable floors. Alternatively, heavy-duty supports, traverses or cable spreaders are used.
Depending on the condition of the floor – both inside and outside – auxiliary structures and floor protection measures may also be necessary.
COMPREHENSIVE EQUIPMENT FOR A COMPLEX TECHNICAL TASK
The term machine assembly covers a wide variety of different tasks that involve different trades – and therefore require special equipment. After all, it is not just a matter of loosening all the plug connections and a few screws to move a machine from its place or, conversely, to move it to its intended position.
From larger elements to the smallest screw connections, from alignment to electrical installation, precision and care are required in all areas. These demands can only be met if the tools and equipment are perfectly matched to the task and its diverse requirements.
Image 1: Adobe Stock © unai
Image 2: Adobe Stock © KPs Photography
Image 3: Adobe Stock © Queenmoonlite Studio
Image 4: Adobe Stock © dekliyngkaea
