Assembly of industrial machinery is a critical aspect of equipment maintenance and repair. Mastering the art of both assembling and disassembling machinery is essential for tasks such as installing new components, replacing worn parts, cleaning internal sections, and conducting routine maintenance. While the precise procedures may vary depending on the type of machine, adhering to general guidelines is crucial for the success of any assembly or disassembly project.

Disassembling Machinery

Disassembly and Assembly of Industrial Machinery

Before jumping into the process, take some time to prepare. Gather any manuals, instructions, or schematics for the equipment. Have the right tools for the job nearby. Clear sufficient workspace with good lighting. Use jacks, blocks, or stands to lift and support the machinery. And consult safety protocols like locking out power sources or releasing stored energy. Rushing into assembly or disassembly can lead to damaged parts, injury, or lost productivity from improper techniques. Additionally, as you explore mounting machine service, ensure that all steps align with the recommended procedures to guarantee a seamless and secure installation or removal process.

Basic Techniques and Tools

Common techniques apply whether you are assembling a new machine or taking an existing one apart. Use screwdrivers, wrenches, and other hand tools to loosen or tighten fasteners. A rubber mallet can help dismantle stubborn connections. Prying tools like putty knives and screwdrivers can aid in disassembly. Always use proper lifting equipment when moving heavy components. Lubricants like penetrating oil help separate stuck parts. Spread out parts methodically to stay organized. And work cleanly to avoid contaminating components.

Safety Tips

Follow all equipment safety precautions during assembly or disassembly. Use appropriate personal protective equipment like gloves, eyewear, and footwear. Lifting correctly prevents back injuries. Support heavy components to avoid crushing hazards. Release pressurized systems safely. And control stored energy in springs, cylinders, and hydraulics before disassembling. Take it slow and focus on the task at hand. Attempting too much too quickly can lead to mistakes and accidents.

Step-by-Step Machine Assembly

Once preparations are complete, it’s time for machinery assembly. While each make and model will vary, certain steps form the backbone of most assemblies.

Mounting the Frame and Base

The frame or body of the machine needs to be in position before adding components. Bolt the frame to the floor or mount it to a mobile base according to instructions. Use shims to level the frame if needed. Having a solid foundation is crucial for machine mechanical assembly operation.

Installing Bearings and Drives

Main bearings like pillow blocks often mount to the frame next. They will support shafts, spindles, and other rotating parts. Install bearings securely with the proper tightening torque. Then slide shafts into place and add retaining rings. Couplings, pulleys, and driveshafts can now be mounted and aligned.

Adding Motors and Controllers

Mount motors onto the frame or dedicated platforms. Ensure they are positioned for proper belt or chain alignments. Electrical control panels can also be mounted at this stage. Then run connect wires for power and control signals to each motor per the wiring diagram.

Attaching Functional Components

Now mount the parts that perform the main actions of the machine. For example, a conveyor system would have rollers, chains, and guides added. A hydraulic press would position cylinders, platens, molds, and pumps. Precision alignment is essential for these components. Leave fittings, handles, and guards off for now to allow adjustments.

Finishing Touches

With the main components installed, add fittings like inlet and outlet piping, nozzles, sensors, valves, and instrumentation. Power up the control system and test for functionality. Make any needed adjustments. Finally install covers, guards, handles and other peripheral parts. Safety test the fully assembled machine before regular electrical assembly operation.

Step-by-Step Machine Disassembly

Taking a machine apart methodically is key for proper reassembly or part replacement. Follow a reverse order from assembly for organized disassembly.

Removing Covers and Guards

Start by taking off external panels, guards, and covers to access the interior components. Remove handles and knobs as well. Place covers and guards together to one side so they can be reinstalled later.

Disconnecting Power and Plumbing

Shut off and disconnect any electrical power, pneumatics, and hydraulic lines. Use lock-out procedures for powered systems. Release stored pressure energy. Drain all liquids from tanks, piping, and reservoirs. Unbolt and detach plumbing lines.

Unmounting Functional Components

Now remove the parts that directly perform the machine’s purpose. For example, detach feed hoppers, mold platens, or roller assemblies. Keep associated fasteners with each component. Avoid damaging fragile parts during removal.

Removing Drives and Bearings

Take off pulleys, gears, and other transmission components. Slide shafts out of bearings and couplings. Unbolt bearings from their mounts. It helps to start with the topmost drives and bearings and work downwards.

Detaching the Frame

Finally, detach the frame from the base or floor. On large machines, separate the frame into sections for easier handling. Keep all mounting hardware together for reassembly. Avoid pinching wires between frame components.

Key Assembly and Disassembly Steps

While every machine is unique, certain steps apply to assembling or disassembling most industrial equipment:

  • Follow safety procedures like lock out/tag out and blocking.
  • Review technical instructions and schematics first.
  • Lay out parts to stay organized.
  • Build a solid base frame before adding components.
  • Install drives and bearings early on for alignment.
  • Attach functional parts once the frame is assembled.
  • Connect plumbing and wiring last.
  • Reverse the assembly order during disassembly.
  • Unmount functional components first.
  • Remove drives and bearings after functional parts.
  • Disconnect all power and plumbing before disassembly.
  • Detach covers, guards, and handles first when disassembling.

Special Considerations

Certain machines like hydraulic presses, turbines, and machine tools require extra precautions and preparation during assembly or disassembly.

Presses

  • Relieve any residual pressure before disassembling.
  • Support the overhead bed before removing the connecting rods.
  • Realign the gibs and guides after reassembly.
  • Adjust the shut height settings after assembly.

Turbines

  • Inspect blading carefully when disassembling rotors.
  • Balance the rotor dynamically after replacing the blades.
  • Check clearances in journal bearings during assembly.
  • Align couplings using precision measuring tools.

Machine Tools

  • Protect ways and leadscrews from damage and debris.
  • Re-scrape slides and re-align if necessary.
  • Clean and oil moving components after reassembly.
  • Qualify accuracy after reassembly to original specs.

Helpful Tips for Assembly and Disassembly

Follow these tips for smooth machinery assembly and disassembly:

  • Work in a clean, uncluttered area with good lighting.
  • Review technical manuals thoroughly before starting.
  • Have all necessary tools and supplies on hand.
  • Label or tag parts to stay organized during disassembly.
  • Document the disassembly steps with photos or videos.
  • Account for and handle fasteners carefully.
  • Protect sealing surfaces, bearings, and precision finishes.
  • Lubricate parts during assembly to aid installation.
  • Check alignments and clearances in bearings and drives.
  • Power up incrementally and test after assembly.
  • Verify all safety systems function after reassembly.
  • Consult the manufacturer if parts are damaged or unclear.

Hazards and Precautions

Assembly and disassembly come with inherent dangers that technicians must prepare for. Common hazards include:

  • Sharp edges can lacerate skin and damage nerves/tendons if hands/arms are mispositioned or slip. Leather gloves are essential PPE when handling metal components.
  • Heavy objects can inflict serious crushing injuries if mishandled or dropped. Use proper lifting techniques, transports, and supports when moving heavy parts.
  • Pressurized fluids and gases can be released if plumbing lines are disconnected improperly. Follow depressurization, drainage, and isolation procedures before unfastening any pressurized system.
  • Moving parts that can entangle clothing, hair, fingers, etc. Isolate drives and use lock-out/tag-out procedures.
  • Pinch points exist wherever two objects are moving together such as gears, belts, rolls, and stock fed into machines. Keep hands well clear or use jigs/fixtures to position parts.
  • Falling objects if disassembled components become unbalanced or unstable. Secure parts as they are detached and keep the center of gravity low.
  • Stored energy in hydraulics, air cylinders, springs, flywheels, etc. Release or block all stored energy before further disassembly.
  • Electrical energy requires becoming familiar with control panels and using proper lock-out/tag-out steps before accessing wiring.

FAQs

What are the main steps in assembling industrial machinery?

The key assembly steps are:

  • Mounting the frame and base
  • Installing bearings, drives, and shafts
  • Attaching motors and control systems
  • Positioning functional components like cylinders or rollers
  • Adding plumbing, wiring, sensors and accessories
  • Testing operation and installing guards

In what order should you disassemble machinery?

Disassemble in the reverse order of assembly:

  • Remove covers, guards, and accessories
  • Detach plumbing and electrical systems
  • Remove functional components
  • Take off bearings, then drives and shafts
  • Unmount the frame from the base

What tools are most useful for machinery disassembly?

Hand tools like wrenches, screwdrivers, pry bars, and mallets allow safe disassembly. Lifting equipment helps move heavy parts. Labeling supplies keep organization. Lubricants ease stuck connections.

How can you avoid damage during assembly and disassembly?

Work slowly with good lighting in a clear workspace. Follow instructions closely. Protect sealing surfaces, bearings, and ways from contaminants. Support heavy components properly. Use power tools carefully.

What safety precautions apply to machinery assembly and disassembly?

Lock out power sources. Release stored energy. Relieve pressures. Handle sharp edges carefully. Use lifting aids when moving heavy parts. Isolate pinch points. Support unstable components.

Conclusion

Assembling and disassembling industrial machinery is an important skill for installation, maintenance, and repair. While specific techniques on machine assembly installation service vary across different machines, following general best practices will lead to safe, efficient assembly and disassembly. Preparation, organization, caution, and patience are essential at every stage. With the right tools, knowledge, and mechanically inclined focus, technicians can master the ins and outs of machinery assembly and disassembly.