In the world of precision mechanics and industrial engineering, there is no room for randomness. Every detail matters – especially where the transmission of large forces and torques is involved. A prime example of such a challenge was one of our recent projects, involving the alignment of the gear base plates of a large gearbox driving a turntable drum at a cement plant.

Why is the alignment of cooperating components so important?

Every mechanical device operates on the basis of cooperating components – shafts, bearings, gears and especially gears. Their mutual position in relation to each other is crucial for the smooth, quiet and trouble-free operation of the entire system.

Incorrect setting may result:

• uneven distribution of forces,
• accelerated wear and tear of components,
• Excessive vibration and noise,
• In extreme cases – major accidents.

Therefore, maintaining proper dimensional relationships when assembling and seating components is an absolute must in any project of this type.

Challenge – precise alignment of mill gearbox base plates

As part of the order entrusted to our company, the task was to set the steel plates that are the base for the gearbox in place. This was a construction requiring very high precision – compliance with the technical documentation was a prerequisite here for the correct cooperation of the gearbox with the mill gear.

The process took place in several key stages:

• Pre-positioning of the plates according to the dimensions and axes specified in the design documentation.
• Locking the position of the plates to ensure stability in subsequent stages.
• Concreting and setting of the material, during which we monitored even the slightest movements of the slabs caused by the concrete setting process.
• Final control measurement – confirming that the panels have maintained the assumed positions after installation.

The role of the Laser Tracker

Precise measurement with the Laser Tracker was crucial in this project.
It made it possible:

• Very precise tide settings relative to the mill’s gear axis,
• Real-time monitoring of plate position changes,
• Responding immediately to any deviations,
• Full documentation of the installation process.

Just as importantly, a final measurement taken after the work was completed confirmed that the foundations for the gearbox had been set to an accuracy consistent with the design intent.

Customer benefits

For the client, the implementation of this project meant:

• certainty of correct installation of the gearbox – without the risk of errors due to improper leveling or misalignment,
• guarantee of parallel alignment of the drive axis with the mill gear axis – which translates into uniform operation of the entire system,
• Less mechanical stress and lower risk of future failure,
• Documented quality control, useful, for example, in the technical acceptance process.

Summary

Precise alignment of gearbox base plates is not just an assembly step – it is an investment in the reliability of the entire drive train. Thanks to the experience of the TREON team and the use of modern measuring tools, our customers ordering the service receive full confidence in the quality of workmanship.

If you are facing a similar challenge – contact us. We can help you build a solid foundation for your technologies.