Three-dimensional laser centering device and method

Abstract

The invention relates to a three-dimensional laser centering device and method.The device comprises a handheld terminal, an M-end laser centering sensor, an S-end laser centering sensor and fixing supports, the fixing supports are installed on the two sides of a coupler of a unit rotor respectively, and the two laser centering sensors are installed on the fixing supports respectively; and the heights of the two laser centering sensors are staggered. The method comprises the following steps: 1, installing a laser centering sensor, and measuring the geometric dimension of a unit by a distance sensing module arranged in the sensor instead of a tape measure; 2, measuring centering data of the unit; 3, calculating the centering state and the adjustment amount of the unit; 4, adjusting the centering state of the unit; and 5, checking the centering state of the unit after adjustment. The distance sensing module is innovatively arranged in the laser sensor, so that the process of measuring geometric parameters of a unit by a tape in a traditional centering process is simplified, the measurement precision of the geometric parameters is improved, and a user is helped to quickly and accurately complete laser centering adjustment of the unit.

Description

Technical Field

[0001] The present invention relates to a device and method for monitoring the state of mechanical equipment, and in particular to a device and method for centering a mechanical structure using laser modulation, optical detection, and mechanical structure. Background Art

[0002] Poor alignment of mechanical equipment will accelerate equipment wear, increase energy consumption, and increase production safety risks. Therefore, mechanical equipment must be aligned and adjusted during installation. According to the tools used for alignment, the common methods for detecting and adjusting the alignment status currently include: dial indicator method and laser alignment method.

[0003] The dial indicator method generally uses several dial indicators (no less than 2) and special centering brackets to measure the centering status of mechanical equipment. It is widely used in the installation process of large machinery. It records data at different positions through multiple turns, calculates deviations and makes adjustments. This method has high accuracy, but it requires customized special centering brackets for different types of equipment, and the operation process is relatively complicated, requiring experienced technicians to operate.

[0004] Laser alignment is a fast and accurate alignment method that is gradually replacing the dial indicator method and is often used in the alignment of equipment such as wind turbines and steam turbine generators. This method uses a pair of laser alignment sensors to measure the alignment status of the unit. By rotating the unit rotor by a certain angle (generally 60° to 180°), the position of the laser on the photosensitive component at different angles is collected, and the unit alignment status is solved in combination with the unit's geometric parameters to guide the user to adjust the unit's alignment status. Although this method improves the efficiency of alignment, the current laser sensors can only measure two-dimensional plane information at most. The third-dimensional parameters such as sensor spacing and unit geometric parameters still rely on tape measurement, and the accuracy and efficiency still need to be improved. Summary of the invention

[0005] In order to solve the problem that traditional laser centering devices can only measure two-dimensional information within the plane of the sensing device (PSD position sensor), the present invention proposes a three-dimensional laser centering device and method that can measure three-dimensional spatial information. By adding a distance sensing module to the laser centering sensor and utilizing the reflection of laser, the distance information in the vertical direction of the sensing device can be measured, thereby simplifying the centering measurement process and improving the measurement accuracy.

[0006] To achieve the above objectives, the technical solution of the present invention is: a three-dimensional laser centering device, comprising a handheld terminal, an M-end laser centering sensor, an S-end laser centering sensor, and a fixed bracket. The fixed brackets are respectively installed on both sides of the coupling of the unit rotor, and the S-end laser centering sensor and the M-end laser centering sensor are respectively installed on the fixed brackets, and the S-end laser centering sensor and the M-end laser centering sensor are arranged with their heights staggered.

[0007] The fixed bracket includes a base, a support rod and a fastening chain. The S-end laser centering sensor and the M-end laser centering sensor are provided with through holes, installed on the support rod and fixed by bolts; the support rod is installed on the base; the base is fixed to the unit rotor with the fastening chain.

[0008] The S-end laser centering sensor has the same structure as the M-end laser centering sensor, both of which include: a metal casing, an optical filter, a laser transmitter, a fine-tuning mechanism, a PSD position sensor, a distance sensing module avalanche photodiode APD, a circuit board containing a tilt sensing device, a battery, a wireless charging coil, a film panel, and a back cover. The metal casing and the back cover are equipped with a circuit board containing a tilt sensing device, a battery, and a wireless charging coil. A fine-tuning mechanism is provided on the circuit board containing the tilt sensing device. A filter, a laser transmitter, a PSD position sensor, and a distance sensing module avalanche photodiode APD are provided in front of the metal casing, and a film panel is provided on the top of the metal casing.

[0009] A method for using a three-dimensional laser centering device, comprising the following steps:

[0010] Step 1: Measure the geometry of the unit

[0011] The distance sensing modules built into the S-end centering sensor and the M-end centering sensor are used to replace the tape measure to measure the geometric dimensions of the unit. Fixed brackets are installed on both sides of the coupling. The S-end laser centering sensor and the M-end laser centering sensor are installed on the fixed brackets respectively. The S-end laser centering sensor and the M-end laser centering sensor are arranged at different heights. The distances a, b, c, and d are measured at four positions of the shield. After the measurement, the height and laser angle of the S-end are adjusted so that the light spot falls at the center of the sensor PSD.

[0012] Step 2: Measure the alignment data of the unit

[0013] The three-point method is used to measure the unit alignment data. First, switch to the alignment mode on the handheld terminal, rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 3 o'clock position, and record the angle α1, the S-end spot position A1, and the M-end spot position B1 readings; rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 12 o'clock position, and record the angle α2, the S-end spot position A2, and the M-end spot position B2 readings; rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 9 o'clock position, and record the angle α3, the S-end spot position A3, and the M-end spot position B3 readings;

[0014] Step 3: Calculate the unit alignment status and adjustment amount

[0015] By using the data from step 2 and combining the shaft radius R, calculate the vertical parallel misalignment VD and angular misalignment VA, and the horizontal parallel misalignment HD and angular misalignment HA of the unit. The formula is as follows:

[0016]

[0017]

[0018] The adjustment amount of the adjustable end of the unit is as follows:

[0019]

[0020] Among them, S x is the x coordinate of the center of the adjustable end relative to the fixed end device, S y is the y coordinate of the center of the adjustable end relative to the fixed end device, M x is the x coordinate of the center of the fixed end relative to the fixed end device, M y is the y coordinate of the center of the fixed end relative to the fixed end device;

[0021] Ad1 is the vertical adjustment of the front foot of the adjustable end. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered.

[0022] Ad2 is the vertical adjustment of the adjustable rear foot. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered.

[0023] Ad3 is the lateral adjustment of the front foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end;

[0024] Ad4 is the lateral adjustment of the rear foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end;

[0025] Step 4: Adjust the unit alignment

[0026] According to the unit adjustment amounts Ad1, Ad2, Ad3, and Ad4 calculated in step 3, the vertical parallel misalignment and angular misalignment of the equipment are improved by adding machine foot pads, and the horizontal displacement of the equipment is fine-tuned to improve the horizontal parallel misalignment and angular misalignment;

[0027] Step 5: Check the alignment of the unit

[0028] Repeat steps 2 and 3 to check whether the misalignment of the unit is within the tolerance range. If it meets the requirements, end the alignment work; otherwise, continue with steps 4 and 5.

[0029] The beneficial effects of the present invention are:

[0030] The present invention proposes a three-dimensional laser centering device and method, which innovatively builds a distance sensing module into the laser sensor, thereby simplifying the process of measuring the geometric parameters of the unit with a tape measure in the traditional centering process, while improving the measurement accuracy of the geometric parameters, helping users to quickly and accurately complete the laser centering adjustment of the unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the three-dimensional laser centering device of the present invention;

[0032] Figure 2 This is a schematic diagram of the laser centering sensor fixing bracket;

[0033] Figure 3 This is a diagram of the construction of a three-dimensional laser centering sensor;

[0034] Figure 4 It is a schematic diagram of geometric parameters;

[0035] Figure 5 It is a flow chart of 3D laser alignment. DETAILED DESCRIPTION

[0036] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0037] like Figures 1 to 3 As shown, a three-dimensional laser centering device proposed in an embodiment of the present invention includes a handheld terminal (including laser centering software), an adjustment end (M end) laser centering sensor 1, a fixed end (S end) laser centering sensor 2, and a fixed bracket 3.

[0038] Fixed brackets 3 are respectively installed on both sides of the coupling of the unit rotor, and the fixed end (S end) laser centering sensor 2 and the adjustment end (M end) laser centering sensor 1 are respectively installed on the fixed brackets 3, and the fixed end (S end) laser centering sensor 2 and the adjustment end (M end) laser centering sensor 1 are staggered in height.

[0039] like Figure 2 As shown, the fixed bracket 3 includes a base, a support rod and a fastening chain. The laser centering sensor is provided with a through hole, installed on the support rod and fixed by bolts; the support rod is installed on the base; the base is fixed to the unit rotor with the fastening chain.

[0040] like Figure 3As shown, the adjustment end (M end) laser centering sensor 1 includes: a metal shell 4, a filter 6, a laser transmitter 8, a fine-tuning mechanism 5, a PSD position sensor 7, a distance sensing module avalanche photodiode APD9, a circuit board containing a tilt sensing device 10, a battery 11, a wireless charging coil 13, a film panel 14, and a back cover 12. The metal shell 4 and the back cover 12 are equipped with a circuit board containing a tilt sensing device 10, a battery 11, and a wireless charging coil 13. The circuit board containing the tilt sensing device 10 is provided with a fine-tuning mechanism 5. The front of the metal shell 4 is provided with a filter 6, a laser transmitter 8, a PSD position sensor 7, and a distance sensing module avalanche photodiode APD9. The top of the metal shell 4 is provided with a film panel 14.

[0041] The structure of the laser centering sensor 2 at the fixed end (S end) is consistent with that of the laser centering sensor 1 at the adjustment end (M end).

[0042] The present invention is a three-dimensional laser centering device and method. The present invention is described in detail below by taking the centering state adjustment of a centrifugal pump group as an example. Figure 5 As shown, the steps are as follows:

[0043] Step 1: Measure the geometric parameters of the unit. Use the distance sensing module built into the S-end laser centering sensor and the M-end laser centering sensor to replace the tape measure to measure the geometric dimensions of the unit, such as Figure 4 As shown in the figure, fixed brackets are installed on both sides of the coupling, and the S-end laser centering sensor and the M-end laser centering sensor are installed on the fixed brackets respectively, so that the S-end laser centering sensor and the M-end laser centering sensor are staggered in height, and the shielding objects are used to block the Figure 4 Measure the distances a, b, c, d at the four positions ①, ②, ③, and ④. After the measurement, adjust the height and laser angle of the S end so that the light spot falls at the center of the sensor PSD, and then proceed to the next step. The parameters of the centrifugal pump group are a = 205mm, b = 70mm, c = 125mm, d = 50mm. This step has the following advantages:

[0044] (1) High measurement accuracy. The distance measurement accuracy of avalanche diodes is much higher than that of tape measures.

[0045] (2) Optimize the installation and measurement process to improve the centering efficiency. Using the built-in distance measurement function of the sensor, all geometric parameters are measured while the sensor is installed.

[0046] Step 2: Measure the unit alignment data. Use the three-point method to measure the unit alignment data. First, switch to the alignment mode on the handheld terminal, rotate the shaft so that the S-end laser alignment sensor and the M-end laser alignment sensor are at the 3 o'clock position, and record the angle α1, the S-end spot position A1, and the M-end spot position B1 readings: α1, A1, B1 = -92.7°, -1.42mm, -1.47mm; rotate the shaft so that the S-end laser alignment sensor and the M-end laser alignment sensor are at the 12 o'clock position. The laser alignment sensor at the S end and the laser alignment sensor at the M end are placed at 9 o'clock, and the readings of the angle α2, the spot position A2 at the S end, and the spot position B2 at the M end are recorded: α2, A2, B2 = 89.8°, -0.07mm, -0.07mm; the shaft is rotated so that the laser alignment sensor at the S end and the laser alignment sensor at the M end are at the 9 o'clock position, and the readings of the angle α3, the spot position A3 at the S end, and the spot position B3 at the M end are recorded: α3, A3, B3 = 187.4°, -0.39mm, -0.01mm;

[0047] Step 3: Calculate the alignment status and adjustment amount of the unit. Based on the data from step 2 and the shaft radius R, calculate the vertical parallel misalignment VD and angular misalignment VA, and the horizontal parallel misalignment HD and angular misalignment HA of the unit. The formula is as follows:

[0048]

[0049]

[0050] The adjustment amount of the adjustable end of the unit is as follows:

[0051]

[0052] The calculation results are as follows:

[0053] VD=-0.06mm, VA=-0.03mm / 100mm

[0054] HD=-0.04mm, VA=0.11mm / 100mm

[0055] The calculation results of the adjustment amount of the adjustable end of the unit are as follows:

[0056] Ad1=-0.10mm

[0057] Ad2=-0.13mm

[0058] Ad3=0.09mm

[0059] Ad4=0.22mm

[0060] Among them, S x is the x coordinate of the center of the adjustable end relative to the fixed end device, S yis the y coordinate of the center of the adjustable end relative to the fixed end device, M x is the x coordinate of the center of the fixed end relative to the fixed end device, M y is the y coordinate of the center of the fixed end relative to the fixed end device;

[0061] Ad1 is the vertical adjustment of the front foot of the adjustable end. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered.

[0062] Ad2 is the vertical adjustment of the adjustable rear foot. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered.

[0063] Ad3 is the lateral adjustment of the front foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end;

[0064] Ad4 is the lateral adjustment of the rear foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end.

[0065] Step 4: Adjust the alignment of the unit. According to the unit adjustment values ​​Ad1, Ad2, Ad3, and Ad4 calculated in step 3, the vertical parallel misalignment and angular misalignment of the equipment are improved by adding machine foot shims, and the horizontal displacement of the equipment is fine-tuned to improve the horizontal parallel misalignment and angular misalignment.

[0066] Step 5: Check the alignment status of the unit after adjustment. Repeat steps 2 and 3 to check whether the misalignment of the unit is within the tolerance range. If it meets the requirements, the alignment work is completed, otherwise continue with steps 4 and 5.

Claims

1. A three-dimensional laser centering device, characterized in that: It includes a handheld terminal, an M-end laser alignment sensor, an S-end laser alignment sensor, and a fixed bracket. The fixed brackets are respectively installed on both sides of the coupling of the unit rotor. The S-end laser alignment sensor and the M-end laser alignment sensor are respectively installed on the fixed brackets, and the S-end laser alignment sensor and the M-end laser alignment sensor are arranged at a staggered height.

2. The three-dimensional laser centering device according to claim 1, characterized in that: The fixed bracket includes a base, a support rod and a fastening chain. The S-end laser centering sensor and the M-end laser centering sensor are provided with through holes, installed on the support rod and fixed by bolts; the support rod is installed on the base; the base is fixed to the unit rotor with the fastening chain.

3. The three-dimensional laser centering device according to claim 1, characterized in that: The S-end laser centering sensor has the same structure as the M-end laser centering sensor, both of which include: a metal casing, an optical filter, a laser transmitter, a fine-tuning mechanism, a PSD position sensor, a distance sensing module avalanche photodiode APD, a circuit board containing a tilt sensing device, a battery, a wireless charging coil, a film panel, and a back cover. The metal casing and the back cover are equipped with a circuit board containing a tilt sensing device, a battery, and a wireless charging coil. A fine-tuning mechanism is provided on the circuit board containing the tilt sensing device. A filter, a laser transmitter, a PSD position sensor, and a distance sensing module avalanche photodiode APD are provided in front of the metal casing, and a film panel is provided on the top of the metal casing.

4. A method for using the three-dimensional laser centering device according to claim 3, characterized in that: The steps are: Step 1: Measure the geometry of the unit The distance sensing modules built into the S-end laser centering sensor and the M-end laser centering sensor are used to replace the tape measure to measure the geometric dimensions of the unit. Fixed brackets are installed on both sides of the coupling. The S-end laser centering sensor and the M-end laser centering sensor are installed on the fixed brackets respectively, so that the S-end laser centering sensor and the M-end laser centering sensor are arranged at different heights. The distances a, b, c, and d are measured at four positions of the shield. After the measurement, the height and laser angle of the S-end are adjusted so that the light spot falls at the center of the sensor PSD. Step 2: Measure the unit alignment data The three-point method is used to measure the alignment data of the unit. First, switch to the alignment mode on the handheld terminal, rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 3 o'clock position, and record the angle α1, the S-end spot position A1, and the M-end spot position B1 readings; rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 12 o'clock position, and record the angle α2, the S-end spot position A2, and the M-end spot position B2 readings; rotate the shaft to make the S-end laser alignment sensor and the M-end laser alignment sensor at the 9 o'clock position, and record the angle α3, the S-end spot position A3, and the M-end spot position B3 readings; Step 3: Calculate the unit alignment status and adjustment amount By using the data from step 2 and combining the shaft radius R, calculate the vertical parallel misalignment VD and angular misalignment VA, and the horizontal parallel misalignment HD and angular misalignment HA of the unit. The formula is as follows: The adjustment amount of the adjustable end of the unit is as follows: Among them, S x is the x coordinate of the center of the adjustable end relative to the fixed end device, S y is the y coordinate of the center of the adjustable end relative to the fixed end device, M x is the x coordinate of the center of the fixed end relative to the fixed end device, M y is the y coordinate of the center of the fixed end relative to the fixed end device; Ad1 is the vertical adjustment of the front foot of the adjustable end. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered. Ad2 is the vertical adjustment of the adjustable rear foot. A positive value indicates that it needs to be raised; a negative value indicates that it needs to be lowered. Ad3 is the lateral adjustment of the front foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end. Ad4 is the lateral adjustment of the rear foot of the adjustable end. If the value is negative, it will shift to the left from the perspective of the adjustable end. Step 4: Adjust the unit alignment According to the unit adjustment amounts Ad1, Ad2, Ad3, and Ad4 calculated in step 3, the vertical parallel misalignment and angular misalignment of the equipment are improved by adding machine foot pads, and the horizontal displacement of the equipment is fine-tuned to improve the horizontal parallel misalignment and angular misalignment; Step 5: Check the alignment of the unit Repeat steps 2 and 3 to check whether the misalignment of the unit is within the tolerance range. If it meets the requirements, end the alignment work; otherwise, continue with steps 4 and 5.

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