Shaft alignment device and method

Abstract

A device for aligning a shaft, the device comprising: a cover plate including a first face and a second face, the cover plate being removably mountable to a bearing housing, the cover plate including at least two apertures configured to receive respective aligning bolts therethrough; wherein the aligning bolts extend normally through the cover plate to contact an end of a shaft when the shaft is positioned within the shaft receiving aperture; and wherein when a first end of each of the aligning bolts contact the end of the shaft, respective second ends of the aligning bolts together define a plane with orientation substantially similar to a plane defined by the end of the shaft, such that the shaft can be brought into proper alignment with the bearing housing.

Description

[0001] SHAFT ALIGNMENT DEVICE AND METHOD

[0002] Technical Field of the invention

[0003] The present invention relates to a device for aligning a shaft. The present invention also relates to a method for aligning a shaft.

[0004] The present invention relates to a shaft alignment device and method. In particular, the shaft alignment device and method has particular application for aligning shafts mounted in bearing housings (or blocks), such as those used in mining and materials handling applications. However, it will be appreciated that the present invention may have applications in other industrial settings.

[0005] Background of the invention

[0006] Rotating shafts are typically supported by bearings, which are mounted into a non-rotating structure (in most instances a housing). It is often the case that shaft ends are obscured behind end covers of the housings. The purpose of end covers on housings is to retain lubricant and prevent the ingress of contaminants into the housing, where they could migrate to the bearing and damage it. However, standard end covers do not facilitate access to the shaft or bearing within a housing without their removal, which introduces the possibility of contamination.

[0007] Correctly aligning rotating shafts is an important engineering practice. Poor shaft alignment can lead to increased vibrations, excessive wear, reduced efficiency, and ultimately, equipment failure. Premature and catastrophic failure of rotating assemblies may result in plant downtime, unplanned replacement costs and in some instances damage to proximate property or even injury to people.

[0008] A shaft should be aligned within a bearing housing to ensure that shaft rotation is "true" about the longitudinally extending central axis of the shaft bearing and in turn, the housing - while also remaining "true" to the relevant parts of the plant to which the shaft is coupled or is otherwise a working component of. If the shaft central axis is misaligned, the shaft will rotate unevenly, creating a rotating unbalance, uneven clearance between seals and improper contact between the working components of the bearing.

[0009] Within bearing housings, often the axis of a shaft is not coaxial to the axis of the housing, owing to manufacturing tolerances of the housing. In such scenarios, the centring hole of the shaft may sit higher or lower, fore, or aft of the housing axis - or any practical combination thereof.

[0010] Shaft misalignment can create several problems for the shaft and bearings and reduce the working lifespan of the bearings. In addition, shaft misalignment may result in damage to associated machinery, such as conveyor belts.

[0011] When shaft misalignment occurs, integral seals on the bearing to which the shaft is mounted and / or seals at the interface between the shaft and the housing containing the bearing, can develop excessive clearances and any such clearances may result in contamination ingress and premature bearing failure.

[0012] Shaft misalignment also creates problems when attempting to couple a shaft with other equipment as it is important to ensure the rotational axes of two coupled shafts are coaxial. Correct shaft alignment is crucial for the smooth operation of rotating machinery, such as pumps, motors, compressors, and turbines and conveyor belts.

[0013] Shaft alignment with respect to housing and bearing position is typically measured using feeler gauges or other similar measurement devices, typically at four positions around the circumference of the shaft referred to as 12 o'clock, 6 o'clock, 3 o'clock and 9 o'clock. Misalignment will be identified by any variation in the measurements at those four positions, and intervention may then be made to align the shaft with respect to housing and bearing position. However, the nature of the misalignment can be difficult to measure and rectify, and opening the housing is undesirable, as it introduces the risk of contaminants entering the bearing housing.

[0014] Aligning a shaft so that it is "true" to the relevant parts of the plant to which the shaft is coupled or is otherwise a working component of, typically requires bringing the axes of the relevant components into coaxial alignment. This is done by determining the shaft axis and moving the housing containing the bearing in which the shaft is mounted. If to do this the axis of the shaft is obtained by removing the housing end cover, the risk of introducing contamination into the bearing housing is again created.

[0015] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application. It is desired to address or alleviate one or more disadvantages or limitations of the prior art, or to at least provide a useful alternative. of the invention

[0016] In some embodiments, the present invention is directed to a device for aligning a shaft, the device comprising: a cover plate including a first face and a second face, the cover plate being removably mountable to a bearing housing, the cover plate including at least two apertures configured to receive respective aligning bolts therethrough; wherein the aligning bolts extend normally through the cover plate to contact an end of a shaft when the shaft is positioned within the shaft receiving aperture; and wherein when a first end of each of the aligning bolts contact the end of the shaft, respective second ends of the aligning bolts together define a plane with orientation substantially similar to a plane defined by the end of the shaft, such that the shaft can be brought into proper alignment with the bearing housing.

[0017] In some embodiments, when the cover plate is mounted to the bearing housing, a central axis of the cover plate substantially aligns with a central axis of a shaft receiving aperture of the bearing housing.

[0018] In some embodiments, the second end of each of the aligning bolts is configured to interface with an adapter.

[0019] In some embodiments, the adapter is configured to interface with an alignment measurement device for determining the alignment between the bearing housing and / or the shaft when the shaft is positioned within the bearing housing, with a reference point.

[0020] In some embodiments, the first face of the cover plate includes at least one seal groove configured to prevent the ingress of foreign material into the bearing housing when the cover plate is mounted to the bearing housing.

[0021] In some embodiments, the device further includes an external cap removably mountable to the cover plate and configured to cover the at least two apertures.

[0022] In some embodiments, the device further includes a respective spacer for each of the two or more adjustment bolts, each spacer removably attachable to a respective adjustment bolt. In some embodiments, when the spacers are attached to respective adjustment bolts, the spacers secure the second end of each of the adjustment bolts at a predetermined distance from the second face of the cover plate.

[0023] Some embodiments of the present invention are directed to a method for aligning a shaft, the method including: mounting a cover plate to a bearing housing wherein the cover plate includes at least two apertures configured to receive respective aligning bolts therethrough; extending the adjustment bolts normally through the cover plate so that a first end of the adjustment bolts contacts an end of a shaft positioned within the shaft receiving aperture; and substantially aligning a plane defined by respective second ends of the aligning bolts with a plane defined by a second face of the cover plate to substantially align the shaft with the bearing housing.

[0024] In some embodiments, mounting the cover plate to the bearing housing includes substantially aligning a central axis of the cover plate with a central axis of a shaft receiving aperture of the bearing housing.

[0025] In some embodiments, substantially aligning the plane defined by respective second ends of the aligning bolts with the plane defined by the second face of the cover plate includes determining that a depth of extension of each of the two or more adjustment bolts is substantially identical.

[0026] In some embodiments, determining that the depth of extension of each of the two or more adjustment bolts is substantially identical includes measuring a distance from the second end of each adjustment bolt to the second face of the cover plate.

[0027] In some embodiments, substantially aligning includes manipulating the position of the bearing housing until the distance from the second end of each adjustment bolt to the second face of the cover plate is substantially identical for each adjustment bolt.

[0028] In some embodiments, the second end of each of the aligning bolts is configured to interface with an adapter, and wherein the method further includes attaching the adapter to the cover plate, via the adjustment bolts.

[0029] In some embodiments, the method further includes attaching an alignment measurement device to the adapter, and using the alignment measurement device to align the bearing housing and / or with the shaft with a reference point. In some embodiments, the method further includes using the alignment measurement device to ensure that one or more of the bearing components of the bearing housing, the bearing housing, and / or one or more bearing seals, are aligned with a reference point.

[0030] In some embodiments, the method further includes aligning the adapter the reference point, wherein the reference point is associated with a plant to which the bearing housing is installed.

[0031] In some embodiments, the method further includes attaching a respective spacer to each of the adjustment bolts that restricts the movement of the adjustment bolts such that the adjustment bolts cannot damage one or more components of the bearing housing and / or one or more components of a bearing contained within the bearing housing when the bearing housing is moved.

[0032] In some embodiments, the respective spacers further stop the first ends of the adjustment bolt from contacting the end of the shaft, when the shaft is positioned with the shaft receiving aperture and / or when the shaft is in operation.

[0033] Some embodiments of the present invention are directed to a method for aligning a shaft using a shaft alignment device, the method according to any of the present disclosures, and the shaft alignment device according to any of the present disclosures.

[0034] In some embodiments, the present invention is directed to a shaft alignment device comprising: a replacement housing end cover, modified to improve sealing performance, coaxially align the invention to the shaft axis, facilitate removal of the invention from the housing and enable the intended function of the invention; a series of precisely engineered adjustment bolts, which insert through the modified end cover and can be advanced or retracted relative to the modified end cover by individual rotation; an external cover that serves to prevent the ingress of moisture and contaminants into the working parts of the invention and contain spacers that set the clearances of the adjustment bolts; and mounting points, capable of accepting the: connection of an alignment device to the modified end cover, be it optical, laser or any alternative mechanism, either directly or indirectly through a rotating spindle; and connection of an alignment device to the adjustment bolts, be it optical, laser or any alternative mechanism, through an adapter, wherein the mounting point(s) is(are) configured to facilitate the unimpeded function of the alignment device.

[0035] In some embodiments, the invention may be configured to accept a swash plate, connected to the end of each adjustment bolt. The modified end cover is prepared with a groove, designed to accept the installation of a seal that resides between the modified end cover and the mounting face of the housing.

[0036] The modified end cover is prepared with a spigot, designed to fit within the spigot entry hole of the housing.

[0037] The modified end cover is prepared with tapped and / or untapped holes arranged circumferentially, with plugs, screws or bolts inserted into them.

[0038] The adjustment bolts are sized such that they cannot excessively advance or retract without their heads contacting the modified end cover or the external cover.

[0039] The ends of the adjustment bolts are designed in such a way that they will not damage the shaft when they are advanced into contact with it.

[0040] The heads of the adjustment bolts are designed in such a way that they will facilitate the installation of the adapter which holds the alignment device.

[0041] The adapter which holds the alignment device is designed to install onto the heads of the adjustment bolts and be held in that position by mechanical or magnetic connection.

[0042] According to some embodiments, the present invention is directed to a method of aligning a shaft using a shaft alignment device, the method including the steps of: securing the invention to a bearing housing containing a bearing, adjacent to a shaft end, by installing the modified end cover in place of a standard end cover that would otherwise be installed to the bearing housing; ensuring that the axis of the modified end cover is coaxial with the axis of the housing, by engaging the spigot of the modified end cover with the spigot entry hole of the housing; removing the external cover from over the adjustment bolt heads; removing the spacers that retain the adjustment bolts in position from under the adjustment bolt heads; rotating each adjustment bolt such that each adjustment bolt advances into the housing, until each adjustment bolt end is in contact with the shaft; rotating the housing about the shaft and continuing to manipulate the adjustment bolts until the depth of advance of each adjustment bolt in contact with the shaft is identical, thereby bringing the axis of the shaft into coaxial alignment with the housing, bearing and / or modified end cover; confirming that the depth of advance of each adjustment bolt in contact with the shaft is identical by measuring the distance between the underside of each bolt head, or some other reliable reference point, and the face of the modified end cover; installing an alignment device to the external face of the modified end cover, which now represents a translated offset plane to the shaft end; aligning the modified end cover to the relevant reference points on the plant to which the bearing housing is installed, ensuring that not only is the shaft aligned to the plant, but also that the housing is aligned to the shaft, the bearing components are aligned within the bearing and the seals on the bearing and / or between the shaft and the housing containing the bearing are aligned as well.

[0043] In some embodiments, the present invention is directed to a method of aligning a shaft using a shaft alignment device, the method including the steps of: securing the invention to a bearing housing containing a bearing, adjacent to a shaft end, by installing the modified end cover in place of a standard end cover that would otherwise be installed to the bearing housing; ensuring that the axis of the modified end cover is coaxial with the axis of the housing, by engaging the spigot of the modified end cover with the spigot entry hole of the housing; removing the external cover from over the adjustment bolt heads; removing the spacers that retain the adjustment bolts in position from under the adjustment bolt heads; rotating each adjustment bolt such that each adjustment bolt advances into the housing, until each adjustment bolt end is in contact with the shaft; mounting an adapter, which represents a translated offset plane to the shaft end, to the adjustment bolt heads; installing an alignment device to the adapter; aligning the adapter to the relevant reference points on the plant to which the bearing housing is installed, ensuring that the shaft is aligned to the plant; rotating the housing about the shaft and continuing to manipulate the adjustment bolts until the depth of advance of each adjustment bolt in contact with the shaft is identical, thereby bringing the axis of the shaft into coaxial alignment with the housing, bearing and / or modified end cover; confirming that the depth of advance of each adjustment bolt in contact with the shaft is identical by measuring the distance between the underside of each bolt head, or some other reliable reference point, and the face of the modified end cover, in doing so ensuring that the housing is aligned to the shaft, the bearing components are aligned within the bearing and the seals on the bearing and / or between the shaft and the housing containing the bearing are aligned as well.

[0044] In some embodiments the risk of mishandling of the bearing housing, or the shaft or component that it is installed to, is reduced. Mishandling in this context could result in excessive load being imparted on the invention, resulting in damage to the invention.

[0045] The step of aligning the shaft may include the step of attaching the alignment device to an extension component which facilitates the alignment at increased distance from the shaft end. This may be required to ensure that reference points on the plant to which the bearing housing is installed are accessible to the alignment device. In some embodiments, the method further includes the step of using spacers that set the clearances of the adjustment bolts to position the ends of the adjustment bolts in contact with, slightly clear of, or well clear of the shaft face. This is facilitated by the use of spacers of various thicknesses. When the adjustment bolt ends are set with or without spacers to be in contact with the shaft end, the effect is to lock the shaft to the housing through the invention, preventing any movement that could risk the housing over-rotating about the shaft during handling and damaging seals and / or working parts of the bearing. In instances where fully constraining the housing and shaft is considered excessive, the use of spacers of a suitable thickness holds the adjustment bolt ends at a distance from the shaft end which still limit the permissible rotation of the housing about the shaft, thus ameliorating the risk of the bearing housing over-rotating about the shaft during handling and damaging seals and / or working parts of the bearing. When the adjustment bolt ends stand well clear of the shaft end, the use of spacers of a suitable thickness ensure this.

[0046] Brief description of the drawings

[0047] One or more embodiments of the present invention are hereinafter described, by way of example only, with reference to the accompanying drawings in which:

[0048] Figure 1 is a perspective view of a second face of a cover plate including an external cap; Figure 2 is a perspective view of the cover plate of figure 1 with the external cap removed; Figure 3 is a perspective view of a second face of the cover plate of figure 1;

[0049] Figure 4 is a cross-sectioned perspective view of the cover plate of figure 1;

[0050] Figure 5 is a perspective view of a bearing housing including the cover plate of figure 1;

[0051] Figure 6 is a cross-sectioned perspective view of the bearing housing and cover plate of figure 5;

[0052] Figure 7 is a perspective view of a bearing housing including the cover plate of figure 2 with a retaining bolt removed;

[0053] Figure 8 is a perspective view of the bearing housing of Figure 7, with spacers removed;

[0054] Figure 9 is a perspective view of the bearing housing of Figure 8 including an alignment measurement device;

[0055] Figure 10 is across-sectioned perspective view of the bearing housing of Figure 9;

[0056] Figure 11 is a cross-sectioned elevation view of the bearing housing of Figure 9;

[0057] Figure 12 is a cross-sectioned elevation view of a bearing housing including a cover plate, an adapter and an adjustment measurement device;

[0058] Figure 13 is a perspective view of a bearing housing including a cover plate, an adapter and an adjustment measurement device;

[0059] Figure 14 is a cross-sectioned elevation view of the bearing housing of Figure 13; Figure 15 cross-sectioned view of a bearing housing including a cover plate, an adapter and an adjustment measurement device wherein the shaft is misaligned with the bearing housing; and

[0060] Figure 16 is cross-sectioned view of a bearing housing including a cover plate, an adapter and an adjustment measurement device wherein the shaft is misaligned with the bearing housing.

[0061] Detailed description of preferred embodiments

[0062] The present disclosure is directed to a device 100 for aligning a shaft, the device 100 comprising: a cover plate 110 including a first face 150 and a second face 155, the cover plate 110 being removably mountable to a bearing housing 200, the cover plate 110 including at least two apertures 160 configured to receive respective aligning bolts therethrough; wherein the aligning bolts 113 extend normally through the cover plate 110 to contact an end of a shaft 1110 when the shaft 300 is positioned within the shaft receiving aperture 610; and wherein when a first end of each of the aligning bolts 165 contact the end of the shaft 1110, respective second ends of the aligning bolts 170 together define a plane with orientation substantially similar to a plane defined by the end of the shaft 1110, such that the shaft 300 can be brought into proper alignment with the bearing housing 200.

[0063] The present device 100 enables the orientation of the shaft 300, as represented by the plane defined by the end of the shaft 1110, to be determined without removing the cover plate 110. By reproducing the plane defined by the end of the shaft 1110 using the plane defined by the second end of the adjustment bolts, the bearing housing 200 (also referred to as the housing 200) may be moved such that the orientation of the bearing housing 200 aligns with the shaft 300. In some embodiments, the at least two apertures 160 are threaded, unthreaded, tapped, or untapped.

[0064] By properly aligning the bearing housing 200 and the shaft 300 wear on the bearings 210, the bearing housing 200, the shaft 300 and / or any other components can be reduced thereby increasing their lifespan. Further, as the cover plate 110 does not need to be removed to align the shaft 300 and bearing housing 200, foreign material is not as easily able to get inside the bearing housing and cause damage to the bearing components therein.

[0065] When the cover plate 110 is mounted to the bearing housing 200, a central axis of the cover plate 110 substantially aligns with a central axis of a shaft receiving aperture 610 of the bearing housing 300. This enables the proper alignment of the shaft with the bearing housing. The second end of each of the aligning bolts 170 is configured to interface with an adapter 500. The adapter 500 can provide a clearer indication of the plane defined by the second ends of the adjustment bolts 170. Further, the adapter 500 is capable of interfacing with an alignment measurement device 400 to further assist in properly align the bearing housing 200 and / or the shaft 300 (when the shaft 300 is within the bearing housing 200), with (or relative to) a reference point. In some embodiments, the reference point is included in / on or otherwise associated with a plant that the bearing housing is to be installed in / on. In some embodiments, the adapter 500 may include a swash plate.

[0066] The adapter 500 is configured to interface with an alignment measurement device 400 for determining the alignment between the bearing housing 200 and / or the shaft 300 when the shaft 300 is positioned within the bearing housing 200, with a reference point. The alignment measurement device 400 may be configured to provide a specific indication (e.g. a readout, measurement, etc.) associated with the degree of alignment between the bearing housing 200 and the shaft 300. In some embodiments, the alignment measurement device 400 may be configured to work in conjunction with one or more alignment markings, references and / or indicators associated with a plant that the bearing housing 200 is being installed in / on.

[0067] According to some embodiments, the alignment measurement device 400 may be attachable or mountable directly to the cover plate 110 without the need for the adapter 500. For example, via a mounting point included in / on the cover plate 110.

[0068] The first face 150 of the cover plate 110 includes at least one seal 115 configured to prevent the ingress of foreign material into the bearing housing 200 when the cover plate 110 is mounted to the bearing housing 200. This ensures that the internal components of the bearing housing 200 is not damaged by foreign material, thereby improving its operational lifespan.

[0069] The device 100 further includes an external cap 120 removably mountable to the cover plate 110 and configured to cover the at least two apertures 160. The external cap 120 provides added protection to the cover plate and to the adjustment bolts 113.

[0070] The device 100 further includes a respective spacer 114 for each of the two or more adjustment bolts 113, each spacer 114 removably attachable to a respective adjustment bolt 113. The spacers 114 ensure that the adjustment bolts cannot be unintentionally moved when alignment is not being performed. For example, vibrations caused by rotation of the shaft or nearby machinery, impacts to the bearing housing or any other such cause, may cause the adjustment bolts to extend towards shaft and / or bearing components at an unwanted time thereby potentially causing damage. The spacers stop the adjustment bolts extending past a certain point.

[0071] When the spacers 114 are attached to respective adjustment bolts 113, the spacers 114 secure the second end of each of the adjustment bolts 170 at a predetermined distance from the second face of the cover plate 155. The predetermined distance may be a sufficient distance such that there is suitable clearance between the adjustment bolts 113 and other components, while the spacers are attached, so as to avoid unintentional contact between the adjustment bolts and other components, thereby preventing damage.

[0072] The present disclosure is also directed to a method for aligning a shaft 300, the method including: mounting a cover plate 110 to a bearing housing 200 wherein the cover plate 110 includes at least two apertures 160 configured to receive respective aligning bolts 113 therethrough; extending the adjustment bolts 113 normally through the cover plate 110 so that a first end of the adjustment bolts 165 contacts an end of a shaft 1110 positioned within the shaft receiving aperture 610; and substantially aligning a plane defined by respective second ends of the aligning bolts 170 with a plane defined by a second face of the cover plate 155 to substantially align the shaft 300 with the bearing housing 200. The method provides for the accurate alignment of the bearing housing 200 and the shaft 300 without the need to remove the cover plate 110, by reproducing the orientation of the shaft 300 externally (outside the bearing housing 200). This enables the quick, accurate and clean alignment of the bearing housing 200 and the shaft 300 in various different environments.

[0073] Mounting the cover plate 110 to the bearing housing 200 includes substantially aligning a central axis of the cover plate 110 with a central axis of a shaft receiving aperture 610 of the bearing housing 200. This enables the proper alignment of the shaft with the bearing housing.

[0074] Substantially aligning the plane defined by respective second ends of the aligning bolts 170 with the plane defined by the second face of the cover plate 155 includes determining that a depth of extension of each of the two or more adjustment bolts 113 is substantially identical. This is performed so that the plane defined by the respective second ends of the aligning bolts 170 (which is in the same orientation as the end of the shaft 1110), is properly aligned with the bearing housing 200.

[0075] Determining that the depth of extension of each of the two or more adjustment bolts 113 is substantially identical includes measuring a distance from the second end of each adjustment bolt 170 to the second face of the cover plate 155. This enables the accurate alignment of the bearing housing 200 and the shaft 300. Substantially aligning includes manipulating the position of the bearing housing 200 until the distance from the second end of each adjustment bolt 170 to the second face of the cover plate is substantially identical for each adjustment bolt.

[0076] The second end of each of the aligning bolts 170 is configured to interface with an adapter 500, and wherein the method further includes attaching the adapter 500 to the cover plate 110, via the adjustment bolts 113. The adapter 500 can provide a clearer indication of the plane defined by the second ends of the adjustment bolts 170. Further, the adapter 500 is capable of interfacing with an alignment measurement device 400 to further assist in properly align the bearing housing 200 and / or the shaft 300 with a reference point.

[0077] The method further includes attaching an alignment measurement device 400 to the adapter 500, and using the alignment measurement device 400 to align the bearing housing 200 and / or the shaft 300 with a reference point (e.g. of the plant). The alignment measurement device 400 may be configured to provide a specific indication (e.g. a readout, measurement, etc.) associated with the degree of alignment between the bearing housing 200 and / or the shaft 300. In some embodiments, the alignment measurement device 400 may be configured to work in conjunction with one or more alignment markings, references and / or indicators associated with a plant that the bearing housing 200 is being installed in / on.

[0078] The method further includes using the alignment measurement device 400 to ensure that one or more of the bearing components of the bearing housing 200, the bearing housing 200, and / or one or more bearing seals, with a reference point. This ensures that wear on the bearing components, the bearing housing, and / or the shaft can be reduced to increase the operational lifespan of the components.

[0079] The method further includes aligning the adapter 500 to the reference point (not shown), wherein the reference point is associated with a plant (not shown) to which the bearing housing 200 is installed. This is performed as the shaft may be mounted to other machinery or components in the plant, and the machinery or components may have been aligned and / or positioned based on the reference points. In an alternative embodiment, the reference points may have been placed after the machinery or components have been installed, and thereby indicate the proper alignment positions for components associated with, or that interact with the shaft 300.

[0080] The method further includes attaching a respective spacer 114 to each of the adjustment bolts 113 that restricts the movement of the adjustment bolts 113 such that the adjustment bolts 113 cannot damage one or more components of the bearing housing 200 and / or one or more components of a bearing contained within the bearing housing 200 when the bearing housing 200 is moved.

[0081] The respective spacers 114 further stop the first ends of the adjustment bolt 165 from contacting the end of the shaft 1110, when the shaft 200 is positioned with the shaft receiving aperture 610 and / or when the shaft 300 is in operation. The spacers 114 ensure that the adjustment bolts cannot be unintentionally moved when alignment is not being performed. For example, vibrations caused by rotation of the shaft or nearby machinery, impacts to the bearing housing or any other such cause, may cause the adjustment bolts to extend towards shaft and / or bearing components at an unwanted time thereby potentially causing damage. The spacers stop the adjustment bolts extending past a certain point.

[0082] The present disclosure is also directed to a method for aligning a shaft using a shaft alignment device 100, the method according to any of the present disclosures, and the shaft alignment device 100 according to any of the present disclosures.

[0083] A further, more detailed description of the invention will now be provided with reference to the figures.

[0084] There is disclosed herein a device 100, also referred to as a shaft and seal alignment device, which can be fitted to an existing or modified bearing housing 200, such as a pillow (plummer) block type bearing housing 200. However, the device 100 may be used with other bearing housings.

[0085] Figure 1 provides a front perspective view of the device 100, including the cover plate 110, also referred to as a modified end cover 110, or simply an end cover 110, and an external cover 120 also referred to as an external cap 120.

[0086] Figure 2 provides a front perspective view of the device 100, including mounting holes 111, threaded jacking bolt holes 112, adjustment bolts 113, spacers 114 and external cap retaining bolt 121 (also referred to as an external cover retaining bolt).

[0087] The external cap retaining bolt 121 may be used to affix the external cap 120 to the cover plate 110. In some embodiments, the mating feature of the cover plate 110 that receives the external cap retaining bolt 121 may also be configured to receive the adjustment measurement device 400. Figure 3 provides a rear perspective view of the device 100, including seal groove 115 and cover plate spigot 116.

[0088] Figure 5 is a front perspective view of the cover plate 110, as it would be installed to the bearing housing 200. Figure 5 provides a front perspective view of the cover plate 110, when it is installed to a bearing housing 200 which contains the end of the shaft 1110.

[0089] Figure 6 is a front cross-sectioned perspective view of the cover plate 110, as it would be installed to a bearing housing 200. Figure 6 provides a front cross-sectioned perspective view of the cover plate 110, installed to a housing 200 which contains a bearing 210 into which the end of a shaft 300 (or the end of the shaft 1110) is mounted or otherwise received. The end of the shaft and / or at least part of the shaft 300 may be received within the shaft receiving aperture 610 of the bearing housing 200.

[0090] Figure 7 is a front perspective view of the device 100, as it would be installed to a bearing housing 200, excluding the external cap 120 and external cap retaining bolt 121. As shown in Figure 7, the device 100 is installed to a housing 200 with external cap 120 removed and external cap retaining bolt hole 122 exposed.

[0091] Figure 8 is a front perspective view of the device 100, as it would be installed to a bearing housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110, or otherwise a face of the shaft 300, held within the bearing housing 200 and excluding the external cap 120, external cap retaining bolt 121 and spacers 114.

[0092] Figure 9 is a front perspective view of the device 100, as it would be installed to a bearing housing 200, with the adjustment bolts 113 advanced to contact the end of the shaft 1110 or otherwise a face of the shaft 300, held within the bearing housing 200. Figure 9 further shows an alignment measurement device 400, mounted concentrically to the cover plate 110. In some embodiments, the alignment measurement device 400 may not be mounted concentrically to the cover plate 110. Figure 9 does not include the external cap 120, external cap retaining bolt 121 and spacers 114. As shown in Figure 9, the device 100 is installed to a housing 200 with external cap 120 removed and an alignment device 400 mounted concentrically to the cover plate 110.

[0093] Figure 11 is a cross-sectioned view of the device 100, as it would be installed to a bearing housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110 or the face of the shaft 300, held within the bearing housing 200. Figure 11 also shows an alignment measurement device 400 mounted concentrically to the alignment measurement device adaptor 500, which itself is attached or mounted to the cover plate via the adjustment bolts 1113. In some embodiments, the alignment measurement device 400 may not be mounted concentrically to the cover plate 110. The cover plate 110 does not include the external cap 120, the external cap retaining bolt 121 and spacers 114 attached.

[0094] Figure 12 is a cross-sectioned view of the device 100, as it would be installed to a bearing housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110 or the face of the shaft 300 held within the bearing housing. The alignment measurement device 400 is mounted concentrically to the alignment measurement device adaptor 500. As shown in Figure 12, the external cap 120, external cap retaining bolt 121 and spacers 114 have been removed from the device 100.

[0095] Figure 13 is a front perspective view of the device 100, as it would be installed to a bearing housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110 when the shaft is misaligned when housed within the bearing housing 200. Figure 13 can also be described as showing the adjustment bolts 113 advanced to the face of the misaligned shaft 300 held within the bearing housing 200. Figure 13 also shows the adapter 500 installed to the heads of the adjustment bolts 113, an alignment device mounted concentrically to the adapter 500. In some embodiments, the adapter 500 may be mounted or mountable to a portion of the adjustment bolts that is not the head, such as a shaft of the adjustment bolts 113 or any other suitable portion of the second end of the adjustment bolts 170, or a portion of the adjustment bolts 113 proximal to the second end of the adjustment bolts 170. The device 100 as shown in Figure 13 has had the external cap 120, external cap retaining bolt 121 and spacers 114 removed.

[0096] As shown in Figure 13, the device 100, installed to the bearing housing 200 with external cap 120 removed, an adapter 500 installed to the heads of the adjustment bolts 113 and an alignment device 400 mounted concentrically to the adapter 500.

[0097] Referring to Figure 6, the device 100 when installed to the bearing housing 200 with bolts inserted through the cover plate mounting holes 111 remains unobtrusive to the external environment and any activities occurring within it, owing to it being designed with a low profile. The external cap 120 acts to protect the heads of the adjustment bolts 113 from damage, while also providing a seal with the cover plate 110 which acts to prevent the ingress of material into the working parts of the device 100 and / or the bearing housing 200.

[0098] To ensure that the device 100 is centralised within the housing 200, the cover plate spigot 116 is inserted into the housing 200 spigot entry hole, also referred to as the shaft receiving aperture 610. As the bolts that install the device 100 to the housing 200 through the mounting holes 111 are tightened, it results in the back face 150 (or first face 150) of the cover plate 110 pulling into firm and even contact with the housing 200. If a seal (e.g. a gasket or O-ring) has been inserted into the seal groove 115, this seal compresses to improve the sealing performance of the cover plate 110 and further resist the ingress of foreign material into the bearing housing 200. When the device 100 is required to be uninstalled from a housing 200, the bolts that install the device 100 to the housing 200 through the mounting holes 111 are either fully or partially released, before some of these bolts are installed into the threaded jacking bolt holes 112. As these bolts are rotated within the threaded jacking bolt holes 112, they force the cover plate 110 away from the housing 200, until the cover plate 110 is sufficiently clear of the housing 200 that it may be removed entirely.

[0099] Figure 10 is a front cross-sectioned perspective view of the device 100, as it would be installed to a housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110 or the face of the shaft 300, when the shaft 300 is held within the housing 200. Figure 10 further shows an alignment measurement device 400 mounted concentrically to the cover plate 110. The device 100, as shown in Figure 10 has had the external cap 120, the external cap retaining bolt 121 and the spacers 114 removed.

[0100] According to Figure 10, when the external cap 120, external cap retaining bolt 121 and spacers 114 are removed the external cap retaining bolt hole 122 becomes exposed and the adjustment bolts 113 may be rotated to advance them into contact with the end of the shaft 1110 contained within the housing 200. Owing to each adjustment bolt 113 being manufactured to be substantially dimensionally identical, once the ends of the adjustment bolts 113 are in contact, and especially when they are in firm contact, with the end of the shaft 1110 the second ends 170 (also referred to as heads) of the adjustment bolts 113 represent a translated offset plane to the end of the shaft 1110. Further, the orientation of the shaft 300 to the housing 200 can be determined from the clearance under the head of each adjustment bolt 113 to the cover plate 110, and specifically the second face 155 of the cover plate 110. In some embodiments, the orientation of the shaft 300 to the housing 200 can be determined by the distance from the most distal point of each of the adjustment bolts 113 to the second face 155 of the cover plate 110. It will also be apparent to the person of average skill in the art that many other reference schemes (between points on the adjustment bolts 113 relative to the cover plate 110) may be employed and still achieve proper alignment of the bearing housing 200 and the shaft 300.

[0101] If the position of the housing 200 is adjusted such that the under the head of each adjustment bolt 113 to the cover plate 110 clearances become identical or substantially identical, then by mechanical communication between the housing 200, cover plate 110, adjustment bolts 113 and end of the shaft 1110, the housing 200 is effectively or properly aligned to the shaft 300.

[0102] It will be appreciated that not only adjustment bolts 113, but any apparatus that allows for the external engagement of the device 100 with the end of the shaft 300 contained within the housing 200 is included within the composition of this invention.

[0103] With the housing 200 aligned to the shaft 300, an alignment measurement device 400 can be mounted concentrically to the cover plate 110. The alignment measurement device 400 can then be used to align the bearing housing 200 and / or the shaft 300 to relevant reference points on the plant to which the housing 200 is installed, ensuring that not only is the shaft 300 aligned to the plant, but also that the housing 200 is aligned to the shaft 300, the bearing components 211 are aligned within the bearing 210 and the seals on the bearing 210 and / or between the shaft 300 and the housing 200 containing the bearing 210 are also aligned.

[0104] Referring to Figure 13, when the ends of the adjustment bolts 113 are in firm contact with the end of the shaft 1110, an adapter 500 may be installed to the heads of the adjustment bolts 113. As the adapter 500 includes corresponding features to the heads of the adjustment bolts 113, the adapter 500 assumes the translated offset plane to the end of the shaft 300. The alignment measurement device 400 can be mounted to the adapter 500 and then be used to align the bearing housing 200 and / or the shaft 300 to relevant reference points on the plant to which the housing 200 is installed.

[0105] Figure 14 is a cross-sectioned view of the device 100, as it would be installed to a housing 200, with adjustment bolts 113 advanced to contact the end of the shaft 1110 or the face of the shaft 300, when the shaft 300 is misaligned within the housing 200. The Figure 14 also includes an adapter 500 installed to the heads of the adjustment bolts 113, an alignment measurement device 400 mounted to the adapter 500. The device 100, as shown in Figure 14, has had the external cap 120, external cap retaining bolt 121, and spacers 114 have been removed. Figure 14 also shows the bearing 210.

[0106] Figure 15 is a detailed cross-sectioned view of the device 100, as it would be installed to a housing 200, with adjustment bolts 113 advanced to the end of the shaft 1110 of the misaligned shaft (or the face of the shaft 300), held within the housing 200. Figure 15 also shows the adapter 500 installed to the heads of the adjustment bolts 113, an alignment measurement device 400 mounted concentrically to the adapter 500. The device 100 has had the external cap 120, the external cap retaining bolt 121, and spacers 114 removed. Figure 16 is a detailed cross-sectioned view of the device 100 illustrating the translated axis of the alignment components (the adjustment bolts 113, the adapter 500, the alignment measurement device 400), as it would be installed to a housing 200. The adjustment bolts 113 are advanced (and in contact with) the end of the shaft 1110 (or the face of the shaft 300), when the shaft 300 is misaligned, when the shaft 300 is held within the housing 200. The adapter 500 is installed to the heads of the adjustment bolts 113, and the alignment measurement device 400 is mounted concentrically to the adapter 500. The device 110 has had the external cap 120, the external cap retaining bolt 121, and the spacers 114 have been removed. Figure 16 shows several reference axis and planes as defined by the components. Axis 1610 (as shown in the thick black line) indicates the axis of the shaft 300. The axis 1615, as shown in the thick black dashed line, indicates an axis of the adaptor 500, adjustment measurement device 400 and / or the bearing housing 200. The plane 1620, as shown in the dashed and single-dotted black line, indicates the plane as defined by the end of the shaft 1110, also referred to as the face of the shaft 300. This plane is reproduced, or otherwise recreated, by the second end of the adjustment bolts 170 and the adapter 500. The plane 1625, as shown in the dashed and double dotted black line, indicates the plane as defined by the cover plate 110 and the bearing housing 200. As is shown in Figure 16, axis 1610 and axis 1615 are not in alignment, and therefore indicate that the shaft 300 and the bearing housing 200 are not in alignment.

[0107] It will be appreciated that depending on the size of the housing to which the device 100 is installed, the quantity, dimensions and location of the components and features that comprise the device 100 will vary such that the device 100 may perform its intended function.

[0108] Further, it will be understood by the person skilled in the art that the device 100 may be formed of or from numerous different types of materials including but not limited to metals such as, steal, iron, steel, stainless steel, aluminium, copper, brass, and cast iron, tool steel and / or nickel alloys.

[0109] Advantageously, the device 100 is able to align the shaft 300 and the seals and the bearing components 211 at the same time, without having to compromise the seal of the housing 200.

[0110] Wherever they are used, the words "comprising" or "composition" are to be understood in their "open" sense, that is, in the sense of "including", and thus not limited to their "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised", "comprises", "compose" or "composed" where they appear. The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A device for aligning a shaft, the device comprising: a cover plate including a first face and a second face, the cover plate being removably mountable to a bearing housing, the cover plate including at least two apertures configured to receive respective aligning bolts therethrough; wherein the aligning bolts extend normally through the cover plate to contact an end of a shaft when the shaft is positioned within the shaft receiving aperture; and wherein when a first end of each of the aligning bolts contact the end of the shaft, respective second ends of the aligning bolts together define a plane with orientation substantially similar to a plane defined by the end of the shaft, such that the shaft can be brought into proper alignment with the bearing housing.

2. The device of claim 1, wherein when the cover plate is mounted to the bearing housing, a central axis of the cover plate substantially aligns with a central axis of a shaft receiving aperture of the bearing housing.

3. The device of claim 1, wherein the second end of each of the aligning bolts is configured to interface with an adapter.

4. The device of claim 3, wherein the adapter is configured to interface with an alignment measurement device for determining the alignment between the bearing housing and / or the shaft when the shaft is positioned within the bearing housing, with a reference point.

5. The device of claim 1, wherein the first face of the cover plate includes at least one seal groove configured to prevent the ingress of foreign material into the bearing housing when the cover plate is mounted to the bearing housing.

6. The device of claim 1 further including an external cap removably mountable to the cover plate and configured to cover the at least two apertures.

7. The device of claim 1 further including a respective spacer for each of the two or more adjustment bolts, each spacer removably attachable to a respective adjustment bolt.

8. The device of claim 7, wherein when the spacers are attached to respective adjustment bolts, the spacers secure the second end of each of the adjustment bolts at a predetermined distance from the second face of the cover plate.

9. A method for aligning a shaft, the method including: mounting a cover plate to a bearing housing wherein the cover plate includes at least two apertures configured to receive respective aligning bolts therethrough; extending the adjustment bolts normally through the cover plate so that a first end of the adjustment bolts contacts an end of a shaft positioned within the shaft receiving aperture; and substantially aligning a plane defined by respective second ends of the aligning bolts with a plane defined by a second face of the cover plate to substantially align the shaft with the bearing housing.

10. The method of claim 9, wherein mounting the cover plate to the bearing housing includes substantially aligning a central axis of the cover plate with a central axis of a shaft receiving aperture of the bearing housing.

11. The method of claim 9 wherein substantially aligning the plane defined by respective second ends of the aligning bolts with the plane defined by the second face of the cover plate includes determining that a depth of extension of each of the two or more adjustment bolts is substantially identical.

12. The method of claim 11 wherein determining that the depth of extension of each of the two or more adjustment bolts is substantially identical includes measuring a distance from the second end of each adjustment bolt to the second face of the cover plate.

13. The method of claim 12, wherein substantially aligning includes manipulating the position of the bearing housing until the distance from the second end of each adjustment bolt to the second face of the cover plate is substantially identical for each adjustment bolt.

14. The method of claim 9 wherein the second end of each of the aligning bolts is configured to interface with an adapter, and wherein the method further includes attaching the adapter to the cover plate, via the adjustment bolts.

15. The method of claim 14, further including attaching an alignment measurement device to the adapter, and using the alignment measurement device to align the bearing housing and / or the shaft, with a reference point.

16. The method of claim 15 further including using the alignment measurement device to ensure that one or more of the bearing components of the bearing housing, the bearing housing, and / or one or more bearing seals with the reference point.

17. The method of claim 14, further including aligning the adapter to the reference point, wherein the reference point is associated with a plant to which the bearing housing is installed.

18. The method of claim 9 further including attaching a respective spacer to each of the adjustment bolts that restricts the movement of the adjustment bolts such that the adjustment bolts cannot damage one or more components of the bearing housing and / or one or more components of a bearing contained within the bearing housing when the bearing housing is moved.

19. The method of claim 18, wherein the respective spacers further stop the first ends of the adjustment bolt from contacting the end of the shaft, when the shaft is positioned with the shaft receiving aperture and / or when the shaft is in operation.

20. A method for aligning a shaft using a shaft alignment device, the method according to any one of claims 9 to 19, and the shaft alignment device according to any one of claims 1 to 8.

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