Camera-Based Shaft Alignment Device for Thermal Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for aligning rotating shafts in machines, such as motors and pumps, face challenges in achieving precise measurements, especially when machines transition from a cold to a warm operating state, due to thermal and operational changes, leading to misalignment issues that can result in inefficiency and wear.
Innovation Solution
A device utilizing a single camera unit for alignment detection, capable of two-axis measurement, eliminates the need for traditional laser-based systems with multiple components, allowing for cost-effective and precise angular and offset error detection without initial alignment requirements, and can measure positional changes between cold and warm states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional laser-based alignment systems with multiple components are used, then measurement capability is provided, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple alignment measurement functions into a single camera unit. Instead of using separate laser transmitters and detectors as in traditional systems, the invention uses one camera to capture images of geometric patterns on both shafts, thereby reducing the number of components while maintaining measurement capability.
Solution Approach 2:
The invention uses optical imaging (camera photos) to create a visual copy of the geometric patterns on the shafts. This optical copying method replaces the need for direct laser beam interaction and multiple sensors, simplifying the system while preserving measurement functionality.
2Measurement precision
If initial alignment is required before measurement, then measurement reference is established, but ease of operation decreases
Solution Approach 1:
The system performs self-alignment through the camera's field of view. The camera automatically captures images of the geometric patterns on both shafts, and the evaluation unit processes these images to determine alignment without requiring manual pre-alignment or setup by the operator.
Solution Approach 2:
Instead of requiring the operator to manually align components before measurement, the system inverts the approach by using the camera's natural field of view to automatically establish measurement references. The geometric patterns serve as self-contained references that the system detects and processes automatically.
3Measurement precision
If shafts are measured in cold state only, then initial alignment is obtained, but reliability under operational conditions decreases
Solution Approach 1:
The system performs preliminary alignment measurements in the cold state by capturing images of geometric patterns on both shafts. This preliminary measurement establishes a baseline alignment that can be compared against operational measurements to detect thermal-induced misalignment changes.
Solution Approach 2:
The system transitions from static cold-state alignment measurement to dynamic operational measurement. By continuously or periodically measuring alignment during operation, the system adapts to thermal changes and operational conditions, maintaining reliability throughout the machine's operational cycle.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a device (1) for measuring and alignment of a first component (2, 4) and a second component (3, 5) in relation to each other, where the device comprises a first detector unit (6) disposed to be mounted on the first component (2, 4) and a second detector unit (7) disposed to be mounted on the second component (3, 5) as well as a control unit (12) which is connected to the first detector unit (6) and the second detector unit (7). The device (1) comprises a first geometric pattern (16) disposed on the first detector unit (6) and a second geometric pattern disposed on the second detector unit (7). The position of the first geometric pattern (16) can be detected by the second detector unit (7) and the position of the second geometric pattern can be detected by the first detector unit (6). The invention also relates to a method for aligning a first component (2, 4) and a second component (3, 5).