Dual Laser Shaft Alignment System with Variable Brightness
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Solution Overview
Problem
Current shaft alignment methods are time-consuming and require technical skill, with traditional methods like visual inspection with a straightedge or dial indicators being inaccurate and labor-intensive, while laser-guided tools, although more accurate, still require pre-alignment processes that are not quick enough.
Innovation Solution
A shaft alignment system using dual laser units that emit and detect green laser beams at varying brightness levels, allowing for both pre-alignment and fine adjustment with high visibility and precision, reducing overall alignment time and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional visual inspection with straightedge or dial indicators is used, then the alignment process is quick and relatively easy, but the accuracy is highly inaccurate and does not provide the exacting degree of accuracy required
Solution Approach 1:
The patent replaces mechanical measurement systems (straightedges, dial indicators) with an optical laser-based measurement system. The laser beam provides a precise reference line for alignment while the system remains easy to operate through simple visual observation of the laser beam position relative to measurement points.
2Measurement precision
If dial indicators are used for fine adjustment, then a higher degree of accuracy is achieved, but the process is time-consuming and requires a high level of technical skill
Solution Approach 1:
The patent replaces the mechanical dial indicator system with an optical laser system that provides both coarse and fine alignment capabilities in a single integrated tool. The laser beam's precision allows for accurate measurement without requiring multiple tool changes or reinstallation, significantly reducing the time required while maintaining high accuracy.
Solution Approach 2:
The laser alignment tool serves multiple functions: it provides both pre-alignment (coarse adjustment) and fine alignment capabilities in a single device. This multi-functionality eliminates the need to switch between different tools (straightedge for pre-alignment, dial indicators for fine adjustment), reducing both time and technical skill requirements.
3Productivity
If laser-guided tools are used, then quick and accurate alignment is achieved, but pre-alignment processes are still required and are not quick enough
Solution Approach 1:
The patent merges the pre-alignment and fine-alignment functions into a single laser-based measurement system. The laser beam serves as both the pre-alignment reference (through direct visual observation of beam position) and the fine-alignment reference (through precise measurement of beam deviation), eliminating the need for separate pre-alignment tools and processes.
Solution Approach 2:
The laser alignment tool provides universal functionality for both coarse pre-alignment and precise fine-alignment in a single device, reducing process complexity while maintaining high productivity. The system handles the entire alignment spectrum from initial rough alignment to final precision alignment without requiring multiple tools or complex procedural steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system simplifies and accelerates the shaft alignment process by enabling quick and accurate pre-alignment with high brightness and precise fine adjustments with low brightness, reducing the time needed for complete alignment and making the process easier to perform.
Implementation Method 1
at least one of the first and second measuring units comprising a laser adapted to emit a laser beam
Implementation Method 2
the laser emits in green color
Data Source
AI summary
A shaft alignment system includes a first measuring unit and a second measuring unit. At least one of the first and second measuring units includes a laser adapted to emit a laser beam and the other of the first and second measuring units is adapted to detect the emitted laser beam. The laser is adapted to emit a laser beam on at least two different brightness levels and the laser beam has a green color.