Imaging-Based Alignment Analysis for Thermal Growth and Vibration
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Solution Overview
Problem
Existing vibration and misalignment analysis methods in operating equipment are inadequate, as they typically only detect one type of vibration or misalignment at a time, leading to incomplete information and requiring repeated shutdowns for incremental adjustments, which is costly and inefficient.
Innovation Solution
A system and method that analyze vibration and misalignment by capturing and comparing multiple sets of image data, including visible light and infrared images, to determine thermal expansion and alignment calibration parameters, allowing for more comprehensive and efficient alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional vibration analysis tools are used to detect misalignment, then one type of vibration or misalignment can be detected at a time, but the information provided is incomplete and cannot guide comprehensive correction
Solution Approach 1:
The patent combines multiple image capture devices (laser alignment tool, visible light camera, infrared camera) into a single integrated system. This merging allows simultaneous capture of multiple types of alignment information (laser reference, visual structure, thermal patterns) that would otherwise require separate tools and multiple shutdowns to collect.
Solution Approach 2:
The imaging tool is designed to perform multiple functions simultaneously: it captures laser alignment references, visible light images for structural analysis, and infrared images for thermal expansion detection. This multi-functionality eliminates the need for separate specialized tools and enables comprehensive misalignment analysis in a single operational state.
2Manufacturing precision
If equipment is repeatedly shut down to incrementally adjust alignment, then alignment can be corrected, but downtime and labor costs increase significantly
Solution Approach 1:
The system performs preliminary comprehensive data collection during a single operational shutdown by capturing multiple image types simultaneously. The imaging tool records laser references, visible structures, and thermal patterns all at once, eliminating the need for repeated shutdowns to collect additional alignment information for incremental adjustments.
Solution Approach 2:
The patent replaces the traditional mechanical trial-and-error alignment process with an optical and thermal imaging-based analysis system. Instead of physically adjusting components through multiple shutdowns, the system uses image processing and thermal expansion calculations to determine precise alignment corrections, reducing iterative mechanical adjustments.
3Manufacturing precision
If alignment is adjusted without accounting for thermal expansion, then alignment may appear satisfactory in cold state, but misalignment recurs when equipment operates in hot state
Solution Approach 1:
The system measures and accounts for thermal expansion parameters by capturing infrared images that reveal temperature distributions and thermal patterns. These thermal parameters are used to calculate expansion amounts and adjust alignment calibration accordingly, ensuring accuracy across both cold and hot operational states rather than relying on cold-state measurements alone.
Solution Approach 2:
The imaging tool provides feedback about thermal expansion conditions by analyzing infrared images and comparing them with visible light images. This thermal feedback loop allows the system to detect and compensate for temperature-induced dimensional changes, enabling alignment calibration that maintains reliability across varying thermal conditions.
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
This approach enables precise determination of misalignment and thermal expansion, reducing downtime and labor costs by allowing for more accurate alignment adjustments during operation, thereby improving equipment efficiency and reducing the likelihood of recurring errors.
Implementation Method 1
a thermal imaging device configured to generate thermal image data representative of a target scene
Implementation Method 2
a visible light imaging device configured to generate visible light image data representative of the target scene
Implementation Method 3
The calculated temperature change can be used with additional parameters (e.g., thermal expansion coefficients, initial dimensions, etc.) to determine an amount of thermal expansion of such portions
Data Source
AI summary
Systems and methods can be used for analyzing image data to determine an amount of vibration and/or misalignment in an object under analysis. In some instances, as operating equipment heats up during operation, temperature changes of various portions of the operating equipment leads to changes in dimensions of such portions, leading to misalignment. Multiple sets of data representative of the operating equipment in multiple operating conditions can be used to determine an amount of misalignment due to thermal offsets. Hot and cold temperatures of the equipment can be used to calculate thermal growth of various portions of the equipment, which can be used to determine an amount a misalignment due to thermal offsets. Additionally or alternatively, image data representing the equipment can be used to observe changes in alignment between states.