Imaging-Based Shaft Alignment Under Thermal Growth and Vibration
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Solution Overview
Problem
Traditional vibration and misalignment analysis tools in rotating equipment, such as motors and pumps, are limited in providing comprehensive information, often requiring repeated shutdowns for incremental adjustments, leading to costly downtime and inefficiencies due to their inability to account for thermal changes and resulting misalignments.
Innovation Solution
A system and method that analyze vibration and misalignment using sets of image data, including visible light and infrared images captured in different operating states, to determine thermal expansion and alignment calibration parameters, enabling more accurate and efficient alignment processes by compensating for thermal growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional vibration analysis tools are used to detect misalignment, then misalignment detection is possible, but the information provided is incomplete and requires repeated shutdowns for incremental adjustments
Solution Approach 1:
The patent transitions from traditional single-dimension vibration analysis to multi-dimensional analysis by capturing images from multiple angles and orientations. The system takes pictures of the coupling and shafts from different positions (radial, axial, and circumferential directions) to obtain complete spatial information about misalignment, eliminating the need for repeated adjustments.
Solution Approach 2:
The patent creates visual copies (images) of the equipment components instead of relying solely on vibration signals. By capturing and analyzing images of the coupling, shafts, and alignment indicators from multiple angles, the system obtains comprehensive alignment information in a single measurement session, providing complete guidance for correction.
2Manufacturing precision
If repeated shutdowns are performed for incremental alignment adjustments, then alignment improvement may be achieved, but downtime and labor costs increase
Solution Approach 1:
The patent performs preliminary comprehensive measurement by capturing images from all necessary angles and positions before any adjustment is made. This preliminary action provides complete alignment information upfront, allowing operators to calculate precise correction values and perform alignment in a single shutdown rather than through repeated incremental adjustments.
Solution Approach 2:
The system provides immediate feedback by analyzing images and calculating misalignment values in real-time. The processing unit generates comprehensive alignment reports with specific correction instructions, enabling operators to make accurate adjustments in one attempt rather than requiring multiple trial-and-error shutdowns.
3Ease of manufacture
If traditional alignment tools are used without thermal expansion compensation, then alignment can be performed, but thermal changes cause recurring misalignment errors
Solution Approach 1:
The patent incorporates thermal expansion as a measurable parameter in the alignment process. The system captures images at different temperatures (cold and hot states) and calculates thermal expansion values for the equipment components. By adding temperature and thermal expansion coefficients to the measurement parameters, the system compensates for thermal effects and predicts alignment under operating conditions.
Solution Approach 2:
The system performs preliminary measurements in both cold and hot states to anticipate thermal expansion effects before final alignment is completed. By calculating the expected thermal growth and adjusting the alignment accordingly, the system prevents recurring misalignment that would otherwise occur when the equipment heats up during operation.
4Measurement precision
If multiple sets of image data are captured and analyzed to determine thermal expansion, then alignment calibration accuracy is improved, but measurement and processing complexity increases
Solution Approach 1:
The patent uses a single imaging device that performs multiple functions: capturing alignment images, measuring thermal expansion, and providing guidance for correction. The same camera system that records the physical arrangement of components also tracks temperature-induced dimensional changes, eliminating the need for separate measurement devices and reducing overall system complexity.
Solution Approach 2:
The system merges multiple measurement capabilities (visual alignment measurement and thermal expansion measurement) into a unified imaging-based measurement system. By combining these functions into one integrated system with a single processing unit that handles all image analysis and calculations, the patent reduces the complexity that would otherwise arise from coordinating multiple separate devices and measurement protocols.
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 allows for precise determination of alignment calibration parameters, reducing downtime and inefficiencies by providing comprehensive insights into thermal-induced misalignments, thereby improving equipment operation and reducing the likelihood of recurring errors.
Implementation Method 1
an infrared imaging device configured to generate thermal image data representative of a target scene
Implementation Method 2
thermal expansion of one or more components of the equipment under test can lead to misalignment between components of the equipment
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.