Laser Belt Alignment Tool for Pulley Systems
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Solution Overview
Problem
Current belt alignment systems for mechanical systems like motors and pulley systems are prone to misinterpretation and error, requiring significant human involvement and are often cost-prohibitive, leading to inefficient maintenance and unexpected shutdowns.
Innovation Solution
A belt alignment tool and system utilizing a laser light source and magnetic targets to provide accurate alignment indicators, allowing for easy adjustment of pulley systems without the need for expensive digital systems, featuring a laser light source positioned within an elongated main body that projects a beam onto a target pattern for alignment and includes magnetic mounting for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive digital alignment systems are used, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a simplified optical copy system where a laser projects a visual representation of the pulley centerline onto a target surface. Instead of complex digital sensors and processors, the system creates an optical copy of the alignment reference that can be visually compared against the target pulley position, achieving accurate alignment measurement through simple optical projection and visual interpretation
Solution Approach 2:
The patent replaces expensive, complex digital alignment systems with inexpensive, simple optical components (laser pointer, target surface, and basic mounting hardware). The system uses low-cost materials such as painted targets on surfaces or magnetic targets that can be easily attached and removed, providing accurate alignment functionality without requiring costly digital equipment
2Device complexity
If traditional alignment methods are used, then device complexity is reduced, but measurement precision and reliability deteriorate due to misinterpretation and error
Solution Approach 1:
The patent introduces a laser projection as an intermediary between the alignment reference and the target pulley. The laser creates a visible reference line that acts as a mediator, allowing operators to clearly see the alignment relationship without requiring complex interpretation of digital readings or subjective judgment of traditional mechanical indicators, thereby reducing human error while maintaining system simplicity
Solution Approach 2:
The patent uses visual contrast through color or brightness differences on the target surface to indicate alignment status. The laser projection creates a distinct visual marker that contrasts with the background, making it easy to identify the centerline position and determine whether the pulley is properly aligned, thereby improving measurement precision through enhanced visual detection
3Ease of operation
If manual alignment adjustment is used, then ease of operation is improved, but productivity decreases due to significant human involvement and training requirements
Solution Approach 1:
The patent enables operators to perform self-aligned adjustments by providing a clear visual reference that directly indicates the correct position. The laser projection shows the exact centerline location, allowing operators to independently adjust the pulley alignment without requiring extensive training or reliance on experienced technicians, thereby improving both ease of operation and maintenance productivity
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 enables precise and cost-effective belt alignment, reducing the likelihood of premature system degradation and shutdowns, thereby improving operational efficiency and extending the life cycle of mechanical parts while minimizing repair costs.
Implementation Method 1
A laser light source is positioned in the center of the main body for generating a relatively wide laser light sheet or beam used as an alignment indicator
Implementation Method 2
The tool may include at least one magnet on a side mounting surface of the main. The magnet is adapted to magnetically mount to a metal surface
Implementation Method 3
A level positioned within the main body and exposed for viewing of a bubble suspended in a transparent liquid to provide an indication that a surface is horizontally or vertically level
Data Source
AI summary
A system for alignment of a pulley system and a method of use are provided. A laser alignment tool includes an arcuate front surface having a target pattern of parallel vertical lines. The tool is provided with a laser light source that projects a laser light beam through an aperture in the front surface. A pair of laser alignment tools may be mounted on two pulleys of a pulley system such that the laser light beams are displayed on the target pattern of the opposite laser alignment tool. In the event of a misalignment, the laser light beams displayed on the target patterns do not align with the vertical lines thereon. A user may adjust the pulleys so that the laser light beams produced by each laser alignment tool are aligned with the vertical lines of the opposite laser alignment tool to achieve alignment of the pulley system.