Laser Shaft Alignment System with Graphical Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for aligning machine shafts, such as engines and pumps, are inefficient and require skilled technicians due to reliance on trial and error, leading to increased energy consumption and potential machine damage from misalignment.
Innovation Solution
A system that includes alignment measurement devices and a controller to provide real-time positional data, graphical displays, and directional indicators for correcting misalignment, allowing for precise alignment without manual trial and error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional trial and error alignment methods are used, then alignment can be achieved, but significant time is lost and skilled technicians are required
Solution Approach 1:
The patent replaces traditional mechanical alignment tools (dial indicators, alignment bars) with a laser-based measurement system. The laser transmitter and receiver provide electronic measurement of shaft positions, eliminating the need for manual mechanical measurements and calculations, thus reducing time while maintaining precision
Solution Approach 2:
The system provides real-time feedback through graphical displays showing the relative positions of shafts and the required adjustments. This immediate visual feedback eliminates the trial-and-error process by guiding technicians directly to the correct alignment position, significantly reducing alignment time
2Manufacturing precision
If traditional alignment methods are used, then alignment can be performed, but energy consumption increases due to misalignment
Solution Approach 1:
By replacing mechanical alignment methods with laser-based electronic measurement, the system achieves more precise and consistent alignment results. This precision ensures optimal power transmission between shafts, reducing energy losses from misalignment while the measurement process itself consumes minimal energy
3Measurement precision
If traditional alignment methods are used, then alignment can be achieved, but machine damage risk increases from improper alignment
Solution Approach 1:
The laser-based measurement system provides highly accurate and objective measurements of shaft positions, eliminating human error in reading mechanical dial indicators. This precise measurement capability ensures shafts are aligned within tight tolerances, preventing the excessive wear and damage that occurs with improper alignment
Solution Approach 2:
The system provides continuous real-time feedback during the alignment process, allowing technicians to make incremental adjustments and verify alignment accuracy before finalizing the connection. This feedback mechanism prevents improper alignment that could lead to machine damage
4Loss of time
If traditional alignment methods are used, then alignment can be performed, but the process complexity increases due to multiple calculation steps
Solution Approach 1:
The system replaces complex manual calculations with automated electronic computation. The controller automatically processes the measurement data from the laser receiver and calculates the required alignment adjustments, eliminating the need for technicians to perform complex mathematical calculations manually
Solution Approach 2:
The controller acts as an intermediary between the laser measurement system and the alignment adjustments. It receives raw measurement data, processes it through alignment algorithms, and presents the results in an easy-to-understand graphical format with clear adjustment instructions, simplifying the overall process
Data Source
AI summary
Methods and apparatus are described for aligning components. Misalignment is calculated based on sensed values with a controller illustrating a process for data acquisition with graphical icons and indicia that include and/or are based on sensed data. The alignment process also includes graphical icons showing the process for alignment and the direction and amount of correction needed to achieve adequate alignment.