Laser Shaft Alignment Mounting for Precise Turbine Reassembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional methods for measuring the alignment of rotational shafts during reassembly require multiple rotations and measurements, which can be cumbersome and imprecise, especially for large machinery where precise alignment within tight tolerances is necessary.

Innovation Solution

A system using magnetic bases with laser photoelectric devices that attach to the circumference of shafts, allowing for precise alignment measurements without the need for repeated shaft rotations, utilizing magnetic affixation and tactile feedback for accurate positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional dial indicator and gauge block methods are used, then measurements can be taken, but the process requires multiple shaft rotations and 16+ measurements which increases complexity and time

Engineering Contradiction:

Improveshaft alignment precisionVSAvoidmeasurement process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the traditional mechanical measurement system (dial indicators, gauge blocks, manual rotation) with a photoelectric detection system. Laser beams are projected through the shaft coupling, and photoelectric detectors automatically measure the alignment, eliminating the need for manual mechanical measurements and multiple rotations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses optical copies (laser beams) to represent the physical shaft alignment. Instead of directly measuring the physical shaft positions with mechanical tools, laser beams create optical references that are detected by photoelectric sensors, providing a simplified measurement model.

Inventive Principle:

Principle #26Copying

2Reliability

If multiple shaft rotations are performed to verify measurements, then alignment accuracy can be verified, but the measurement time increases significantly

Engineering Contradiction:

Improvemeasurement verificationVSAvoidmeasurement time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent enables continuous measurement capability where the photoelectric detectors continuously monitor the laser beam positions as the shaft rotates, rather than requiring discrete stops at multiple rotation positions. This allows verification of alignment throughout the entire rotation cycle in a single continuous operation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent performs preliminary alignment adjustments using the photoelectric feedback system before final shaft rotation verification. The system provides real-time feedback during adjustment, allowing alignment to be optimized before the shaft is rotated for final verification, reducing the need for repeated measurement cycles.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If dial indicators are glued to shaft coupling faces, then measurements can be obtained, but the mounting precision and repeatability are limited

Engineering Contradiction:

Improvemounting precisionVSAvoidmounting ease

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical mounting of dial indicators with magnetic mounting of photoelectric detectors. The magnetic bases provide precise and repeatable positioning without requiring adhesive application or mechanical fastening, improving both mounting precision and ease of installation/removal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables reproducible and precise alignment measurements, reducing the complexity of the measurement process and improving accuracy to within the required tolerances for large machinery, such as power plant turbines.

Implementation Method 1

Each base has a switch to vary magnetic flux for affixation and release from the shaft surface

Methodology Applied

Scientific EffectMagnetic flux: Magnetism

Implementation Method 2

Brackets attached to the bases are designed to attach laser photoelectric devices, the photoelectric devices designed to measure shaft misalignment

Methodology Applied

Scientific EffectPhotoelectric detection: Photoelectric Effect

Data Source

PatentUS11300404B2Alignment of rotational shafts

Publication Date: 2022.04.12 SHORELINE ALIGNMENT & VIBRATION LLC

AI summary

Apparatus for measuring alignment of two shafts. Two magnetic bases each have two linear contact edges designed to engage with a circumferential surface of the two shafts and to ensure alignment between the base and an axis of rotation of the shaft to within a tolerance compatible with alignment tolerances of the shaft. Brackets attached to the bases are designed to attach laser photoelectric devices, the photoelectric devices designed to measure shaft misalignment.