Laser Shaft Alignment Mounts for No-Rotation Precision Measurement
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Solution Overview
Problem
Traditional methods for measuring and aligning rotational shafts are cumbersome and require multiple rotations to achieve precise alignment, which can be time-consuming and prone to errors, especially in large machinery where rotation is difficult or impractical.
Innovation Solution
A system using magnetic bases with linear contact edges and laser photoelectric devices that attach to the shafts to measure misalignment without rotating the shafts, allowing for precise alignment by taking multiple measurements at fixed positions around the circumference, reducing the need for shaft rotation and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional dial indicator and gauge block methods are used to measure shaft alignment, then measurements can be taken at multiple rotational positions, but the process requires multiple shaft rotations and is time-consuming
Solution Approach 1:
The patent replaces the traditional mechanical measurement system (dial indicators, gauge blocks, manual rotation) with a laser-based optical measurement system. The laser alignment device projects a laser beam that reflects off mirrors attached to the shafts, allowing alignment measurements to be taken without physically rotating the heavy shafts. This substitution eliminates the time-consuming manual rotation process while maintaining measurement precision.
Solution Approach 2:
The patent introduces optical measurement in a different dimension by using laser beams and mirror reflections to measure shaft alignment. Instead of mechanical contact measurement at discrete points, the laser system creates optical paths that can detect alignment deviations across the entire shaft length simultaneously, reducing the need for multiple rotations and measurements.
2Reliability
If multiple rotations are performed to verify alignment measurements, then measurement accuracy can be improved, but the complexity of the alignment process increases
Solution Approach 1:
The laser alignment system replaces complex mechanical measurement procedures with a simplified optical system. The laser beam, mirrors, and detector create a straightforward measurement path that inherently provides reliable data without requiring multiple rotations or complex verification procedures. The system calculates alignment parameters directly from the optical measurements.
3Measurement precision
If shafts are rotated frequently during alignment measurements, then comprehensive alignment data can be collected, but the risk of introducing errors and misalignment increases
Solution Approach 1:
The patent eliminates the need to rotate shafts during measurement by using a laser system that can measure alignment in the shaft's current position. The laser beam reflects off mirrors on each shaft and the intersection point of the beams indicates alignment status. This non-contact optical method collects comprehensive alignment data without mechanically disturbing the shafts, thereby preventing introduction of errors.
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 accurate and efficient alignment of rotational shafts to within tight tolerances (e.g., 16 arcseconds) by eliminating the need for repeated shaft rotations, enhancing measurement precision and reducing the number of adjustments required, thus improving alignment accuracy and reducing the time needed for alignment.
Implementation Method 1
Each base has a switch to vary magnetic flux for affixation and release from the shaft surface
Implementation Method 2
Brackets attached to the bases are designed to attach laser photoelectric devices, the photoelectric devices designed to measure shaft misalignment
Data Source
AI summary
For alignment of rotational shafts, two devices for attachment to circular faces of two shaft segments. Each of the two devices has a laser photoelectric device for ascertaining a dimension of displacement of the two shafts from a desired axis of rotation relative to each other. Each of the two devices having a base surface with two linear contact edges designed to engage with a circumferential surface of a shaft and to ensure alignment between the device and an axis of rotation of the shaft to within a tolerance compatible with alignment tolerances of the shaft. Each of the two linear contact edges includes at least two terminal end regions and a center region together defining a line contact at linear intersection of two surfaces meeting at a non-zero angle linear contact edges designed to affix and release from the shaft surface, and to ensure parallel alignment between the device and an axis of rotation of the shaft to a precision allowing measurements to within tolerances required by machinery driven by the shaft. The base surface of at least one of the devices has been modified from its commercially-delivered condition to provide raised rails designed to improve tactile feedback of to a user of the alignment between the base and an axis of rotation of the shaft, and has affixed thereto two rails designed to improve tactile feedback of to a user of the alignment between the base and an axis of rotation of the shaft. Each base has a magnet and a switch to vary magnetic flux for affixation and release from the shaft surface. Each device has brackets designed to securely and reproducibly position laser photoelectric devices relative to the base and axis of rotation of the shaft. The attaching includes a human placing at least one of the devices slightly askew relative to the axis of rotation of the shaft, and the human gently twisting the device to allow the liner contact edges to seat on the circumferential surface of the shaft, to provide tactile feedback to the human to confirm parallel alignment between the at least one device's laser photoelectronic device and the axis of rotation of the shaft.