Laser Shaft Centerline Alignment for Rotating Equipment
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Solution Overview
Problem
Conventional methods for aligning the shaft centerline of rotating equipment, such as gas turbine rotors, on roller stands are time-consuming and require significant manpower, often necessitating the skills of two technicians using rudimentary tools to achieve perfect alignment, which can take up to eight hours.
Innovation Solution
An alignment system utilizing a laser transmission unit and a target unit, where a laser beam is directed from one roller stand to the center of a target on the opposing stand, with hydraulic cylinders and a control unit to automatically adjust the roller stands for precise alignment, reducing the time and effort required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional alignment methods using rudimentary tools are employed, then alignment accuracy can be achieved, but the time required and manpower needed increase significantly
Solution Approach 1:
The patent replaces conventional mechanical alignment tools (tape measures, shims, levels) with a laser-based optical measurement system. The laser transmission unit projects a beam through transmission holes in the roller stands to a target, enabling precise alignment measurement without mechanical contact, thereby achieving high accuracy while dramatically reducing alignment time from hours to minutes.
Solution Approach 2:
The patent introduces laser beams as an intermediary medium to transfer alignment information between the roller stands. Instead of directly measuring physical dimensions with tools, the laser beam serves as a mediator that visually indicates misalignment, allowing technicians to quickly identify and correct positioning errors without complex measurements.
2Ease of manufacture
If conventional alignment methods are used, then alignment can be performed with simple tools, but the complexity of the process and manpower requirements increase
Solution Approach 1:
The patent replaces complex mechanical alignment procedures with a simple optical system. The laser transmission unit and target create an intuitive visual alignment indicator that is easier to use than conventional methods, reducing both tool complexity and process complexity while maintaining or improving accuracy.
Solution Approach 2:
The patent utilizes the visual property of laser light to indicate alignment status. When the laser beam passes through the transmission holes and strikes the target, it creates a visible light pattern that immediately shows whether alignment is correct or needs adjustment, providing intuitive feedback without complex instrumentation.
3Ease of operation
If manual alignment adjustment is performed, then flexibility can be maintained, but the time and effort required increase significantly
Solution Approach 1:
The patent implements a feedback mechanism where the laser beam's position on the target provides real-time information about alignment status. This visual feedback allows technicians to make quick, informed adjustments to the roller stand positions, maintaining operational flexibility while dramatically improving alignment efficiency by eliminating trial-and-error procedures.
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 a single technician to achieve alignment in minutes, significantly reducing the time and manpower needed, while ensuring accurate and efficient alignment of the rotor centerline within the roller stands.
Implementation Method 1
a laser centrally mounted through the first back plate and extending to the first front plate, such that a laser beam produced by the laser is transmitted through the first laser transmission hole of the first front plate
Data Source
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AI summary
An alignment system and method for aligning the shaft centerline of rotating equipment positioned on opposing roller stands are provided. The system includes a laser transmission unit on the first stand and a target unit on the second stand. The laser transmission unit includes a laser that transmits a laser beam to a target on the target unit. When the laser beam contacts the center of the target, the roller stands are aligned. The system may be automated to detect the position of the laser beam relative to the target center and to adjust, as needed, the position of one of or both the roller stands using hydraulic cylinders coupled to a roller stand platform. The system and method reduce the time, effort, and manpower required to perform the alignment.