Magnetic Laser Mounts for Rotational Shaft Alignment Without Repeated Rotation
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Solution Overview
Problem
Traditional methods for measuring the alignment of rotational shafts are cumbersome and require multiple rotations to achieve precise alignment, which can be time-consuming and prone to errors, especially for large machinery where rotation is difficult or impractical.
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, by moving the devices to take multiple measurements along the shaft's circumference and utilizing magnetic affixation for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional dial indicator and gauge block methods are used to measure shaft alignment, then measurement precision can be achieved, but the measurement process becomes extremely time-consuming and complex requiring multiple shaft rotations and 20+ measurements
Solution Approach 1:
The patent replaces the traditional mechanical measurement system (dial indicators, gauge blocks, manual rotation) with an optical measurement system using laser transmitters and photoelectric detectors. The laser alignment system projects laser beams across the shaft coupling gap, and photoelectric detectors automatically capture the beam positions, eliminating the need for manual gauge block measurements and repeated shaft rotations. This substitution reduces the measurement process from requiring 20+ manual measurements to just a few automated optical readings.
2Reliability
If multiple shaft rotations are performed to verify alignment measurements, then measurement reliability improves, but the complexity of the measurement process increases significantly
Solution Approach 1:
The patent implements feedback by having the laser alignment system automatically take multiple measurements at different angular positions around the shaft coupling and use this data to compute alignment parameters. The system provides real-time feedback on alignment status and can guide adjustment operations. Multiple measurements are taken automatically at various positions (0°, 90°, 180°, 270°) and the results are processed to verify consistency, providing reliability without requiring manual repetition of the entire measurement sequence through multiple shaft rotations.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the laser transmitters and photoelectric detectors at specific locations around the shaft coupling before measurements begin. The measurement planes and detector positions are predetermined and configured in advance, so that when measurements are taken, the system is already optimized for capturing alignment data. This preliminary setup eliminates the need for complex real-time adjustments during the measurement process.
3Measurement precision
If shafts are rotated frequently during measurement to account for gauge block measurement changes, then measurement accuracy is maintained, but the difficulty of operation increases especially for large machinery
Solution Approach 1:
The patent replaces the mechanical gauge block measurement system with an optical laser measurement system that does not require physical contact with the shaft surfaces or repeated shaft rotations. The laser beams project across the coupling gap and are detected by photoelectric sensors, providing measurement data without requiring the shaft to be rotated into specific positions for gauge block placement. This eliminates the operational difficulty of manually rotating large shafts multiple times while maintaining measurement precision through automated optical detection.
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, accurate, and precise alignment of rotational shafts within tight tolerances, reducing the need for multiple rotations and improving measurement efficiency, particularly in large machinery applications where traditional methods are inefficient.
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.