Rotating Machinery Shaft Alignment Device for Operational Conditions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current shaft alignment methods for rotating equipment are inadequate as they primarily focus on non-operational state alignments, neglecting operational variables like thermal effects and 'soft foot' issues, leading to frequent misalignment and downtime.
Innovation Solution
A method and device that allow for real-time alignment of rotating machinery while operational, using interlocking U-shaped metal plates with bolt and nut arrangements to adjust for vertical offset and angularity, combined with laser alignment for precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional laser alignment methods are used during non-operational state, then alignment measurement can be completed, but thermal effects and operational variables are not accounted for leading to misalignment during operation
Solution Approach 1:
The patent transitions from static alignment measurement (non-operational state) to dynamic alignment measurement (operational state). The system continuously monitors alignment while the equipment is running, allowing real-time detection of thermal effects and operational variables that cause misalignment. This dynamic approach ensures alignment remains accurate under actual operating conditions rather than just during installation.
Solution Approach 2:
The patent implements a feedback mechanism where alignment data is continuously collected during operation and used to generate real-time guidance for operators. The system provides feedback on thermal expansion effects, soft foot conditions, and other operational variables, enabling operators to make adjustments based on actual performance data rather than initial static measurements.
2Ease of operation
If alignment is performed in ambient environment during non-operation, then equipment remains stationary for measurement, but operational variables like thermal effects and soft foot are not captured
Solution Approach 1:
The system enables alignment measurement under dynamic operational conditions rather than static ambient conditions. By performing measurements while equipment is running at operating temperature and load, the system captures thermal expansion, soft foot, and other operational effects that only manifest during actual use, making the alignment process adaptable to real-world conditions.
Solution Approach 2:
The patent changes the operational parameters under which alignment is performed - transitioning from ambient temperature and zero load to operating temperature and full load conditions. This parameter change allows the system to account for thermal expansion, material deformation, and other temperature-dependent effects that significantly impact alignment during operation.
3Reliability
If frequent shim replacements are performed to maintain alignment, then alignment can be restored, but downtime and operational costs increase
Solution Approach 1:
The patent performs preliminary identification and correction of alignment issues during operational monitoring before they escalate into problems requiring shutdown and shim replacement. By continuously monitoring alignment parameters and providing early warning of misalignment trends, the system enables proactive maintenance that prevents the need for frequent corrective interventions and downtime.
Solution Approach 2:
The system enables self-monitoring of alignment conditions during operation, allowing operators to detect and address alignment issues without requiring external intervention or equipment shutdown. The continuous monitoring and real-time feedback empower operators to maintain alignment through minor adjustments rather than frequent major maintenance events involving shim replacement.
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
This approach ensures precise and stable alignment, reducing downtime and operational costs by considering operational conditions and eliminating the need for frequent shim replacements.
Implementation Method 1
Laser alignment was introduced in the 1980's and utilizes one or more diode lasers and detectors (PSD's)
Data Source
AI summary
A system and method for aligning multiple pieces of rotary machinery equipment by coupling rotating shafts extending from at least one of the multiple pieces of rotary machinery equipment. The system includes mounting a first piece of rotary machine equipment to a device comprising two U-shaped plates that are interlocked with each other. The alignment method includes a process for adjusting the first piece of rotary equipment with respect to a first U-shaped plate to correct for either a vertical offset or angular misalignment.