Rotary Machine Component Alignment Using Rotor-Mounted Sensor
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Solution Overview
Problem
Existing methods for aligning components of rotary machines, such as container treatment machines, are complex and time-consuming, often requiring multiple marking fields and laser pointers, and can result in minor misalignments during module fixation, which are difficult to correct.
Innovation Solution
A device with a sensor on the rotor and reference elements on the stator allows for precise alignment by measuring distances, enabling manual or automatic adjustment, and accommodating rotational degrees of freedom, facilitating easier integration and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple marking fields and laser pointers are provided for each treatment module, then alignment precision can be improved, but device complexity increases significantly
Solution Approach 1:
The patent merges multiple alignment systems into a single sensor unit that can measure positions of multiple treatment modules simultaneously. Instead of having separate laser pointers and marking fields for each module, one sensor on the rotor measures distances to multiple reference elements on the stator, significantly reducing system complexity while maintaining alignment precision.
Solution Approach 2:
The sensor on the rotor serves multiple functions: it measures distances to multiple different treatment modules, determines rotor position, and enables alignment verification for various components. This universal measurement capability replaces the need for dedicated alignment devices for each treatment module.
2Ease of operation
If manual alignment adjustment is performed, then ease of operation is improved, but alignment precision deteriorates due to human error
Solution Approach 1:
The system provides automated feedback by having the sensor measure actual distances between the rotor and treatment modules, comparing these measurements to reference values, and automatically generating alignment correction information. This feedback loop enables precise alignment while reducing manual intervention and human error.
Solution Approach 2:
The patent replaces manual mechanical alignment procedures with an automated optical/electronic measurement system. The sensor automatically measures positions and calculates alignment deviations, substituting human judgment and manual adjustment with precise automated measurement and calculation.
3Ease of operation
If alignment is performed only when the machine is stationary, then ease of operation is improved, but productivity deteriorates due to downtime
Solution Approach 1:
The alignment system is designed to function dynamically during machine operation. The sensor on the rotor can measure distances to treatment modules while the rotor is rotating, enabling alignment verification and adjustment without stopping production, thus maintaining both operational simplicity and high productivity.
4Productivity
If the sensor measures alignment while the rotor is moving, then productivity is improved, but measurement precision may deteriorate due to vibrations
Solution Approach 1:
The system performs preliminary alignment measurements when the rotor is stationary to establish reference positions, then uses these references for continuous monitoring during operation. This preliminary action ensures high precision baseline measurements are captured before vibrations during operation begin.
Solution Approach 2:
The sensor performs periodic measurement cycles, alternating between stationary precision measurements and operational monitoring. During operation, measurements are taken at regular intervals when vibration patterns are consistent, allowing precision maintenance while keeping the system dynamic and productive.
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 solution simplifies the alignment process, enhances precision, and allows for real-time monitoring and compensation of deviations due to vibrations, ensuring accurate and reliable component alignment in rotary machines.
Implementation Method 1
the sensor comprises at least one of a pneumatically operated probe, an optical sensor, an ultrasonic sensor
Implementation Method 2
the sensor comprises at least one of a pneumatically operated probe, an optical sensor, an ultrasonic sensor
Data Source
Figure 1a
Figure 1b~1c
Figure 2a~2c
AI summary
Apparatus and method for orienting components of a rotary machine, such as a container treatment machine, where the rotary machine comprises a stator and a rotor and also at least one component which is arranged on the stator, wherein the apparatus comprises at least one reference element which is arranged on the stator and a sensor which is arranged on the rotor so as to rotate with it, wherein the sensor is suitable for measuring the distance from the reference element and from the component, and the stator, the rotor and the component can be oriented in relation to one another based on the values measured by the sensor.