Shaft Alignment Device Using Quality-Based Data Filtering
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Solution Overview
Problem
Existing shaft alignment measuring devices face challenges in achieving reliable measurements due to measurement errors caused by clutch play, angular acceleration, and non-optimal connections, leading to deviations in light beam impact positions and reduced reliability of curve-fitted data.
Innovation Solution
A method and device that assess the quality of individual measurement data points based on angular velocity, angular acceleration, and deviation from a fitted curve, excluding low-quality data to improve the reliability of shaft displacement determination, and allowing for partial revolution measurements with curve fitting to extrapolate over the remaining angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measurement data is collected during shaft rotation to determine alignment, then alignment information can be obtained, but measurement errors occur due to clutch play, angular acceleration, and non-optimal connections causing deviations in light beam impact positions
Solution Approach 1:
The system performs preliminary actions by evaluating the quality of measurement data points before final curve fitting. It calculates angular velocity and angular acceleration for each measurement point, identifies suspicious points using quality criteria, and removes them before determining the final alignment parameters. This preliminary filtering ensures that only high-quality data contributes to the alignment measurement, resolving the contradiction between obtaining alignment information and avoiding measurement errors.
Solution Approach 2:
The system implements feedback by continuously monitoring measurement quality through angular velocity and angular acceleration calculations. It uses this feedback to identify and exclude suspicious measurement points that deviate from expected patterns, thereby improving the reliability of the final alignment determination while maintaining measurement precision.
2Measurement precision
If complete revolution measurements are performed to ensure accurate curve fitting, then alignment precision improves, but measurement time increases
Solution Approach 1:
The system applies partial action by performing quality-based filtering on measurement points during rotation. Instead of requiring complete revolutions for sufficient data, it selectively uses high-quality measurement points that meet predetermined criteria, achieving accurate curve fitting with reduced measurement time and fewer required revolutions.
3Measurement precision
If multiple measurement points are collected to improve curve fitting reliability, then data accuracy improves, but the influence of suspicious data points from clutch play and vibrations increases
Solution Approach 1:
The system extracts and removes suspicious measurement points from the data set before final curve fitting. By calculating angular velocity and angular acceleration for each point and comparing them against quality criteria, it identifies and excludes data points affected by clutch play, vibrations, and non-optimal connections, thereby improving the reliability of the remaining data for alignment determination.
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 enhances the reliability of shaft misalignment determination by filtering out poor-quality data points and achieving accurate alignment measurements even with partial revolution data, thereby increasing the confidence in the determined shaft offset.
Implementation Method 1
At least one of the two measuring units has means for generating at least one light beam
Implementation Method 2
at least one of the two measuring units has detection means for acquiring data relating to the impact position of the light beam on at least one detection surface
Implementation Method 3
at least one of the two measuring units is provided with at least one sensor for detecting the angle of rotation of the shaft
Data Source
Figure 1~2
Figure 3A~4
Figure 5~6
AI summary
The device has an analysis unit (30) that determines angle-of-rotation position, angular velocity and angular acceleration of shafts (10,12) in measured positions from the sensor data showing angle of rotation of shafts. Analysis unit analyzes quality of sensor data, based on difference between impingement positions of a light beam bundle (22) on detection area (24,26). Analysis unit analyzes quality rating of sensor data to exclude measured position data and to consider only reduced weighting data for determining the shaft offset, when quality rating lies below threshold value.