Shaft Alignment Measurement Using Standard Dimensions and Laser Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional shaft alignment methods often result in misalignment despite precise measurements, requiring repeated adjustments and significant time, leading to costly downtime and premature machinery failure.
Innovation Solution
A method utilizing an algorithm that calculates misalignment by inputting measured values between machine points and standard dimensions, allowing for lateral movement and vertical shimming to correct horizontal and vertical misalignment, reducing the need for repeated adjustments and minimizing measurement errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional shaft alignment methods (visual inspection with straightedge or dial indicators) are used, then the alignment process is simple and quick, but measurement precision and alignment accuracy are insufficient
Solution Approach 1:
The patent replaces conventional mechanical alignment tools (straightedges, dial indicators) with laser-based measurement systems. Laser beams provide precise optical measurement paths between shafts, eliminating mechanical contact and enabling higher measurement precision while reducing the complexity of manual measurement procedures.
Solution Approach 2:
The patent introduces laser beams as intermediary carriers for measurement information. The laser beams serve as mediators that transmit alignment data between the two shafts, enabling accurate measurement without direct mechanical contact and facilitating automated data processing.
2Manufacturing precision
If multiple adjustment iterations are performed to achieve proper shaft alignment, then alignment accuracy can be improved, but time consumption and productivity are reduced
Solution Approach 1:
The patent performs preliminary laser measurement before any physical adjustments are made. The laser system captures alignment data in advance, allowing the calculation of precise shim requirements before the actual alignment work begins. This preliminary measurement action eliminates the need for repeated measurement-adjustment cycles.
Solution Approach 2:
The patent implements a feedback mechanism where laser measurement data is processed through algorithms that calculate the exact alignment corrections needed. This feedback loop provides precise guidance for single-step adjustments, eliminating the trial-and-error nature of conventional iterative alignment methods.
3Reliability
If shims are inserted and alignment measurements are repeated to verify proper alignment, then alignment reliability is improved, but the alignment process time increases
Solution Approach 1:
The patent replaces repeated mechanical measurement verification with a single laser-based measurement and calculation process. The laser system provides reliable measurement data that, when processed through the alignment algorithm, guarantees alignment accuracy without requiring repeated verification measurements.
Solution Approach 2:
The patent creates a digital copy of the alignment situation through laser measurement data. This digital representation allows for precise calculation and verification of alignment parameters without requiring physical remeasurement, thereby reducing verification time while maintaining reliability.
Data Source
AI summary
A method for improving measurements when performing an alignment of the shafts of a first machine and a second machine includes providing to an algorithm a first value measured between two points of the first and second machines, providing to the algorithm a second value measured between one of the two points of the first or second machine and a front foot of the first or second machine, providing to the algorithm a normalized value or standard value between the front feet and the back feet of the first or second machine, and extracting from the algorithm values to compensate for or correct the horizontal and vertical misalignments.