Shaft Alignment System Using Laser Measurement and Jacking Compensation
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Solution Overview
Problem
Existing precision shaft alignment systems fail to achieve high accuracy in concentric alignment of rotatably mounted shafts, leading to inefficient energy transfer, increased friction, noise, and potential machine failure, due to limitations in processing multiple measurement data and compensating for static movement caused by pressure differences.
Innovation Solution
A precision shaft alignment system that utilizes laser or digital measuring means to provide accurate positioning data to a control and computing module, which calculates and controls the alignment of shafts automatically or manually, incorporating a jacking system with a coil-operated floating engagement device to compensate for static movement and perform dynamic direct response calculations without user input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual alignment methods are used, then the system is simple to operate, but the alignment precision is insufficient leading to energy loss and machine failure
Solution Approach 1:
The patent replaces conventional manual mechanical alignment methods with an automated optical measurement system using lasers and digital sensors. The system uses laser beams to measure shaft positions and a computer control system to calculate and guide alignment adjustments, eliminating the need for manual measurement tools and procedures while achieving much higher precision.
Solution Approach 2:
The alignment system performs self-measurement and self-correction by automatically detecting shaft misalignment through laser measurements, calculating the required adjustments, and guiding the alignment process without requiring external measurement devices or manual intervention for data collection and analysis.
2Measurement precision
If multiple measurement data are collected to improve accuracy, then the alignment precision increases, but the difficulty of processing information increases
Solution Approach 1:
The system continuously collects measurement data from multiple laser sensors positioned at different locations, feeds this data to the computer control system, which processes the information and provides real-time feedback on alignment status and required adjustments. This closed-loop feedback system handles the complexity of multiple data points automatically while improving positioning accuracy.
Solution Approach 2:
The computer control system serves multiple functions simultaneously: it collects data from multiple sensors, processes measurement information, calculates alignment corrections, guides the alignment process, and monitors progress. This multi-functional integration simplifies the overall system by consolidating data processing tasks into a single intelligent controller.
3Measurement precision
If static movement compensation is implemented, then the alignment accuracy improves, but the device complexity increases
Solution Approach 1:
The system performs preliminary measurements to detect static movement or soft foot conditions before final alignment is achieved. By identifying and compensating for these preliminary issues, the system prevents them from affecting final alignment accuracy without requiring complex real-time compensation mechanisms during the alignment process itself.
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 system achieves high accuracy in concentric alignment, reducing energy loss, friction, and noise, while extending the lifespan of components by enabling precise horizontal and vertical alignment with built-in soft foot detection and automatic compensation for static movement.
Implementation Method 1
a coil operated floating engagement device when activated applies pressure when deactivated allows freedom of axis movement thereby having the ability to allow measurement of compensation for static movement caused by applied pressure difference
Data Source
AI summary
A precision shaft alignment system for establishing precise concentric axial alignment of a first shaft rotatably mounted and extending from a fixed unit and a second shaft extending from a variable position unit towards the first shaft includes a control and computing interface module, a pair of measuring means for precisely measuring at least one position of the first shaft and the second shaft and a jacking system for precisely aligning the shafts. The pair of measuring means is in communication with the control and computing interface module for transferring the at least one position of the first shaft and the second shaft for establishing precise concentric axial alignment of the first shaft and the second shaft. The jacking system is controlled by the control and computing interface module for precisely aligning the shaft.