Coaxial Shaft Alignment Using Laser Range Finder
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Solution Overview
Problem
Existing methods for aligning coaxially coupled rotatable shafts, such as those in motor and pump pairs, often result in power losses and premature coupling failure due to misalignment, and require manual inspection and adjustment, which can be inefficient and imprecise.
Innovation Solution
An apparatus and method using a servo-operated positioning device and a laser range finder to measure and align the shafts while they are rotating, calculating necessary adjustments to achieve precise coaxial alignment through a best-fit circle algorithm, allowing for real-time alignment during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical surface plate gauges are used for alignment, then the alignment can be performed, but the process requires manual inspection and adjustment which is inefficient and imprecise
Solution Approach 1:
The patent replaces traditional mechanical surface plate gauges with an automated optical measurement system using a laser range finder. The laser range finder electronically measures distances to multiple spots on the shafts, eliminating the need for manual mechanical inspection and adjustment, thereby improving both precision and efficiency
Solution Approach 2:
The system automatically performs alignment measurements and calculations without requiring manual intervention. The laser range finder autonomously measures distances to multiple points on the shafts, the processor automatically calculates centerlines and misalignment, and the system generates adjustment recommendations, making the alignment process self-service oriented
2Reliability
If alignment is performed while shafts are rotating in normal operating condition, then real-time alignment can be achieved, but the measurement system becomes more complex
Solution Approach 1:
The laser range finder serves multiple functions: it measures distances to multiple spots on both shafts, collects data at different axial positions, and enables measurements while the shafts are rotating. This multi-functional device simplifies the overall system compared to having separate specialized measurement instruments for each function
Solution Approach 2:
The system changes the measurement parameters by taking multiple distance measurements to multiple spots on the shafts at different axial positions. By collecting a set of distance data points and analyzing their geometric relationships, the system determines shaft centerlines and misalignment without requiring complex mechanical adjustment procedures
3Measurement precision
If multiple distance measurements are taken at different axial positions to determine shaft center, then alignment precision is improved, but the measurement time and data collection complexity increase
Solution Approach 1:
The system pre-establishes a grid of measurement spots on both shafts at different axial positions before beginning the alignment process. The laser range finder automatically measures distances to all predetermined spots in a systematic sequence, eliminating the need for real-time calculation and reduction of measurement time while maintaining precision
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
The solution enables precise and efficient alignment of rotating shafts, reducing power losses and extending the lifespan of coupling components by ensuring accurate alignment even when the shafts are 'hot and running', offering a higher level of precision than traditional methods.
Implementation Method 1
A laser range finder (LRF) is affixed to the positioning device and spaced a distance from the two rotating shafts, to measure the distance between the LRF and a spot on the rotating shafts
Data Source
AI summary
An apparatus and method for aligning two coaxially coupled rotatable shafts. A servo operated multi axis positioning device is movable along a longitudinal axis parallel to the axis of the shafts, and movable vertically to position a laser range (LRF) adjacent to the two shafts, which measures the distance between the LRF and a spot on the shafts. A controller having a processor and memory communicates with the positioning device and the LRF to collect data at two axial positions on each shaft. At each position the LRF measures the distance to the shaft and stores the measurement and location data. The LRF is vertically repositioned and the measurement and storing steps are repeated over a scan distance sufficient to provide enough data to determine the location of the shaft center. The processor then calculates and compares the shafts centerlines and determines the necessary adjustments needed to move the shafts into coaxial alignment.