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 current alignment techniques are not precise enough, especially when the shafts are in operation.
Innovation Solution
An apparatus and method using a servo-operated positioning device and a laser range finder to measure and calculate the centerlines of rotating shafts while they are in operation, allowing for real-time adjustments to achieve precise coaxial alignment by determining the necessary adjustments needed to align the shafts using a best-fit circle algorithm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical surface plate gauges or manual laser detectors are used to align shafts, then alignment can be performed with existing equipment, but the alignment precision is insufficient and cannot be performed while shafts are rotating
Solution Approach 1:
The patent replaces traditional mechanical surface plate gauges and manual laser detectors with an automated laser-based measurement system. The laser detector automatically tracks shaft positions while rotating, eliminating the need for manual measurement and significantly improving alignment precision without requiring shaft shutdown.
Solution Approach 2:
The alignment system is designed to measure and adjust shaft alignment dynamically while the shafts are rotating at operating speed. The system captures multiple measurement points during rotation and processes them to determine precise alignment, enabling hot alignment rather than cold alignment requiring shutdown.
2Reliability
If shafts are aligned while rotating in normal operating condition, then real-time alignment adjustment is achieved, but the measurement and positioning system becomes more complex
Solution Approach 1:
The system uses the rotating shafts themselves as the measurement target, with the laser detector automatically tracking features on the shaft surface. The shafts provide their own measurement references through their rotation, eliminating the need for external alignment fixtures or additional alignment equipment.
Solution Approach 2:
The system continuously measures shaft positions during rotation and provides feedback to determine alignment deviations. The controller processes measurement data from multiple points and calculates the precise adjustments needed, enabling real-time alignment verification and correction while operating.
3Measurement precision
If multiple measurement points are collected around the shaft circumference, then accurate shaft center determination is achieved, but the data collection time and processing complexity increase
Solution Approach 1:
The laser detector continuously measures shaft positions throughout the entire rotation cycle, collecting multiple data points around the circumference in a single continuous measurement sequence. This continuous measurement approach captures all necessary alignment information during one complete rotation, eliminating the need for multiple separate measurement passes.
Solution Approach 2:
The system leverages the periodic rotation of the shafts to automatically present multiple measurement points to the laser detector. By synchronizing measurements with the rotational period, the system efficiently collects circumferential data points as the shaft naturally rotates, converting rotational motion into measurement opportunities.
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
Enables accurate alignment of rotating shafts while they are 'hot and rotating', reducing power losses and extending the lifespan of the coupling by ensuring precise alignment, which is not achievable with existing methods.
Implementation Method 1
a laser range finder (LRF) 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
Implementation Method 2
The LRF measures the distance between the LRF and a spot on the shaft
Data Source
AI summary
An apparatus and method for aligning two coaxially coupled rotatable shafts. A servo operated 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.