Shaft Alignment Distance Measurement Using Reference Surface Geometry
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Solution Overview
Problem
Conventional shaft alignment methods often result in misalignment despite precise measurements, requiring repeated adjustments and substantial time, leading to increased maintenance costs and unplanned downtime.
Innovation Solution
A method that secures a measuring unit to a shaft, determines the length of a segment to a reference surface, and calculates the distance using standard manufacturing dimensions, ensuring accurate alignment with reduced error and time by combining segment length with predetermined dimensions.
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 the measurement precision and alignment accuracy are insufficient
Solution Approach 1:
The patent replaces mechanical measurement systems (straightedges, dial indicators) with an optical measurement system using laser beams. The laser alignment tool emits laser beams that are detected by sensors, providing precise digital measurements of shaft positions and alignment deviations, thereby improving measurement precision while reducing the complexity of manual mechanical measurement processes.
Solution Approach 2:
The patent introduces a laser beam as an intermediary between the measurement tool and the shafts. The laser beam serves as a reference line that mediates the alignment measurement process, allowing for precise measurement of shaft positions and angular deviations without direct contact with the shafts, thus improving accuracy while simplifying the measurement procedure.
2Measurement precision
If laser guided tools are used for shaft alignment, then measurement precision and alignment accuracy are improved, but the device complexity and time required for calculations increase
Solution Approach 1:
The patent implements a feedback mechanism where the laser alignment tool continuously measures the positions of both shafts and provides real-time feedback on alignment deviations. The system calculates the required adjustments and guides the operator through the correction process, enabling alignment to be achieved in one or two measurements rather than requiring multiple iterative adjustments, thereby reducing the overall time required.
Solution Approach 2:
The patent performs preliminary calculations of the optimal alignment configuration before the actual alignment process. The system pre-calculates the required shim thicknesses and adjustment amounts based on the measured shaft positions, allowing the operator to make precise adjustments in one step rather than through repeated trial and error, thus reducing the time required for the alignment process.
3Reliability
If repeated adjustments are made to achieve proper shaft alignment, then alignment accuracy is improved, but the loss of time and productivity decrease
Solution Approach 1:
The laser alignment tool provides continuous feedback on alignment deviations, allowing the operator to make precise adjustments and verify results immediately. This feedback mechanism ensures that proper alignment is achieved in one or two measurements, eliminating the need for repeated adjustments and thereby maintaining high productivity while ensuring reliable alignment results.
Solution Approach 2:
The replacement of manual mechanical measurement with automated laser measurement and digital calculation eliminates human error and the need for repeated measurements. The system automatically calculates alignment deviations and required adjustments, providing reliable results in a single measurement cycle, thus maintaining both high reliability and productivity.
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 allows for accurate shaft alignment the first time, reducing the need for rework and minimizing downtime, while simplifying the process and increasing precision through the use of standard dimensions and pulsed light technology.
Implementation Method 1
laser guided tools typically consist of two units, each capable of emitting a precise laser beam and detecting a laser beam from the other unit
Implementation Method 2
each capable of emitting a precise laser beam and detecting a laser beam from the other unit
Data Source
AI summary
A method for determining distance between a measuring unit and a point of a first machine when performing a process of aligning the shafts of the first machine and a second machine includes a step of securing the measuring unit to one of the shafts. The method further includes the steps of determining the length of a segment between the measuring unit and a reference surface of the first machine and calculating the distance between the measuring unit and the point of the first machine from the determined length of the segment and a predetermined dimension between the reference surface and the point of the first machine.