Rotating Shaft Collar Sensors for Accurate Misalignment Measurement
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Solution Overview
Problem
Existing methods for measuring misalignment of rotating shafts are inadequate due to sensor dislodgment, limited space for internal sensors, and damage or failure of strain gauges incorporated with sensors.
Innovation Solution
A sensor assembly is mounted on a rotating shaft with a collar that includes first and second sensors to measure changes in angles of radially outer rims of couplings, allowing for accurate misalignment measurement without the need for internal sensors and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are mounted externally to measure shaft misalignment, then measurement capability is provided, but sensors become dislodged during rotation
Solution Approach 1:
The sensor assembly is nested within a collar that fits over the shaft, creating a protected housing structure. The collar acts as a container that holds the sensor(s) in a fixed position relative to the shaft, preventing dislodgment during rotation while allowing the sensor to measure misalignment of internal components.
Solution Approach 2:
The collar is pre-installed onto the shaft before the sensor assembly is positioned within it. This preliminary mounting action secures the collar to the shaft, creating a stable base structure that will subsequently hold the sensor in place during operation.
2Measurement precision
If internal sensors are used to measure shaft misalignment, then measurement accuracy is improved, but space for sensors is limited
Solution Approach 1:
The sensor assembly is nested within the collar structure that fits over the shaft. This nested configuration allows the sensor to be positioned close to the shaft for accurate measurement while the collar provides the necessary mounting space and structural support, effectively utilizing the limited radial space available.
3Measurement precision
If strain gauges are incorporated with sensors for measurement, then measurement capability is enhanced, but damage or failure occurs
Solution Approach 1:
The sensor and strain gauge components are nested within the protective collar housing. This nested configuration shields the fragile strain gauge elements from external damage, mechanical stress, and environmental factors that would otherwise cause failure during shaft operation.
Solution Approach 2:
The collar structure serves as a protective housing that cushions and protects the sensor and strain gauge components from damage before failure can occur. The rigid collar walls absorb external forces and prevent direct impact on the fragile measurement elements.
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A method for sensing misalignment of a rotating shaft includes rotating the shaft. A distance from a sensor on the shaft to a first rim of a first coupling mounted to an end of the shaft is sensed as the shaft rotates. A change in the distance from the first sensor to the first rim of the first coupling is determined based on the sensed distance. An angle of the first coupling based on the change in the distance from the first sensor to the first rim of the first coupling during one revolution of the shaft is determined based on the sensed change in the distance from the first sensor to the first rim. An angle of the shaft is determined based on the sensed distance from the first sensor to the first rim of the first coupling representing the sensed change in the distance from the first sensor to the first rim.