Imaging Tool for Thermal-Offset Misalignment Analysis
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Solution Overview
Problem
Traditional vibration and misalignment analysis tools provide incomplete information, leading to inefficient and costly adjustments in rotating equipment, and existing methods require repeated shutdowns for incremental alignment adjustments.
Innovation Solution
An imaging tool that captures visible light and infrared image data of equipment in different operating states to determine thermal expansion and misalignment, using thermal image data to calculate temperature changes and alignment calibration parameters for subsequent alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional vibration analysis tools are used, then one type of vibration or misalignment can be detected at a time, but complete alignment information cannot be obtained
Solution Approach 1:
The patent combines multiple vibration analysis capabilities (parallel and angular misalignment detection) into a single integrated system. The analysis tool simultaneously captures and processes both types of misalignment data, eliminating the need for separate measurement tools or multiple measurement sessions, thereby achieving complete alignment information while maintaining reasonable device complexity.
Solution Approach 2:
The analysis tool is designed to perform multiple functions: detecting parallel misalignment, detecting angular misalignment, and providing comprehensive alignment guidance. This multi-functional approach allows a single device to replace multiple specialized tools, improving measurement completeness without proportionally increasing device complexity.
2Manufacturing precision
If repeated shutdowns are performed for incremental alignment adjustments, then alignment can be improved incrementally, but downtime and labor costs increase
Solution Approach 1:
The system performs preliminary comprehensive analysis of both parallel and angular misalignment simultaneously before any adjustment is made. By capturing complete alignment information in a single measurement session, the system provides full guidance for the necessary adjustments, eliminating the need for repeated shutdowns and incremental adjustments, thereby reducing downtime while achieving accurate alignment.
Solution Approach 2:
The system provides comprehensive feedback on both parallel and angular misalignment components in a single measurement cycle. This complete feedback enables operators to make all necessary adjustments in one alignment session rather than requiring multiple iterative adjustments across separate shutdowns, significantly reducing equipment downtime and labor costs.
3Productivity
If traditional alignment methods are used, then equipment can be aligned, but additional improvements are not realized and inefficiencies persist
Solution Approach 1:
The analysis tool acts as an intermediary that translates complex vibration data into comprehensive alignment guidance. By simultaneously analyzing both parallel and angular misalignment components and providing integrated adjustment recommendations, the system enables operators to achieve optimal alignment and realize additional productivity improvements that would be missed by traditional methods.
Solution Approach 2:
The system replaces traditional mechanical alignment measurement methods with advanced vibration analysis technology. This substitution enables simultaneous detection of multiple misalignment types and provides comprehensive digital guidance, eliminating information losses inherent in traditional methods and enabling further productivity improvements through more accurate and complete alignment data.
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 precise alignment calibration by determining thermal expansion and misalignment, reducing downtime and labor costs by providing comprehensive alignment guidance without repeated shutdowns.
Implementation Method 1
a plurality of sets of image data (e.g., visible light (VL) and/or infrared (IR) image data) representative of an object... The thermal image data can be used to calculate the temperature change (e.g., between the cold state and hot state) of a portion of the object
Implementation Method 2
The calculated temperature change can be used with additional parameters (e.g., thermal expansion coefficients, initial dimensions, etc.) to determine an amount of thermal expansion of such portions
Data Source
AI summary
Systems and methods can be used for analyzing image data to determine an amount of vibration and/or misalignment in an object under analysis. In some instances, as operating equipment heats up during operation, temperature changes of various portions of the operating equipment leads to changes in dimensions of such portions, leading to misalignment. Multiple sets of data representative of the operating equipment in multiple operating conditions can be used to determine an amount of misalignment due to thermal offsets. Hot and cold temperatures of the equipment can be used to calculate thermal growth of various portions of the equipment, which can be used to determine an amount a misalignment due to thermal offsets. Additionally or alternatively, image data representing the equipment can be used to observe changes in alignment between states.