Benefits of shaft alignment

What is the problem?

Misalignment generates forces in the coupling between the machines

Rotational centers

All shafts, whether they are straight or bent, rotate on an axis called the rotational center. The rotational center forms a straight line.

Misalignment

Misalignment - when the two shafts are not collinear.

Types of misalignment Offset misalignment

Angular misalignment

Measuring Misalignment Viewed from the top - Horizontal Misalignment

Viewed from the side - Vertical Misalignment

Shaft alignment – basics Measure and adjust the machines so there

rotational centers are colinear

Shaft alignment - basics One of the machines is a reference–

Stationary machine

Shaft alignment - basics The second machine is adjusted

Moveable machine

Shaft alignment - basics The alignment system measure the position of the

moveable machine according to the stationary

Shaft alignment - basics Adjustments are done on the moveable machine until the two rotational centers

are collinear.

Alignment tolerances

Alignment Methods With all alignment methods measurements

are taken at the shafts or couplings.

Alignment Methods Misalignment is corrected at the feet.

Alignment Methods

Mechanical methods

Straight edge/feeler gauge method

Determine the direction and amount of offset using a straight edge and feeler

gauges.

Measure the gap at two points 180° apart to determine the direction and amount of

angular misalignment.

Dial indicator methods

Rim-Face method

Reversed-Rim method

Rim- Face Alignment method

The rim dial measures offset

The face dial measures angularity

Reversed- Rim alignment method

• Widely acknowledged as the“preferred method” of shaftalignment.

• Both dials measure offset onthe Rim. The Angular error isthe slope between the twooffset values.

• Easy to plot or calculate thefeet correction values.

Laser Shaft Alignment Systems

Single laser systems with a single or double detectors.

Twin laser systems using the Reversed-Rim method.

Misalignmet – the biggest single cause to high vibration levels

Misalignment – is it common?

Studies has shown that up to 90% of all rotating machinery runs outside recommended alignment tolerances.

Shaft alignment – it is important!

• Key factor in successful condition based maintenance

• Misaligned machines are the single largest cause to high vibration levels.

• Cause failure in bearings, seals and couplings

• Will lead to machine breakage and increased down-time if not implemented

Vibrations

General and coarse analyse of vibration results: • Horizontal vibration indicates unbalance (H) • Vertical vibrations indicates a weak or loose

foundation(V) • Axial vibrations indicates misalignment (A)

37

Energy savings

Correctly aligned machines can save up to 15% in energy consumption, sometimes more

38

Wear of components

Bearings Increased load will mean an exponential decrease in lifetime on bearings. Example: double the load, reduce the lifetime to 1/8

39

Wear of components

Seals

Misalignment can reduce lifetimes of mechanical seals with 50-70%. Leakage - a typical indication of misalignment

40

Production capacity

• A modern production process is extremely depenent on availability.

• Cost for lost production is high, 10-100 kUSD/h

• The cost of a stop in production is normally a lot higher than cost for, be several times…

41

Product quality

• Decreased vibration levels can directly give effect on product quality.

• Example: products with high level of surface treamment could be directly effected by misalignment.

42

Fixturlaser product range

Shaft alignment

Alignment of belt drives Geometrical measurements

Benefits of shaft alignmentFixturlaser product rangeWhat is the problem?Rotational centersMisalignmentTypes of misalignmentMeasuring MisalignmentShaft alignment – basicsShaft alignment - basicsShaft alignment - basicsShaft alignment - basicsShaft alignment - basicsAlignment tolerancesAlignment MethodsAlignment MethodsAlignment MethodsMechanical methodsDial indicator methodsRim- Face Alignment methodReversed- Rim alignment methodLaser systemsMisalignmet – the biggest single cause to high vibration levelsMisalignment – is it common?Shaft alignment – it is important!VibrationsEnergy savingsWear of componentsWear of componentsProduction capacityProduct quality