sm how to move roller alignment - mechanics - aimcal · web 101.72sm – how to move roller...
TRANSCRIPT
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72.1
Web 101.72SM – How to Move
Roller Alignment - Mechanics
©2012 David Roisum, Ph.D. Finishing Technologies, Inc.
Figure Courtesy of Oasis Alignment Services
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72.2
Why is Alignment So Important?
Affects the Web: • Flatness: Bagginess and apparent Bagginess • Position: Path and Registration (e.g. Printing) • Runnability (Web Breaks) • Winding: Roll Quality • Wrinkles
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Two Views of Alignment
• Mechanical – Level – Square – Common Centerlines
• Web Handling – In-plane (bending)
• Path control • Web breaks • Wrinkles
– Out-of-plane (twisting) • Web damage/breaks at
edges • Center wrinkle
– Offset Centerlines • Guide runs off center • Web runs off center 72.3
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72.4
Hand Tools - Types
Figures Courtesy of Oasis Alignment Services
Pi Tape
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Hand Tool - Limitations
• Level – At best good to 0.001”/foot – (Optics can be 20X tighter)
• Square – There is no squaring tool – Parallelism Problems
• Doesn’t help square vertical spans (1-2 and 3-4) • Accumulation of error
• Level and Square – Large Tendency to Sloppiness
72.5
1
2 3
4
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Hand Tool – Application
• Step 1 – I might have an alignment related problem – Path Control
• Printer Registration • Wound Roll Edge
– Web Breaks – (Diagonal) Wrinkling
• Step 2 – Verify working hypothesis that problem might be exacerbated by misalignment – Level by level – Parallel by Pi Tape
• Step 3 – Align (Optics?)
72.6
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72.7
Optical Tooling
Figures Courtesy of Oasis Alignment Services
Similar to surveying equipment, but > 10X more precise
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72.8
Baseline Installation
• Alignment means – Establishing ‘offset centerline’ for alignments – Look for ‘monuments’ (small plugs) in floor
Figure Courtesy of Oasis Alignment Services
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72.9
Centerline Survey
• Alignment means – Level, – Square, AND – Middle of Rollers on Same Centerline
Figure Courtesy of Oasis Alignment Services
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72.10
Squaring With Optics
• Precision Square w.r.t. Baseline • Uses a pair of TTS • Precision right angles
Figure Courtesy of Oasis Alignment Services
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72.11
Other High Tech Alignment Tools
Figures Courtesy of Oasis Alignment Services
Laser Trackers Coordinate Measuring Total Station
Laser Shaft Alignment
The standard for motor to roller alignment
Gyroscope
Gyro – Fast setup and position readout
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Alignment Details - Preparation • $$$ for Downtime • Machine Builder
– Standards & Instructions – Alignability
• Maintenance – Remove Excess Rollers – Roller Maintenance – Dowel/Mark
• Align Crew – Plug Lines – Report with before & after readings
• Design for Service (alignability) – Individual rollers
easily moved – Preserve Level
• Shear ledge • Jack bolts
• Match Drilled Frames?
72.12
Dowel Pin
Shear Ledge
Dunn, Jim M. Precision Alignment of Winders. Tappi J., vol 79, no 6, pp 67-71, June 1996
Williams, Fritz (OASIS). Alignment Methods and Best Practices for Cost Effective Alignment of Production Equipment. AIMCAL AWEB, Charlotte, May 7-10, 2006
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Alignment Challenges • Bearing Housings
– At an angle – Bolt bound designs (e.g., match
drilled frames) – No shear ledge
• Rollers - General – Flimsy frames – Flimsy foundations – Loose mounting
• Rollers – Specific – Pivoting / translating – Skewable – Curved axis (bowed spreaders) – Segmented
• Alignment – No line of sight – Flimsy floors – Hand tools
• Procedural – Lack of guidance
• Which rollers • How close
– Not enough time
• Special – Foil – Close packed rollers – Narrow rollers (wheels)
72.13
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72.14
Review Questions
• Why might we need to align? • What are the instrument based definitions
of alignment? • What are the common measures of
misalignment? • What are the common realignment
instruments?
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72.15
Review Answers
• Why might we need to align? – Path, web breaks, wrinkling
• What are the instrument based definitions of alignment? – Level, square, common centerlines
• What are the common measures of misalignment? – Precision level, Pi tape or trammel
• What are the common realignment instruments? – Precision level, TTL
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72.16
Questions?
Answers:
David Roisum, Ph.D. http://www.webhandlingblog.com/
http://www.roisum.com
920-725-7671 office
920-312-8466 cell