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Laser Alignment Service

laser_alignment_serviceWhen two machines are connected together through a shaft coupling, every effort must be made to eliminate misalignment of those shafts which can lead to damage or wasteful loss of energy. Lasers are highly accurate and easy to use in aligning objects. Using laser shaft alignment techniques can reduce the amount of time in the alignment process.

Precise laser coupling alignment is used to reduce bearing and seal damage,vibrations, minimise energy loss, and reduce production downtime. Performing coupling alignment on a scheduled basis will make machinery last longer and perform more efficiently.

There are several methods used to align couplings including 'eying' it, dial calibration and laser alignment. Each method varies in its degree of accuracy and dial calibration can be a very time consuming process.

Utilising a state-of-the-art laser measurement system, a technician will measure and align couplings, universal joints and belts. This alignment allows conveyor systems and manufacturing machines to run in a straight line. A factory line that makes masking tape is a good example of the need for precision alignment. In order for the tape to spool neatly and at a high rate of speed, the take up reel shaft must be exactly perpendicular to the incoming tape. Any deviation will decrease the quality of the end product.

To control the co-linearity and angle of two shafts at the coupling, where the power is transmitted - laser shaft alignment technology can help to perform the measurement easily. The Laser "shoots" onto a position sensitive detector, during continuously rotating the shafts the detector collects all changes and can calculate the gap & offset at the coupling position.

In addition the shaft alignment device can check whether the alignment is in within OEM tolerances or not.

Performing a correction saves time and money. Misalignment is the most common cause of machine vibration. Understanding and practicing the fundamentals of shaft alignment is the first step in reducing unnecessary vibration, reducing maintenance costs, and increasing machine uptime.

Misalignment costs time and money

Shaft misalignment
Shaft misalignment is responsible for up to 50% of all costs related to rotating machinery breakdowns. These breakdowns increase unplanned machinery downtime, resulting in higher maintenance costs and loss of production. Additionally, misaligned shafts can increase vibration levels and friction, which can significantly increase energy consumption and can cause premature bearing failures.

  • An offset alignment of only 1mm can use up to 3% more energy, and at 1.25mm offset, this dramatically rises to 8% more energy - a huge unnecessary expense.
  • An offset misalignment of 1.2mm between a pump and its motor will destroy in one month a seal which would normally last for 8 years.  Even with a misalignment of 0.05mm (or 50 microns) the seal life will be reduced by a factor of 10 

laser_alignment_toolTraditional shaft alignment methods
Traditional alignment methods, although very common, do not often produce the exacting degree of accuracy required by today’s precision machinery. The rough alignment methods still used nowadays, such as using a straight edge and feeler gauge, may be quick, but they can be inaccurate. Another traditional method employing dial indicators offers a higher degree of accuracy, but it requires specialist operators and can be time consuming.

Laser shaft alignment method
Laser alignment methods are a marked improvement on traditional ones. A laser shaft alignment tool facilitates a quicker and more accurate alignment than traditional methods. Since shaft misalignment has a direct, negative, impact on bearing service life, Proviso offers a range of high precision, easy–to–use laser shaft alignment tools. Our alignment tools combine simplicity with a high degree of accuracy. They feature a three–step process for correcting alignment: Measuring, Aligning and Documenting.

Accurate shaft alignment can help you:

  • Increase bearing life
  • Reduce stress on couplings and thereby the risk of overheating and breakage
  • Reduce wear on seals, helping to prevent contamination and lubricant leakage
  • Reduce friction and thereby energy consumption
  • Reduce noise and vibration
  • Increase machinery uptime, efficiency and productivity
  • Reduce costs of replacing components and machinery downtime

Contact us for more details. 

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