Machinery Laser Shaft Alignment
Misalignment and Vibration
EMX Industrial Repair can help reduce overall operating costs and increase equipment efficiency, reliability and productivity with our expert laser alignment service.
At some time during a motor’s life, it is likely to experience high vibration levels. What’s behind this maintenance phenomenon? The cause may be an electromagnetic or mechanical imbalance, loose components, rubbing parts, bearing failure, resonance, or shaft to shaft misalignment.
Misaligned equipment is subjected to higher vibration levels significantly reducing the service life of bearings, seals, shafts and couplings. When a problem occurs, it is critical to quickly identify the source and take corrective action. Using EMX’ vibration-analysis latest diagnostic techniques can save you money and downtime. EMX’ vibration-analysis systems is a portable, route-based instrument used for collecting vibration data on rotating machinery. It reduces collection time, analysis, and reporting time, when compared with similar devices. This allows EMX to determine the severity of the stress level of bearing or gear wear on your motor. The data is recorded from each machine and uploaded on the software, providing quick recognition of change in the vibration pattern, as an indicator of deterioration. Corrective actions of any kind of machine misalignment are then taken.
Misalignment is the number one cause for machine failure. Misalignment occurs when the center lines of two shafts are not co-linear. Misalignment destroys bearings, seals, couplings, rotors, stators, shafts, etc. Misalignment of the driving and driven shaft(s) in a machine train adds stress forces to the shafts, which are transferred to the bearings, seals, etc. These forces work against all of these components to reduce the productive life of the machine. Misalignment will also create high levels of vibration and friction. This can result in excess heat that can reduce the effectiveness of the lubricant. Excess vibration will result in shorter machine life and, in some cases, poor
product quality resulting in scrap and waste. Misalignment can be diagnosed using vibration analysis tools. There are distinct patterns that reveal the presence of misalignment. Angular misalignment is characterized by high axial vibration caused by the push/pull movement of the misaligned shafts. Offset misalignment is characterized by high radial vibration. Misalignment typically appears in the spectrum at 1 times and 2 times running speed. There are many programs that still insist that a straight edge is sufficient for aligning two machines at the coupling. This may be acceptable for a rough alignment, but it is no replacement for a precision alignment tool. Dial indicators can be a precise way to align shafts, but requires complex methods and extensive math. EMX uses Laser alignment tools which are a faster alternative to dial indicators. Laser tools take the guesswork out of the alignment process by displaying the offset and angle of the shafts and calculating the necessary moves to correct the problem.
Documentation & Certification
Good documentation is important in alignment. It is a record of who performed the alignment, when it was done and how well it was done. All work is electronically documented and a shaft alignment report with alignment data as well as original and final results, is generated upon completion of the job. The commitment for alignment is to do it every time a machine is installed and make it a regular preventative maintenance step when machines are inspected. A quick alignment measurement can save a lot of headaches down the road.
Precision Laser Alignment initially establishes the alignment conditions of newly installed components of new projects. This gives the original misalignment readings. Also provided are horizontal and vertical diagrams to illustrate these findings. Precision Laser Alignment procedures are then used to make precise installation adjustments on the new equipment mentioned above. In some instances, precision alignment is not achievable. If this is the case, notice is given to the end user. Additional millwright work may be required. After the adjustments are completed on the new equipment, final recorded results will be provided. This includes horizontal and vertical cad style drawings.
Vibration Analysis is then used to establish baselines for the vertical, horizontal and axial in a detailed report. These readings confirm the Laser Alignment Precision Installation of the new equipment and overall expected increased reliability of the equipment. This process assures the client an unbiased opinion of conditions and that any necessary adjustments have been made.
These three steps lead to Certified Precision Installations using industry standards for new equipment.