Shaft alignment is a prerequisite to running machines, the misalignment of which can cause malfunctions, accidents and injuries. Positioning shafts relies on certain tools as human judgment leaves too much room for error. Laser shaft alignment is one example which can guarantee perfect coupling and tolerances well below the recommended margin.
Laser shaft alignment is based on laser-technology, not a new concept but one which has undergone changes to become very reliable and precise. Gyroscope-based systems are the only other way to align couplings. Though cheaper, they don't offer the precision of laser systems and are difficult to set up, not a solution where remedies have to be made quickly.
The misalignment experienced between components falls into either of two categories - angular and parallel. In angular misalignment the lines of shafts are at an angle (vertically or horizontally) whether on the same plane or on a different plane. With parallel misalignment the lines of shafts are parallel but separated vertically or horizontally. Irrespective of what misalignment is experienced, laser shaft alignment can correct the error.
In order to understand how the technology is able to derive such precision, an example can be made with laser leveling tools. The laser shoots a perfectly straight line with tolerances that are extremely minor. In the same way, shaft alignment with laser technology is able to achieve the same within hundredths of a millimeter.
The equipment consists of three main components, the laser, sensor and an electronic device that calculates measurements. When the laser shoots a beam of light to the sensor the electronic device picks up the readings and displays what adjustments have to be made. Since the data gathered is so precise remedial actions can follow the same tolerances.
The technology is applied to a variety of equipments and components such as coupling, generators, turbines, compressors, gearboxes and propeller shafts. Similarly, it's utilized by a list of industries including construction, gas and oil industries, paper and pulp, pharmaceutical and waste water management sectors.
Not only does laser shaft alignment make quicker work of adjusting components but it does so at a lower cost. Labor costs are reduced, time is shortened and set up is fast. All these translate to a cheaper alignment method. Take a look at how exactly plants stand to benefit when using the technology as part of their alignment management practice.
Factories can significantly lower the risk of wasting money and resources by having systems function seamlessly. Just a single point of improved efficiency can have a noticeable impact on savings. For example, machines as small as 10 hp with a final efficiency (after laser alignment) of 90.5 can save 605 kWh of energy a year. That translates to over $40 in monetary savings a year. For large machines of 200 hp with a final efficiency of 96.0, energy savings can amount to over 10,000 kWh and monetary savings to about or more than $600. In the long-term, the figures amount to much and more.
This cost is not inclusive of the cost of machinery failure, labor time and the drop in productivity that misalignment can produce. Add up everything and it can translate into hundreds or thousands of dollars. With laser shaft alignment all worries can be laid to rest, production can continue unhindered, workers can focus on core duties and plants can save large sums of money.
