Shaft Alignment Tools

The Importance of Precision Shaft Alignment Tools

Ever since the first time one rotating shaft was connected to another, machine operators have appreciated the need for a shaft alignment tool. Experts estimate that excessive vibration from misaligned shafts is the root cause of half of all premature machine failures. The type of failure can vary from coupling, bearing and seal failures to cracked or broken shafts.

Accurate alignment always depends on valid measurement data. Getting it is the challenge. The two most influential factors on measurement are the hardware setup and the shaft alignment tool or method used. While applications of rotating shafts run the gamut, the choices of how to align fall in these broad areas.

1. Squint and measure, or rough alignment by the human eye
   
   Alignment by straight edge was most likely the first method developed after use of the naked eye. Using a straight edge, such as a four-foot aluminum I-beam for example, is a line-of-sight method of rough alignment. The feeler gauge method involves inserting a gauge between the two coupling faces, measuring, rotating the couplings simultaneously half-way, and measuring again. Any deviation (i.e. misalignment) is corrected by lifting the machinery or shimming its platform. Both of these methods of rough alignment may be adequate where hardware has looser tolerances but they fail to meet the standard for precision alignment.
    
2. Alignment by dial gauge (and very expert user)
   
   Aligning by dial gauge can be precise in the hands of a skilled user who can do the calculations. Two methods, rim-and-face and reverse rim, are the most common. For the most accurate result, the user gets two consecutive sets of data and checks to see if they repeat, making sure each set of data is correct mathematically.

As mechanical devices, dial gauges can be problematic. The following could occur:

Human error - Reading dials in cramped, poorly lit conditions or in a rush or both can cause mistaken readings.
Poor resolution - A rounding error of up to 0.005mm can occur in any reading.
Inconsistent dial hands - If the hands stick or jump, the indicator needle may settle on an incorrect value.
Internal mechanics - Play in gear linkages might go unnoticed yet produce erroneous results.
Not at 90-degrees - If the gauge is tilted even slightly from a right angle, the measurement is off.
Shaft endplay - Axial movement can affect face readings for angularity.

For these reasons, finding an easier-to-use, more accurate shaft alignment tool can be very beneficial.

Shaft Laser Alignment Tools - easiest, fastest, most accurate

Today's state-of-the-art shaft laser alignment system uses low-power laser beam transmitters and receivers to align industrial machinery with a level of precision previously impossible: to within thousandths of an inch. Housed in a compact handheld unit and married with sophisticated software, a top shaft laser alignment tool can align any application of rotating shafts - and will repay its investment many times over in the wear and tear and damage to machinery that it can prevent.

All shaft laser alignment tools are not made equal, however. Some are extremely complex to learn and use. Others, such as those from Swedish manufacturer Fixturlaser, have been designed from the start for ease of learning and use with displays that use recognizable icons and graphic animation to guide through alignment step by step. As a consequence, Fixturlaser alignment system can perform most alignments in about a quarter of the time of conventional methods - and with virtually guaranteed accuracy. All shaft laser alignment tools are not made equal, however. Some are extremely complex to learn and use. Others, such as those from Swedish manufacturer Fixturlaser, have been designed from the start for ease of learning and use with displays that use recognizable icons and graphic animation to guide through alignment step by step. As a consequence, Fixturlaser alignment system can perform most alignments in about a quarter of the time of conventional methods - and with virtually guaranteed accuracy.

Fixturlaser's two bestselling systems have every reason to be.

The Fixturlaser GO system makes precision vertical and horizontal motor alignment a quick and easy process - and with high-end sophistication at a more affordable price.

The Fixturlaser XA system is the leading high-end laser alignment system for precision alignment of motors in horizontal and vertical shaft applications, with softfoot measurement included. Upgrade kits expand Fixturlaser XA capabilities to alignment measurements of cold and hot conditions machines, offset-mounted machines, and machine train configurations.

Laser alignment services from VibrAlign

As the North American distributor for the USA for Fixturlaser systems, VibrAlign offers on-site alignment services for such industries as:

• Chemicals
• Food processing
• Foundries
• General industry
• Manufacturing
• Mining and Aggregates
• Oil and Gas Refineries
• Pharmaceuticals

Engineers and technicians who are experts in laser alignment deliver VibrAlign alignment services. Service includes measurement and correction of misalignment in motors and driven units and includes complete documentation for quality assurance and compliance.

For more information on VibrAlign's shaft laser alignment tools