Lab: Shaft Alignment

Georgia Southern University

Department of Mechanical
Engineering

Professor: Dr. Valentin Soloiu

TABLE OF CONTENTS
1) Introduction
2) Key Terms
3) Background
a. Balance
b. Alignment
4) Use of Fixturlaser EVO
a. Objective
b. Safety
c. Introduction
d. Mounting
e. Procedure of Alignment Program
5) Nomenclature
6) References

INTRODUCTION
In practically every machinery, all the necessary steps taken to ensure
quality of the material, the surface finish, and precision in tolerance, can
mean nothing if components are not balanced and aligned within the limits
of the particular application. Unbalanced, rotating parts produce centrifugal
force, creating excessive vibration. Machinery with misaligned shafts creates
rotation outside its collinear axis, causing the rotation to become three
dimensional. Unbalanced and/or misaligned parts lead to premature failure in
bearings, couplings, seals, and the shaft themselves. The objective for this
lab is to instruct how to do a proper shaft alignment in order to prevent all
the consequences that come from a misalignment. Laser alignment
equipment from Vibralign will be used to facilitate this procedure. Laser
alignment has overtaken the industry due to its dependability and faster
nature compared to traditional shaft alignment, which consisted of using dial
gauges and hand calculations.
KEY TERMS
Motor: An electrically driven power unit.
Shaft: A long smooth-surfaced piece of metal with a circular cross
section.
Pump: A device for moving liquid or gas by decreasing or increasing
the pressure on it.
Rotor: A small rotating cap-like unit at the end of the distributor shaft.
Coupling: A connecting device used between two objects so motion of
one will be imparted to the other; it may be mechanical, hydraulic, or
electrical.
Alignment: the practice of aligning two or more shafts with each other
to within a tolerated margin.
Quasi-static: happening so slowly as to appear to be static.

BACKGROUND
Unbalanced parts have an uneven distribution of mass rotating about its
centerline. The uneven distribution of mass may be due to the materials
porosity, voids, and other imperfections. Shaft misalignment can occur due
to poor installation practices, foundation settlement, and loosening of
hardware. When significant component damage is done due to unbalance
and/or misalignment, various costs are involved that may include cost of
parts, labor, and special equipment rental, while production output is zero. A
well balanced and aligned system will maximize efficiency and reduce
energy consumption. To minimize maintenance cost and downtime, condition
monitoring of the machinery should be in place in addition to initial
installation corrections, such as balancing. Predictive maintenance is the
analysis of environment and conditions of the operating machinery. Such
analysis can be done by monitoring vibration, which can indicate bearing
wear and shaft alignment.
BALANCE
An unbalanced rotor is the uneven distribution of its mass. Ideally, a
balanced system has its mass concentration and the center of rotation (COR)
equal to each other as much as possible. As the rotor spins in a machine, a
centrifugal force is exerted. The following equation represents the force:
F=m 2

(1)

Figure 1 displays the centrifugal force due to center of gravity acting outward
from the geometrical center.

Figure 1. Cross sectional view of an unbalanced rotor

The force causes the components to undergo stress as the particles

extend out and away from the COR. An unbalanced system may be due to
the materials non-uniform density structure, finish surface and tolerance
quality, symmetry, and distortion during operation such as thermal growth.
The following figure is an exaggerated image of before and after a turbine
blade undergoing centrifugal force.

Figure 2. Before (solid) and after (dashed) effect of centrifugal

force on a turbine blade
There are three primary types of unbalanced conditions: static, couple,
and dynamic. Static unbalance refers to a condition that is caused by a point
mass at some distance away from the COR. The principal axis of inertia (PAI)
is offset and parallel to the COR. This condition is corrected by adding
weights to counter the unbalance. This situation is ideal for rotating parts,
such as a flywheel, with most of their mass concentrated around one plane.
PAI

COR

Figure 3. Correcting static unbalance where M is the mass of the

wheel, r is the radius, and m is the added mass.
The unbalance (U) can be found using the following relationship:
U=mr

(2)

The specific unbalance (u) is found using Equation (3):

u=

mr
M

(3)

Couple unbalance refers to an equal unbalance that are 180 apart and
at opposite ends of the rotor. To correct the unbalance, vibration
measurements must be taken while the rotor is spinning and masses are
added in two planes.

Figure 4. Correcting couple unbalance at two planes

Dynamic unbalance may be produced by an axial location of the
unbalanced mass on the rotor. It can occur on the rotor or in the case of
quasi-static unbalance, which is a subset of dynamic unbalance, occur on a
component such as a coupling. The PAI and the COR do not coincide.

Figure 5. Correcting dynamic unbalance by adding weights that

are not diametrically opposed and correcting quasi-static unbalance
by adding weight to an unbalanced coupling.
ALIGNMENT
It is typically desired for the shafts to rotate about a collinear axis. The
collinear axis is the COR of two shafts, which is not the same as the COR of
each individual shaft. In most cases, it is impossible for both the shafts to
share the exact same COR. Depending on the application, a certain degree of
misalignment is acceptable or required. There are three types of shaft
misalignment. When the horizontal or vertical distance from the collinear
axis is considered, it is referred to as offset misalignment. When the angle
between the shafts is considered, it is referred to as angular misalignment.
The third type of misalignment, which is most common, is the combination of
the previous two. The following figure represents the different types of
alignment.

Figure 6. Shaft alignment

The process of aligning a shaft either during installation or for correction
requires measuring the position at several locations along the shaft in
reference to the systems COR. Traditionally, the process was time
consuming, as the measurements were taken manually with dial indicators.
Any misalignment was then corrected with hand calculations. Laser
technology has enabled the shaft alignment process to be completed with
higher accuracy and at a faster rate. Typically within a system, the driving
component is considered as the moveable element, and the driven
component is considered as the stationary element. The location of the
reference point must be determined, which is the plane of power
transmission. Generally, this is at the center of the coupling. The moveable
element must be aligned to the stationary element by adding or removing
shims for vertical adjustments, and moving the element side-to-side by
utlizing jackscrews for horizontal adjustments.
BACKLASH
Backlash is the unintended movement that occurs when rotating the
shafts during an alignment process. It can cause errors in measurement and
non-repeatable readings. To control backlash, shaft should be rotated in the
direction of rotation during machine operation. The coupling should be
preloaded before zeroing by keeping the coupling half of the shaft on the
movable machine in the lead. While holding one half of the coupling
stationary, allow gravity to position the other. Ensure that the coupling half
on the shaft of the movable machine stays in the lead and rotate the shafts
180.
USE OF FIXTULASER EVO
OBJECTIVE

Student must write a technical report following the completion of the

experiment. The lab report must include: an introduction of the experiment
(background) along with defining keywords, procedure, and steps taken
during the experiment, tables of any data taken, discussion of results, a
conclusion where results are stated, and an abstract. Be sure to include any
error that might have occurred during the experiment.
SAFETY
Do not disassemble, modify or use the equipment in
other ways than explained in the operating
instructions.
Class 2 is considered safe for its intended use with
only minor precautions required. These are:

Never stare directly into the laser transmitter.

Never shine the laser directly into anyone elses eyes.

INTRODUCTION
Shaft alignment: Determine and adjust the
relative position of two machines that are connected,
such as a motor and a pump, so that the rotational
centers of the shafts are collinear, when the machines
are working in a normal operating condition. Correction
of horizontal shaft alignment is done by moving the
front and the rear pair of one machines feet, vertically and horizontally, until
the shafts are aligned within the given tolerances. A tolerance table is
available in the system. The tolerances are not standardized but are utilized
within Vibralign.
The Fixturlaser EVO system has two measuring units that are placed on
each shaft by using the fixtures supplied with the system. After rotating the
shafts into different measuring positions the system calculates the relative
distance between the two shafts in two planes. The distances between the
two measuring planes, distance to the coupling and distances to the machine
feet are entered into the system. The display box then shows the actual
alignment condition together with the position of the feet. Adjustment of the
machine can be made directly, according to the displayed values.
MOUNTING
The sensor marked M should be mounted on the movable machine
and the sensor marked S on the stationary machine. The block are marked
with an S and M to indicate where the sensors are placed. The sensors shall

be assembled on their V-block fixture, and placed on each side of the

coupling. Hold the V-block fixture upright and mount it on the shafts of the
measurement object (Figure 7).

Figure 7. Positioning of Sensor.

Lift the open end of the chain (Figure 8), tension it so that the slack is
removed and attach it to the hook.

Figure 8. Securing the sensor.

Firmly tighten the chain with the tensioning screw (Figure 9). If necessary,
use the supplied tensioning tool. Do not over tighten. If the shaft diameter is
too large the chains can be extended with extension chains.

Figure 9 Tensioning Screw

Adjust the height of the sensor by sliding it on the posts until a line of sight is
obtained for both lasers (Figure 10). Secure its position by locking both
clamping devices on the back of both units.

Figure 10 Sensor Adjustment and power button

The laser of the M-sensor can be adjusted with the adjustment screw on the
top of the unit. There is normally no need to adjust the laser, but this might
be necessary when measuring at long distances.

PROCEDURE OF ALIGNMENT PROGRAM

1) Turn on the monitor and wait for the program to boot up. Also turn on
the sensors.
2) Start the alignment program by touching the Horizontal
Shaft Alignment icon in the Main Menu. The Tripoint
method will be used for a parameter setting of 900 rpm.

Tripoint method
In the Tripoint method, the alignment condition can be calculated by taking
three points while rotating the shaft at least 60. In this method all points are
taken manually.

Figure 11 Shaft Alignment Kit

Enter dimensions

Figure 12 Touch button to start logging measurements.

3) The screen displays the movable machine. The traffic lights show
green when the laser hits the detector. Select dimension boxes to enter
dimensions (Figure 12).
4) Measure and enter dimensions using the tape measure provided
(Figure 13).

Figure 13 Measuring distance between sensors

5) You must enter the distance between the sensors, and the distance
between the center of the coupling and the M-sensor. (If you only wish
to check shaft alignment, these are the only necessary distances).

Figure 14 Measuring distance for the motor feet

6) The distance between the M-sensor and the first pair of feet and the
distance between the first and the second pairs of feet can be entered
now or later (these distances are necessary to provide the feet values).
(Figure 14)
Measurement point registration

Figure 15 Touch icon for first reading

7) Set the sensors at approximately the same rotational angle at the first
measurement position. Touch the register icon. This registers the first
reading.

Figure 16 Rotate shaft towards green area

8) Rotate the shafts to the next position (Figure 16). Use the side wheels
to help with the rotation of the shaft. The shafts must be rotated over a
minimum of 45. Green sector show permitted positions. Red sector
show forbidden positions. The Register icon is not shown if the rotation
is less than 45.

Figure 17 Touch icon for second reading

9) Touch the register icon. This registers the second reading. Rotate the
shafts to the third position.

Figure 18 Move shaft to last position in green area

10)
Touch the register icon. This registers the third reading. While
registering the third reading at the 3 oclock position, the sensors will
be ready for horizontal alignment.

Measurement results

Figure 19 Corrections that need to be done for alignment

The Measurement Result screen shows coupling values and foot values in
both the vertical and horizontal direction. The symbol to the left of the

coupling values indicates the angular direction and offset, and also if the
values are within tolerance.

Within tolerance (green).

Within double tolerance (yellow and inverted).

Out of double tolerance (red and inverted).

When a coupling is in tolerance in one direction, this is indicated by

the check symbol at the motor.

The machine picture itself also indicates the coupling alignment.

Evaluating the result
The angle and offset values are used to determine the alignment quality.
These values are compared with the alignment tolerances to determine
whether correction is necessary. If suitable tolerances are selected in the
tolerance table, the symbols described above indicate if the angle and offset
values are within tolerance or not. The foot values indicate the
movable machines foot positions where corrections can be
made.
11)
Go to Shimming by touching the shim icon and the
program will show the option of how many shims have to be allocated
to balance the shaft. The shims are to be inserted where the threads of
the knobs are located on the attached plate (Figure 21). Shims are
already found below the plates to provide an easier access to the
inserting the additional shims required below. It is not recommended to
remove the existing placed shims. Use the shims in an orderly manner.
Loosen the knobs before inserting shims and be sure place thinner
shims between thicker shims for easier placement.

Figure 20 Program showing the shim length to be added in inches

Figure 21 Presentation and positioning of shims

Alignment
12)
If the machine has been adjusted vertically in the shimming
screen, go directly to alignment in the horizontal direction. If the
machine has not been adjusted in the shimming screen, alignment in
the vertical direction has to be done first. (It is safe to skip the
shimming screen as if a mistake is made, corrections can be made by
observing the live alignment which will provide feedback such as if
backlash is taking place.)

Figure 22 Live vertical alignment (side-view)

13)
Rotate the shafts to the 12 or 6 oclock position to make
adjustments in the vertical direction. The angle guide helps you to
reach the right position. Adjust the machine vertically until the values
for both angular and parallel alignment are within tolerance (Figure
22). The arrows at the feet show in which direction the machine shall
be moved.

Figure 23 Live Horizontal alignment (top-view)

14)
Rotate the shafts to the 3 or 9 oclock position to make
adjustments in the horizontal direction. The angle guide helps you to
reach the right position. Adjust the machine horizontally until the
values for both angular and parallel alignment are within tolerance
(Figure 23). The arrows at the feet show in which direction the machine
shall be moved. Be careful with manipulating the shaft because any
sudden movements will cause angular misalignment and more
corrections will have to be carried out.

Figure 24 Shaft Aligned (within tolerance)

If not given enough tension, the shaft will not hold the sensor at the 3 oclock
position so be sure to hold the shaft at the coupling to prevent the sensor
from hitting the table.

Figure 25 Holding the shaft to prevent backlash and sensors moving

down

15)
Rotate the shafts back to the 12 oclock position and check that
the machine is still within tolerance. Alignment is now completed. To
confirm the
result, re-do the measurement.
16)
Remeasure.

NOMENCLATURE
COR Center of Rotation
PAI

Principal Axis of Inertia

CG

Center of Gravity

Motor

Stationary

REFERENCES
[1]

Fixturlaser EVO Manual

http://www.fixturlaser.com/Documents/Manuals/Fixturlaser%20EVO/P0252-GB%20Fixturlaser%20EVO%20Manual,%201st%20ed.pdf
(accessed June 25, 2015).

[2]

Don't let shafts be an afterthought

http://machinedesign.com/mechanical-drives/dont-let-shafts-beafterthought (accessed March 25, 2015).

[3]
A Practical Guide to Shaft Alignment (2002) Edition: 4; 4-03.007.
Pruftechnik LTD.
[4]

IRD Balancing, Balance Quality Requirements of Rigid Rotors.

http://www.irdbalancing.com/downloads/techpaper1balqualityreqmts.p
df (accessed July 29, 2014).

[5]

RCDON, GRV-1 Turbotug Project 1/1/05.

http://www.rcdon.com/html/grv-1_turbotug_project_1_1_05.html
(accessed July 25, 2014).

[6]

Engineering Dynamics Incorporated, Balance This!.

http://www.engdyn.com/images/uploads/93-balance_this!__peg&tdf.pdf (accessed July 20, 2014).