Alignment Case Histories Using the Dual-Pass Mode

By: Dan Nower, P.E. Abstract With the introduction of patent-pending, high-speed angle sensors, high-speed processors (CPU) and RF communications integrated into Emerson Process Management-CSI Divisions new UltraSpec Pro Laser Alignment system. These new technologies allow the number of alignment application jobs to be expanded. Because of the new Dual Pass Mode, alignment data was acquired simply by passing each of the two lasers by its corresponding target several times. When each individual laser passes by the vertical axis of the target on the opposite laser head, the processor grabs the information concerning the laser position on the target and the rotational angle. Equipment, Case History #1: Rock Crusher, two components, motor-shaft with sheave Motor speed, maximum, 1170 RPM Fluid coupling to connect motor to drive shaft Tolerances used, Standard (offset & angle) in the 600-1200 RPM range It is obvious from its name what a rock crusher does, but its location is not so clear. This equipment is located underground 700 feet below the surface. It crushes the limestone to a manageable size for the production lift to take it to the surface for processing. Because of its location, the equipment is not easy to maintain. The alignment process has to be as easy as possible.

Motor

Fluid Coupling

Figure 1. Rock Crusher Drive with Fluid Coupling

Alignment Challenges Fluid couplings provide smooth, gradual starts with overload protection and there is no transmission wear since there is no mechanical connection. These advantages come with a cost however. One cost being that this fluid coupling is difficult to align. As you can see in Figure 1 the coupling is a large diameter and several binary blocks were required to shoot the lasers over the coupling. Also, since there is no mechanical connection between the two components, the shafts rotate independent of each other. The application is similar to an uncoupled situation. Alignment Process Because of the new Dual Pass Mode, alignment data was acquired simply by passing each of the two lasers by its corresponding target several times (a minimum of eight is recommended). Once the laser heads are turned on and set to this mode, they begin detecting the presence of the opposite laser beam on its PSD. If a laser beam is not on a PSD, the laser head's LED will be flash yellow. When each individual laser passes by the vertical axis of the target on the opposite laser head, the processor grabs the information concerning the laser position on the target and the rotational angle. The user knows that a good data point has been acquired when the LEDs briefly turn to green. When the beam has moved off the target the data point closest to the vertical axis is stored in the laser head memory. The user can then stop rotating that shaft and slowly turn the other shaft until the laser head on that shaft passes its corresponding target until the LEDs again blink green. A laser synchronizing cable is required to connect the laser heads together if wireless (RF) communication is used. If direct connect communication is used, no additional cables are required. The RF communication eliminates a cable linked to the analyzer adding convenience to the job. Equipment, Case History #2: Ball Mill, three components, only motor-gearbox Motor speed maximum, 900 RPM Semi-rigid coupling to connect motor to gearbox Tolerances used, Standard (offset & angle) in the 600-1200 RPM range The ball mill is located at the surface and is designed to pulverize the processed limestone to a powder. The numerous balls are each the size of a small bowling ball and are located in a rotating drum as shown in Figure 2. The balls roll over the product (and themselves) until it is ground to the proper particle size. Alignment Challenges A large percentage of alignments are performed by rotating both shafts together. This is not always practical, as in this case. To rotate both shafts together, in this case, the balls have to be removed and then replaced after the alignment is complete. The ball removal process can take a long days work for a couple of people. It requires the same amount of time to replace the balls. A total of 64 hours.

An alternative alignment method is non-rotational or stationary alignment. This is where one or both of the components shafts are not rotated during the alignment data acquisition process. By combining the Soft-Mount Alignment Bracket (Model Number 800052) and the Dual Pass Mode the alignment was completed with the balls left in place. The labor cost of removing and replacing the balls was avoided. Also avoided was the safety risk in the handling of these heavy balls.

Drum Motor Gearbox

Figure 2. Ball Mill Machine Train Alignment Process Since the machine was easily uncoupled and we only had a single Soft-Mount Bracket the coupling was uncoupled. This allowed us to use a standard mounting fixture on the motor to rotate the motor shaft. The Soft-Mount Bracket was mounted on the gearbox coupling hub, which was not rotatable. The Soft-Mount Bracket, shown mounted in Figure 3, has multiple bearing and nylon riders in the chain so that it can be slid on the shaft or coupling surface. When rotating the mounting bracket around the coupling, it is best to grasp the fixture at the base of the bracket, not by the laser head. Another word of caution, when mounted to a coupling hub, insure that there is NO runout in the coupling hub. This typically cannot be measured after the hub is installed. Remember, the shaft cannot be rotated in-place to measure the runout. So be proactive, put a tight concentric tolerance on the coupling hub when the bore is being turned in the lathe. This will allow a more accurate alignment. At this point the alignment data acquisition process is the same as Case History #1.

Soft-Mount Bracket

Motor Gearbox

Figure 3. UltraSpec Pro, 20x20mm Setup -Across Stationary Coupling Summary The advent of new alignment technologies of RF communication, high-speed angle sensors, and high-speed CPUs create a useful data acquisition process that opens up new alignment applications. Difficult applications similar to case histories discussed here, can now be done with more ease, save money or applications can now be done that would not have been considered before. It is left up to your imagination.