International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 05 | May -2017
p-ISSN: 2395-0072
www.irjet.net
A Laser Shaft Alignment by IPS- PSD’s for Rotary machine Sitaram Garg1, Sanjeev Kumar2, Rahul Deshpande3, A.K. Sharma4 1Machine
Design, Department of Mechanical Engineering, C.B.S. Group of Institutions Jhajjar Haryana India Professor, Department of Mechanical Engineering, C.B.S. Group of Institutions Jhajjar Haryana India 3 Manager, Department of Reliability and Condition Monitoring, SKF India Ltd Pune Maharashtra India 4 A.K. Sharma, Assistant Professor, Department of Mechanical Engineering MITS College of Engg. Gwalior M.P. India ---------------------------------------------------------------------***--------------------------------------------------------------------2Assistant
Abstract
vibration when running because of shaft misalignment and the vibration affects the using life of machine and damages the parts. As we know almost 50% of the rotating machinery fault is caused by the shaft misalignment. So shaft alignment is an important process in power machinery assembly. The degree to which two machines are misaligned can be determined by examine the amount of offset and angularity that exists between them. Offset is the distance between the two rotational centerlines, and angularity is the angle between the centerline created by the misalignment of the two centerlines. The design and develop of a laser shaft alignment instrument based on the two dimensional PSD (Mu Li* Wang Xinwei, 2012). The traditional precise shaft alignment method is dial indicator alignment (Piotrowski, 1995), and the two most popular methods are the rim and face method and the reverse indicator method. With the traditional technique, the measurement results must be graphed out manually and the calculations must yield the corrections required. With the laser alignment system all these are done automatically. Real time management values are displayed as the machine moves. The laser alignment system cuts the measurement time at each coupling by 50% compared to the previous method of taking 16–point rim and face dial readings (Perry, 1998). The improved accuracy of the laser also minimized the number of subsequent bearing alignment corrections required. The laser alignment system has been adopted for more and more precise shaft alignments, such as rotor system (Brommundt and Kramer, 2005), vibration (Lee, 2004), cooling tower fans (Luedeking, 2003), gas turbine (Luedeking, 2005), Link coupling (Pan etal., 1998), turbine driven feed water pump (Patry, 2001), etc. The single PSD laser alignment system designed by us has been applied in actual shaft alignment (Jiao et al., 2006). Dual PSDs method is based on the single PSD laser alignment, and has evidently improved the system measurement accuracy through some modification in the light road, circuits, and software. The advanced Laser technology is the key technology in measuring and adjusting shaft misalignment. The alignment purpose can be realize by adjusting shaft position according to the calculate result.
Laser-optical alignment of shafts in rotating machinery is simple and more accurate than conventional mechanical methods and can result in reduced power consumption and increased mean time between failures. For a typical steel plant running 500 small to medium-to-medium-sized rotating machines consuming15 MW of power, total savings can amount to dollar 0.5 million / year as a result of a supported laser shaft alignment methods. Shaft alignment is an important technique during installation and maintenance of a rotating machine. A high precision laser alignment system has been designed with PSDs (Position Sensing Detector) and IPS (Inductive Proximity Sensor) to change tradition manual way of shaft alignment and to make the measurement easier and more accurate. The system is comprised of two small measuring unit (Laser transmitter and detector) and PDA (Personal digital assistant) with measurement software. The laser alignment system with PSD has been successful for designing and implements actual shaft alignment. SKF offers precise laser shaft alignment tools TKSA 11 and TKSA 20 for proper alignment of shafts and reduced troubleshooting issues. It can measure errors and display resolution less than 2% / 10 µm (0.4 mils). Key words: Rotating machine, Shaft alignment, Laser alignment, Position sensing detector (PSD), Laser micro displacement measurement, Transmitter and Detector, Alignment Software SKF TKSA 11, Display unit SKF TKSA 20
INTRODUCTION Laser shaft alignment is a way of measuring misalignment between two or more shafts. Laser alignment will provide this long term benefit. Improved machine reliability and productivity, reduced machine repair costs, reduced labor costs, reduced power consumption of machinery, minimization of machine installation and repair time, allow verification of machine performance throughout the machine life. Perfect alignment of machinery shafts is crucial to prevent premature bearing failures, Shaft fatigue, Sealing problems and vibrations. It further reduces the risk of over-heating and excessive energy consumption, reduced unwanted breakdowns and improves down -time. Precise alignment occurs when the centerlines of rotation of two shaft essentially collinear with each other. Machine joined by coupling would generate
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MAIN METHODS AND TECHNIQUES Laser alignment system: The measurement principle of laser alignment is based on the dual indicator method. Alignment while dial indicator is an
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