登录查看更多内容

What are the most effective ways to identify and correct mechanical misalignments?

由人工智能和领英社区提供技术支持

Mechanical misalignments are common causes of equipment failure, reduced performance, and increased wear and tear. They can affect various components of electromechanical systems, such as shafts, couplings, bearings, pulleys, belts, gears, and motors. To prevent costly breakdowns and downtime, it is essential to identify and correct mechanical misalignments as soon as possible. In this article, you will learn some of the most effective ways to do so, using both visual and measurement methods.

此文章中的业界达人

由社区从 3 条内容中精选。了解更多

1 Visual inspection

One of the simplest and fastest ways to identify mechanical misalignments is to perform a visual inspection of the equipment. You can look for signs of abnormal wear, damage, noise, vibration, heat, or leakage in the components. For example, if you notice that the belts are cracked, frayed, or slipping, or that the pulleys are worn or loose, you may have a misalignment issue. Similarly, if you see that the shafts are bent, twisted, or cracked, or that the couplings are distorted, corroded, or leaking, you should check for alignment problems. Visual inspection can help you spot obvious misalignments, but it may not be enough to detect subtle ones.

添加您的观点

Calvin (Sam) Johnson

Factory automation engineering services.
举报内容
In the instances of belt drives and chain drives it is often easy to see misalignment due to excess wear surfaces, glazing, powdered debris from belt material loss, surface gouging, uneven deformation of the belts, etc... Noise can be a factor. A properly aligned drive will be quiet (within reason), not overly noisy. Chains will sometimes create popping sounds.

已翻译

赞

2 Straightedge method

Another way to identify mechanical misalignments is to use a straightedge tool, such as a ruler, a level, or a steel bar. You can place the straightedge across the faces of the components, such as the coupling hubs or the pulley rims, and check for any gaps or deviations. The straightedge method can help you measure the angular and parallel misalignments between the components, but it has some limitations. It may not be accurate enough for high-speed or precision equipment, and it may not work well for flexible or flanged couplings.

添加您的观点

JD Glenn

Certified Control Systems Technician Master
举报内容
This is a little bit deceptive, when it comes to pulleys. The straight edge method does not work on all pulleys (v belts, flat "gear belts", ect.). There may be instances where a flat belt pulley will have a face on one side and not on the other. There may be instances where one pulley is not faced, or is corroded, or angled... The point is, not all pulleys have a completely flat face. In instances like this, it is preferable to lay a string, or piano wire, across the belt surface area. Using this method give a much better visual guide to how true your belts will be, as you will be able to use the inside edges of the pulley for a reference to where the belt will run.

已翻译

赞

3 Dial indicator method

A more accurate and reliable way to identify mechanical misalignments is to use a dial indicator, which is a device that measures the displacement of a probe. You can attach the dial indicator to one component, such as the shaft or the coupling hub, and rotate it around the other component, such as the motor or the driven machine. The dial indicator will show you how much the components move relative to each other, in both radial and axial directions. The dial indicator method can help you measure the angular and parallel misalignments between the components, as well as the runout and endplay. It can also work for different types of couplings, such as rigid, flexible, or flanged.

添加您的观点

4 Laser alignment method

The most advanced and precise way to identify mechanical misalignments is to use a laser alignment system, which consists of a laser emitter and a receiver. You can mount the laser emitter on one component, such as the motor shaft, and the receiver on the other component, such as the driven machine shaft. The laser emitter will project a beam of light that will hit the receiver, which will measure the deviation from the center. The laser alignment system will display the results on a screen or a computer, showing you the angular and parallel misalignments between the components. The laser alignment method can also compensate for thermal expansion, shaft sag, and soft foot. It can work for any type of coupling, and it can save you time and money by reducing the number of trial-and-error adjustments.

添加您的观点

5 Correction methods

Once you have identified the mechanical misalignments, you need to correct them by adjusting the position of the components. Depending on the type and degree of misalignment, you may need to use different methods, such as shims, jacks, bolts, or keys. You may also need to use the same measurement methods that you used to identify the misalignments, such as the straightedge, the dial indicator, or the laser alignment system, to verify that the corrections are effective. You should always follow the manufacturer's instructions and specifications when correcting mechanical misalignments, and use the appropriate tools and safety precautions.

添加您的观点

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

添加您的观点

SAJAL KUMAR DAS GUPTA

Retired from ACC Ltd as Joint manager (Mechanical) after serving the company for 39 yrs
举报内容
Laser alignment techniques may not be necessary to use in all cases,depending upon the type of machine ,rpm,use and the accuracy it needs a simpler method can be used using straight edge, dial indicators, thread,level Guage, feeler Guage may be considered Before starting the couplings alignment work, one must ensure that bearings are not having excess clearance, bearing outer race is not loose in the housing, shafts are not bent,there is no soft foot at the base of both connected machines, both machines are perfectly in level, no loose foundation bolts. While aligning a pair of coupling, match marking couplings in particular position where coupling bolts will fit and rotating both together while aligning gives better results

已翻译

赞

Mechanics

+ 关注

给文章评分

我们借助人工智能创建了此文章。您认为这篇文章怎么样？

很棒不太好

举报此文章

查看全部

What are the most effective ways to identify and correct mechanical misalignments?

1

2

3

4

5

6

1 Visual inspection

2 Straightedge method

3 Dial indicator method

4 Laser alignment method

5 Correction methods

6 Here’s what else to consider

Mechanics

给文章评分

感谢您的反馈

更多Mechanics相关文章

更多相关阅读内容

What are the most effective ways to identify and correct mechanical misalignments?

1

2

3

4

5

6

1 Visual inspection

2 Straightedge method

3 Dial indicator method

4 Laser alignment method

5 Correction methods

6 Here’s what else to consider

Mechanics

给文章评分

感谢您的反馈

查看其他技能