The precise alignment of shafts is essential for the smooth operation and longevity of rotating machines in industry. The choice of alignment tool has a decisive influence on efficiency and maintenance costs. In this context, laser alignment has established itself as the preferred method, as the use of adaptive laser alignment systems, in contrast to conventional tools, enables a time and cost-efficient approach as well as optimized overall machine performance. Laser alignment systems adapt flexibly to a wide variety of systems, situations and user knowledge levels and measure shaft alignment efficiently and with high quality.
Shaft alignment Definition
Shaft alignment on standard machines refers to the process of precisely adjusting two or more machine shafts to ensure that they are correctly aligned with each other and that there is no misalignment. Accurate shaft alignment ensures optimal machine performance, efficiency and service life and reduces machine-related downtime. Shaft alignment methods are:
- Shaft alignment with shims
- Theodolite method
- Laser alignment
- Dial indicators for shaft alignment
- 3-point method
What is laser optical wave alignment?
Laser-optical shaft alignment is an important part of machine diagnostics for the precise alignment of rotating shafts, alongside pump vibration measurement or ultrasonic flow monitoring. Compared to conventional shaft alignment methods, this advanced technology provides an efficient and accurate way to measure the rotational axes of machine components; laser optical measuring devices are used to identify and correct parallel and angular misalignments.
Laser-optical shaft alignment machines achieve a high level of accuracy and flexibility, which saves users time and money. In addition, shaft alignment increases the service life of the machines and reduces their energy consumption. This advanced method has proven to be an efficient solution to minimize wear on couplings, bearings, seals and other machine parts, thus improving the overall performance and reliability of the machines.
Reliable machine performance with laser-optical shaft alignment
Approximately half of all malfunctions of rotating machines can be traced back to misaligned shafts. These misalignment irregularities often result in unplanned downtime and lead to significant production losses and rising maintenance costs. In addition, misaligned shafts increase vibrations and can lead to premature wear of bearings and seals – which in turn drives up energy consumption. Modern laser-optical systems for shaft alignment overcome these challenges and ensure precise measurement results for horizontal flange-mounted machines as well as vertically offset machines and those with cardan drives.
Compared to other measuring systems, laser optical alignment systems enable fast and precise alignment in millimetres within a very short time and are much more reliable than dial gauges, for example, which often only achieve inadequate results. All relevant data is precisely recorded and processed.
Why laser optical wave alignment is crucial
Misalignment of machine shafts can have significant negative effects. Even minor deviations from exact alignment can lead to increased stress on bearings, seals and other machine parts, which in turn shortens the service life of these components. Accurate shaft alignment therefore not only minimizes wear on these critical components, but also has a direct impact on operating costs. The risk of unplanned downtime is also significantly reduced, which improves the overall service life of the machines and minimizes maintenance costs.
Once the shafts are correctly aligned, this offers many advantages such as
- Guaranteed availability of the machines
- Less need to replace bearings and seals
- Reduced consumption of lubricants and energy
- Less friction and vibrations
- less machine damage.
Another plus: thanks to the fast and precise alignment, laser-optical systems generally pay for themselves after six months at the latest.
Advantages of laser-optical shaft alignment with Shaftalign Touch and Co.
Laser alignment, for example with the Fluke laser alignment measuring device, is undoubtedly one of the most efficient methods for adjusting machine shafts with pinpoint accuracy. The use of adaptive laser alignment systems, such as the Shaftalign Touch alignment system, allows highly precise alignment with remarkable advantages:
- Reduced repair costs: Adaptive laser alignment enables precise adjustment of machine components, which minimizes normal wear. This leads to a significant reduction in repair costs over the entire service life of the machine.
- Less stress on machine parts: Precise alignment reduces loads on critical parts such as roller bearings. This extends the service life and contributes to the overall robustness of the machine.
- Lower energy costs: Precisely aligned machines work more efficiently and require less energy, which is particularly advantageous in times of rising energy prices.
- Less downtime: By avoiding misalignment and optimizing machine performance, unplanned downtime is minimized and all production processes are maintained.
- Low noise level: Precisely aligned machines generate less vibration and noise, which generally contributes to a more pleasant working environment.
Safety in every zone: Laser-optical shaft alignment in EX zones
Even in industrial environments where explosive atmospheres pose a potential danger – so-called EX zones – laser-optical wave alignment guarantees the best results. However, laser-optical shaft alignment devices in EX zones require special certification to ensure that all instruments meet the strict safety standards in potentially explosive atmospheres. In this way, shaft alignment precision is guaranteed even in risky environments without compromising on safety.
Serafima – Your expert for laser-optical shaft alignment
When rotating machines get out of sync, the Serafima team comes into play: We are problem solvers and your partner in need. As a team with years of experience in all aspects of fluidic systems, we are at your side anytime and anywhere to get your systems back on track. Our comprehensive services in the field of ultra-modern laser-optical shaft alignment go far beyond smooth routine inspection and preventive maintenance and guarantee rapid troubleshooting. We rely on the unrivaled expertise of our technicians to assist you with all matters relating to your machines with coupled and uncoupled shafts and cardan shafts.
Our service includes:
- Alignment of cardan and intermediate shafts
- Technical diagnosis and recording of the machine status
- Commissioning of rotating machines through precise laser alignment
- Monitoring of machines, for example using thermography or infrared radiation
- Process optimization of pumps during operation
- Measurement of clutch misalignment, clutch gap and misalignment of the machine
- Evaluation of the recorded data
- Advising the customer and jointly defining the measures
Benefit from our customer-oriented field service, which is tailored to your individual needs. At Serafima, you get everything from a single source – independent of time and manufacturer. Whether shaft alignment, ultrasonic flow measurement, the provision of ultra-modern and precise shaft alignment devices, vibration analysis or more, our service managers will take care of your concerns at all times so that you can concentrate on the essential aspects of your value chain.
Make your appointment now and put your trust in Serafima – your reliable partner for laser shaft alignment.