Laser Shaft Alignment
On-Site Laser Shaft and Belt Alignment
Did you know over 50% of rotating equipment failures are directly related to misalignment and unbalance? Misaligned or unbalanced equipment are subjected to higher vibration levels significantly reducing the service life of bearings, seals, shafts and couplings.
Electromechanex can help reduce overall operating costs and increase equipment efficiency,
reliability and productivity with our Expert Laser Alignment Service and Precision Balancing
Our Field Service personnel are
OSHA/MSHA trained for safe work practices. Call us for a free consult.
At some time during a motor’s life, it is likely to experience high vibration levels. What’s behind this maintenance phenomenon? The cause may be an electromagnetic or mechanical imbalance, loose components, rubbing parts, bearing failure, resonance, or shaft to shaft misalignment.
Misaligned equipment is subjected to higher vibration levels significantly reducing the service life of bearings, seals, shafts and couplings.
When a problem occurs, it is critical to quickly
identify the source and take corrective action. Using EMX’ vibration-analysis latest diagnostic techniques can save you money and downtime. EMX’ vibration-analysis systems is a portable, route-based instrument used for collecting vibration data on rotating machinery. It reduces collection time, analysis, and reporting time, when compared with similar devices. This allows EMX to determine the severity of the stress level of bearing or gear wear on your motor.
The data is recorded from each machine and uploaded on the software, providing quick recognition of change in the vibration pattern, as an indicator of deterioration. Corrective actions of any kind of machine misalignment are then taken.
Shaft Misalignment
Misalignment is among the leading causes of machine failure!
Misalignment occurs when the center lines of two shafts are not co-linear. Misalignment destroys bearings, seals, couplings, rotors, stators, shafts, etc. Misalignment of the driving and driven shaft(s) in a machine train adds stress forces to the shafts, which are transferred to the bearings, seals, etc. These forces work against all of these components to reduce the productive life of the machine.
Misalignment will also create high levels of vibration and friction. This can result in excess heat that can reduce the effectiveness of the lubricant. Excess vibration will result in shorter machine life and, in some cases, poor product quality resulting in scrap and waste. Misalignment can be diagnosed using vibration analysis tools. There are distinct patterns that reveal the presence of misalignment.
Angular misalignment is characterized by high axial vibration caused by the push/pull movement of the misaligned shafts. Offset misalignment is characterized by high radial vibration. Misalignment typically appears in the spectrum at 1 times and 2 times running speed. There are many programs that still insist that a straight edge is sufficient for aligning two machines at the coupling. This may be acceptable for a rough alignment, but it is no replacement for a precision alignment tool. Dial indicators can be a precise way to align shafts, but requires complex methods and extensive math. EMX uses Laser alignment tools which are a faster alternative to dial indicators. Laser tools take the guesswork out of the alignment process by displaying the offset and angle of the shafts and calculating the necessary moves to correct the problem.
Pulley & Belt Alignment
2X Cross-Firing Laser Line
Pulley and Belt Alignment
The precise alignment of the belt, specifically the alignment of its pulleys, is an essential factor for the efficient operation and longevity of a machine’s belt drive systems. Machines are often left in misaligned or unknown conditions and their underlying problems remain undetected and uncorrected.
When the pulleys are not correctly aligned, additional loads are induced, directly affecting the tension of the belt and other components of the system, preventing the machine from performing optimally.
Electromechanex will correct common issues found with belts and prevent them to help improve the up-time and reliability of your belt drive applications.
A-Consequences of Belt Misalignment
- Uneven belt wear: misalignment can cause the belt to wear unevenly or to develop cracks, leading to premature failure
- Belt slippage: misalignment can cause the belt to slip off its pulley, resulting in reduced power transfer and system inefficiency
- Reduced system efficiency: a gradual reduction in belt performance by increased wear and fatigue, resulting in increased energy consumption
B-Benefits of Pulley and Belt Alignment
- Increased service life: of belts, pulleys and bearings
- Improved efficiency: properly aligned belts operate more efficiently, reducing energy consumption and improving overall system performance. The result is increased machine efficiency and a reduction in overall friction losses
- Reduced Maintenance Costs
- Increased machine availability
- Reduced noise level
- Safer working environment
By utilizing the B.A.T. Belt Alignment Tool System® cross-firing XF green laser belt alignment configuration, precision adjustments made to the offset and angularity of the entire sheave face. Both sheaves are checked at the same time for offset, twist and angularity. The double laser alignment design system records accurate measurements.
Solutions for Precise Alignments
V-Belts
Timing Belts
Flat Belts
Drive Chains
Motor Base Level
Conveyor Belt Tracking
Documentation & Certification
Good documentation is important in alignment. It is a record of who performed the alignment, when it was done and how well it was done. All work is electronically documented and a shaft alignment report with alignment data as well as original and final results, is generated upon completion of the job. The commitment for alignment is to do it every time a machine is installed and make it a regular preventative maintenance step when machines are inspected. A quick alignment measurement can save a lot of headaches down the road.
Precision Laser Alignment initially establishes the alignment conditions of newly installed components of new projects. This gives the original misalignment readings.
Precision Laser Alignment procedures are then used to make precise installation adjustments on the new equipment mentioned above. In some instances, precision alignment is not achievable. If this is the case, notice is given to the end user. Additional millwright work may be required.
After the adjustments are completed on the new equipment, final recorded results will be provided. This includes horizontal and vertical cad style drawings.
Vibration Analysis is then used to establish baselines for the vertical, horizontal and axial in a detailed report. These readings confirm the Laser Alignment Precision Installation of the new equipment and overall expected increased reliability of the equipment. This process assures the client an unbiased opinion of conditions and that any necessary adjustments have been made.
These three steps lead to Certified Precision Installations using industry standards for new equipment.
Vibration-Analysis
At some time during a motor’s life, it is likely to experience high vibration levels. What’s behind this maintenance phenomenon? The cause may be an electromagnetic or mechanical imbalance, loose components, rubbing parts, bearing failure, or resonance.
When a problem occurs, it is critical to quickly identify the source and take corrective action. Using EMX’ latest Vibration Analysis diagnostic techniques can save you money and downtime. EMX’ uses VibePro 7.3.5 which is a portable device, route-based instrument used for collecting vibration data on rotating machinery. It reduces collection, analysis and reporting time, compared
with similar devices. This allows EMX to determine the severity of the stress level of bearing or gear wear on your motor. The data is recorded from each machine and uploaded on the software, providing quick recognition of change in the vibration pattern, as an indicator of deterioration. Corrective actions are then taken.
