Pruftechnik Blog

Adaptive Alignment

Instantly share alignment data with your team via the cloud

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Alignment Reliability Center

It’s an age-old problem: the technicians in the field performing shaft alignments are often physically separated from the managers and engineers who need the measurement data being gathered.

That’s why PRUFTECHNIK alignment systems — such as ROTALIGN touch and OPTALIGN touch — provide software to transfer data and measurements to the cloud to share with teams for analysis within minutes.

This cloud transfer capability, exclusive to PRUFTECHNIK, is one way Adaptive Alignment systems unlock team capacity regardless of where team members are located. Technicians can leverage cloud transfer functionality to send measurements to other team members, whether they are in the same plant or on the other side of the world.

Running the PRUFTECHNIK software application on a desktop computer puts advanced collaboration facilities at the fingertips of managers and experienced technicians, allowing engineering decisions to be made by engineers, not mechanics.

In addition to sending measurements, the cloud data transfer feature enables engineers to access a machine’s past alignment history.

How cloud transfer works

After a measurement is taken, teams can verify its accuracy and determine the next steps. Measurement results can be shared instantly with maintenance management by using a WiFi connection, cloud connectivity, and PRUFTECHNIK ARC (Alignment Reliability Center) 4.0 software.

Supervisors or others can make changes on the desktop, and send specific guidance back to a technician at the machine. Instead of waiting to get back to the office, the technician can send the measurement to a senior engineer who can then provide directions, optimizing time for both parties.

PRUFTECHNIK Adaptive Alignment systems enable maintenance teams to take on any alignment task, asset configuration, or situation in the field. With the cloud transfer capability, these systems offer even more versatility by supporting remote team collaboration. It simplifies and speeds the process of guiding technicians in performing precise alignments when they’re physically separated by distance or environmental conditions, such as those brought on by the COVID-19 pandemic.

The cloud transfer capability is another Adaptive Alignment innovation differentiating PRUFTECHNIK laser shaft alignment systems. To learn more, please visit our website and download our Adaptive Alignment white paper.

Watch Adaptive Alignment features come to life through webinar video demos

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It’s commonly known among maintenance teams that misalignment in rotating equipment is caused by excessive loading, vibration, worn couplings, soft foot, and more. But diagnosing and correcting misalignment in machinery often is considered specialized work—reserved for the team’s most experienced millwrights and engineers.

Fast forward to today, with modern Adaptive Alignment laser systems from PRUFTECHNIK, which feature the ability to adapt to any situation, asset, or user skill level.

In the webinar, “Adaptive Alignment: the next generation in laser shaft alignment systems,” Jonathan Gough, Fluke Reliability product manager for PRUFTECHNIK, used a series of video demonstrations to illustrate how laser alignment tools assist the user through a range of difficult alignment situations. This technology makes it possible for even inexperienced technicians to perform alignments and achieve precision results.

Until 1984, machinists used the kind of straight edge and feeler gauges or dial indicators pictured in Figure 1 to align the shafts of rotating equipment, utilizing years of experience and technique to get as close as possible to precision alignment. Then, when PRUFTECHNIK introduced its OPTALIGN® system, the world’s first laser alignment tool, it became clear that even the best manual alignment was less precise than what laser alignment could accomplish.

Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984. Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984.

Figure 1. The PRUFTECHNIK ALI2000 Dial alignment tool circa 1982 versus the PRUFTECHNIK OPTALIGN laser alignment tool introduced in 1984.

In past decades, as illustrated in Figure 2, each type of alignment system required a different level of skill to do the job. Performing a manual alignment with a straight edge took exceptional talent. Using a dial indicator required a more specialized type of skill. But when the laser alignment tool entered the picture, it became feasible for less experienced machinists and more general technicians to perform quality alignments, down to 0.05 mils (0.001 mm).

Figure 2. Degree of precision in alignment results and skill level required to perform the alignment by alignment method.

Figure 2. Degree of precision in alignment results and skill level required to perform the alignment by alignment method.

With today’s advancements in laser shaft alignment systems, including Active Situational Intelligence (ASI), the corrective capabilities more than ever can support users of all skill levels.

According to Gough, Adaptive Alignment occurs when the alignment system adjusts to the situation encountered in real time, as well as to the skill level of the person performing the alignment. Adaptive Alignment systems can adjust to the:

  • Asset itself
  • Alignment situation or challenge
  • Technician and team charged with completing the alignment task

The built-in software known as ASI detects difficulties and compensates for them on the fly during the work. Multiple quality factors such as rotation angle, speed, and evenness are evaluated in real time, allowing the tool to provide instant feedback to the user.

In the videos presented, Gough demonstrated how alignment jobs could be done faster and with higher precision because of the technology’s ability to adapt in real time, eliminate errors, and correct for situational challenges.

To best grasp Gough’s demos, watch the full webinar online. Here are indicative shots, in freeze-frame, of the first video demonstration (there are eight demonstrations in all).

Figure 3a. A coupled machine in continuous sweep mode

Figure 3a. A coupled machine in continuous sweep mode

Gough starts by demonstrating a ROTALIGN touch single-laser, double XY detector alignment system mounted on a coupled machine. The touch screen used then shows the instructions, measurements, and feedback provided as the alignment progresses. Misalignment is identified, instructions are provided to correct the feet, instant feedback given during the realignment and then re-measurement and confirmation occur.

Figure 3b. Coupling play

Figure 3b. Coupling play

In the next example, the user has not initially centered the laser into the middle of the detector area. The ASI software flags the issue before the alignment begins and coaches the user on how to correct the setup. Once that’s fixed, a coupling backlash or “play” occurs, changing the relative position of the laser during the measurement and threatening its accuracy.  In this case, the system notifies the user of coupling play and removes the inaccurate data from the final qualified measurement result.

Figure 3c. User issues

Figure 3c. User issues

If the user doesn’t perform the alignment correctly (opposite directions, rough rotations, and other problems), the system identifies the issues and filters them out. It guides the user on how to correct the problem for next time and compensates for it in the final measurement result.

 

Using single-laser technology and Active Situational Intelligence, Adaptive Alignment acclimates in real time during alignment tasks, supporting the technician and a broad range of critical rotating asset types and alignment challenges.

Get more information about Adaptive Alignment at the PRUFTECHNIK.com website. Also, learn more about the Adaptive Alignment concept and feature set in PRUFTECHNIK systems by downloading the white paper at this webpage.

How adaptive alignment tools adapt to a range of situations and challenges

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Machinery alignment scenarios are rarely the same. Using an easy shaft alignment tool that works for some simple jobs can introduce new errors on more complex projects. This unnecessarily complicates the alignment process, frustrating technicians, and driving up operational costs. Frequently, what maintenance leaders save with a cheaper system they lose in manual efforts and rework.

Enter adaptive alignment, a signature feature of PRUFTECHNIK laser shaft alignment systems.

This combination of software and hardware innovations enables maintenance teams to address any shaft alignment task, from the standard, daily, and straightforward alignment jobs to more complex and challenging tasks – such as aligning Cardan shafts, vertical flanged machines with right-angle gearboxes, or extensive machine trains with gearboxes.

Adaptive alignment systems contain Active Situational Intelligence (ASI), a software innovation with capabilities that enable the solutions to take on from the standard to complex and challenging tasks and complete them faster and with more accuracy than the many more basic solutions on the market.

Here are some of the adaptive alignment enhancements:

Multi-Factor Quality Enhancement

With this feature, the software detects and compensates for many factors that might negatively influence a measurement. It provides technicians with immediate feedback and allows even less experienced technicians to fetch high-quality measurements just by following the steps and tips displayed on the screen.

Uncoupled Shaft Awareness

When installing machines, the alignment should begin with uncoupled shafts to remove any residual forces in the machine train. But basic systems don’t have optimized measurement procedures for uncoupled shafts. Technicians must manually hold shafts to make sure both are at the same relative angle, then manually take the point, then manually move them. This method dramatically increases the risk of errors.

With adaptive alignment, uncoupled shafts can be in any position—the laser only needs to hit the detector. During the measurement, shafts can be freely moving while the adaptive system works out the angles and obtains the measurement. This capability delivers high ROI when teams are installing an asset because you get accurate results and required machine movements in the fastest possible time.

Virtual Move Simulator

Moving the machine is often the costliest part of alignment—and carries with it the risk of additional cost and time if it turns out to be the wrong move. Virtual Move Simulator (VMS) has saved technicians thousands of hours across many industries around the world by enabling them to model different options for a move, see the results, and refine choices before actually doing the physical movement. Read this separate blog post for more on VMS.

Live Move

Single-laser technology delivers rapid completion of alignment tasks while improving precision. Systems outfitted with this technology let technicians see corrections in real-time. They can view updated live results in both vertical and horizontal planes simultaneously across the full range of the sensor detection surfaces. With this capability, you avoid the limitations inherent to non-adaptive, dual-laser systems that have a line-over-length divergence problem.

Adaptive alignment can save time, improve accuracy, and offer numerous other advantages. Learn more about the adaptive alignment concept and feature set in PRUFTECHNIK systems by visiting our website.

Active Situational Intelligence provides real-time measurement guidance

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Active Situational Intelligence

Misaligned machinery is costly for a number of reasons, from increased energy consumption to more frequent repairs and failures to shorter asset life cycles. Precisely aligned machines use up to 10 percent less energy than misaligned ones.

Correct alignment is important not just at commissioning, but as part of regular, ongoing maintenance. Laser alignment is an accurate, efficient way to make sure assets are precisely aligned. To ensure the most effective alignment, you need a tool that pairs the right hardware with the right software. Alignment may seem simple on the surface, but in reality, the process is full of variables.

Adaptive alignment tools are designed to save time and money, enabling maintenance teams to solve alignment challenges from the simple to the complex, and for almost any asset or situation.

Active Situational Intelligence, or ASI, is a Pruftechnik innovation that makes an adaptive alignment tool accessible for users of any skill or experience level. The software provides instant—and specific—feedback to the user as they are performing a continuous sweep and lets them know exactly what they need to do differently to improve the accuracy of a measurement. For instance, a notification will pop up on a tool’s screen to say “rotate slower” or “direction reversed” so the technician can make the necessary corrections in the moment.

In addition to this real-time guidance, ASI automatically detects and filters out errors such as environmental vibration or coupling backlash. In non-adaptive alignment systems, these factors can compromise measurement quality. With ASI, a quality measurement is ensured—even in the most challenging situations. Over time, technicians with the least training and experience can learn how to improve on subsequent measurements and ultimately obtain the same quality of results as more experienced technicians.

By eliminating errors and guesswork, ASI allows maintenance teams to unlock their full potential and capacity—and to do the same for their assets.

Adaptive alignment: How to solve virtually any shaft alignment challenge

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Maintenance leaders are demanding alignment systems that can adapt to their assets, challenges, and teams

From basic alignment jobs to more complex and difficult tasks, maintenance teams regularly face unique alignment challenges. Because machines and their misalignment problems vary greatly, teams today require hardware and software alignment systems that adapt to virtually any situation in the field.

They also need tools that adjust to the experience and skill levels of different team members – especially as veteran employees move on or retire, and newcomers assume their duties.

With adaptive alignment, that’s exactly what they get. Adaptive alignment is a strategic complement of features designed to provide maintenance teams with a complete solution to meet just about any challenge, from an asset, situation, or user skill level.

Alignment systems with adaptive features maximize production time and minimize unplanned downtime, all without sacrificing ease of use.

 

New levels of accuracy and speed

Adaptive features, such as those in the PRUFTECHNIK line of industry-leading alignment systems, eliminate human error while delivering new levels of accuracy and speed. The next-generation laser shaft alignment technology in PRUFTECHNIK tools is made possible by two essential underlying innovations: Single-Laser Technology and Active Situational Intelligence.

Here’s a look at both:

  • Single-Laser Technology. With a single-laser system, users have just one sensor and one laser to set up. Not only is this faster, but it eliminates the many frustrations and risk of inaccuracies that occur when working with two lasers firing in opposite directions. Single-Laser Technology enables rapid completion of alignment tasks and improves precision.
  • Active Situational Intelligence (ASI). This software provides maintenance teams with real-time, actionable intelligence. It’s situationally aware and delivered as work is being done. It dynamically reacts to everything involved in the alignment process and uses predictive intelligence to enable technicians to evaluate different possible courses of action before embarking on the time-consuming task of moving a machine.

By leveraging these two advanced technologies, maintenance teams can deliver on the promise of adaptive alignment in all three critical areas common to every alignment task: the asset, the situation, and the maintenance team.

  • Adapting to the asset. Basic laser alignment systems are not engineered to support the broad range of critical rotating asset types and can be difficult to use with them. This makes for a costly and time-consuming problem for plants that rely on those assets or on certain specialized but common asset configurations. When laser alignment systems support the widest range of assets and configurations—as adaptive alignment systems do—they eliminate manual workarounds and inaccuracy problems common to non-adaptive systems.
  • Adapting to the situation. Perhaps the strongest attribute of adaptive alignment is Active Situational Intelligence software, with its ability to adjust to many different variables – including degree of rotation angle, speed, and evenness — while delivering a smooth, rapid, and accurate alignment experience. That enables technicians of all skill levels to take high-quality measurements just by following the steps and tips displayed on the screen. ASI evaluates many quality factors simultaneously in real time and provides instantaneous feedback. Included among those factors are common issues such as instant coupling backlash filtering and environmental vibration.
  • Adapting to the team. Adaptive alignment has the intelligence to discard many errors a technician may inadvertently make. It utilizes analytics in real time, removing the incorrect data. With basic laser alignment systems, both experienced and inexperienced technicians often obtain different results. Adaptive systems unlock team capacity: even if an inexperienced technician is doing the alignment, the system corrects common errors to enable the technician to obtain the same high-quality results as a more experienced engineer.

 

Shaft alignment is one of the most important factors in asset life, cost of operation, and ultimate value to the business. That’s why maintenance leaders are demanding alignment systems that are more complete and can adapt to their assets, their alignment challenges, and their team capacity. This is the thinking behind the PRUFTECHNIK adaptive alignment systems from Fluke Reliability.

Learn more about the Adaptive Alignment concept and feature set in PRUFTECHNIK systems in this white paper.