Pruftechnik Blog

machinery alignment

Innovators or Imitators?

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ROTALIGNIt looks like we’ve struck a nerve in the laser shaft alignment market with our announcement of Adaptive Alignment systems.

All of a sudden, various forms of the word “adaptable” have been popping up on social media posts about laser alignment systems that do not possess Adaptive Alignment technology.

We at PRUFTECHNIK are glad to see others admit that adaptability is indeed a valuable must-have in laser alignment systems. We welcome them to the conversation.

Of course, it’s easy to use words like “adaptable” in a social media post. The hard part is actually engineering Adaptive Alignment capabilities into a laser alignment system. By that, we mean features that make adaptability happen during an alignment job, – such as single-laser technology and Active Situational Intelligence (see our white paper here).

Breakthrough engineering work is what separates innovators from imitators. PRUFTECHNIK—the undisputed world leader in laser shaft alignment—has continued to revolutionize with patented inventions that are realized in our Adaptive Alignment solutions.

But when many vendors freely use the word “adaptable,” how can maintenance practitioners separate true Adaptive Alignment systems that deliver higher precision with faster job completion from imitators that still operate in a basic way?

By asking, “How.”  How do systems claiming to be adaptable actually deliver Adaptive Alignment benefits?  Here are some specific questions:

  • Does the system include single-laser technology?
    If not, it cannot adapt to situations such as large misalignments. Common workarounds that add time and potentially compromise precision include recommendations to do “rough alignment” or “pre-alignment” before tackling the rest of the job.
  • Does the system deliver real-time feedback during, as opposed to after, the measurement?
    If not, it is not adapting to user needs.
  • Does the system automatically detect and eliminate coupling backlash as measurements are taken?
    Basic systems leave it up to the user to make sure backlash is not influencing the measurement.
  • Does the system include the ability to share measurements over the cloud to support team collaboration?
    If not, the technician is on his own at the machine, and the system is not adapting to teams that need collaborative capabilities
  • Is the system automatically aware of and can handle uncoupled shafts?
    A common installation-time need, Uncoupled Shaft Awareness, eliminates the manual positioning exercises commonly needed with basic alignment systems.

There are other questions that practitioners could and should ask before investing in a laser shaft alignment system. If you want to know what they are, don’t hesitate to contact us.

In the meantime, we at PRUFTECHNIK, a division of Fluke Reliability, welcome the marketplace validation of the value of Adaptive Alignment.

As with any advance that is imitated, sly usage of similar terms can make it difficult for users to separate the innovation from the imitation. We encourage maintenance leaders to learn about the key ingredients of Adaptive Alignment – which they can do here.

In the end, it’s not merely a battle over the meaning of the word “adaptable.” For maintenance teams charged with keeping their machines at peak performance while operating at peak efficiency themselves, Adaptive Alignment is one key to a successful future.

If you’d like to learn more about our Adaptive Alignment systems, we suggest digging into the information on this page or getting in touch with your PRUFTECHNIK sales representative today!

What does it mean for a laser shaft alignment system to be ‘adaptive’?

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Adaptive AlignmentAdaptive, adaptable. What’s the difference?

If you want the ultimate in shaft alignment technology, the difference is huge. It’s the difference between maximizing production time and team efficiency or squandering time and money.  It’s the difference between minimizing downtime or watching the clock tick as the maintenance team tries to apply an “adaptable” solution to a complicated situation.

Above all, it’s the advantage a company gains when it uses alignment systems that minimize human error while delivering new levels of accuracy and speed.

That’s the promise of Adaptive (not adaptable) Alignment. Delivering on this promise means capitalizing on the core innovations of single-laser technology and Active Situational Intelligence. We own patents for these and other fundamental Adaptive Alignment components.

Here’s a quick refresher course on what makes Adaptive Alignment genuinely adaptive.

  • Single-laser technology. A system with just one laser and one sensor speeds set up and eliminates the frustration and risk of inaccuracies that occur when working with two lasers firing in opposite directions. It also enables the faster completion of alignment tasks and results in higher precision.
  • Active Situational Intelligence (ASI). This analytics software equips maintenance teams with real-time, actionable insights. Yes, usable intelligence while the measurements are taking place, not after the fact. ASI dynamically reacts to everything involved in the alignment process. It uses predictive intelligence to enable technicians to evaluate different possible courses of action before embarking on the time-consuming task of moving a machine.

This is what maintenance teams need: innovative Adaptive Alignment products that automatically adapt to the asset, to the specific situation, and also to the needs of the team—all in real time.

The big difference between Adaptive Alignment products and an “adaptable” solution is in who does the adapting. For years, maintenance technicians have had to adapt to the limitations of various other laser alignment systems. These limitations include, for example:

  • Only available in dual laser configurations
  • Can’t provide users with instantaneous visual feedback on measurement quality during the rotation
  • Have no optimization for working with uncoupled shafts during installation
  • Can’t automatically detect and eliminate coupling backlash.

The list goes on. You quickly wonder how applicable the word “adaptable” is to these systems.

PRUFTECHNIK, on the other hand, is the first to deliver true Adaptive Alignment. We chose “adaptive” because it means “serving or able to adapt; showing or contributing to adaptation.” And this clearly describes what we have done: we’ve incorporated the adaptive capabilities into all our alignment products as an inherent feature.

PRUFTECHNIK Adaptive Alignment products have built-in intelligence that adapts to the maintenance team needs automatically and in real time. We created this functionality as a direct response to issues customers historically told us they were having on their machines.

If you’d like to see what a real Adaptive Alignment system can do, get in touch with us for a demo. We’re the only company that can show you one.

Learn more about the powerful Adaptive Alignment concept and feature set are built into PRUFTECHNIK systems at our website, where you can download the Adaptive Alignment white paper or request to speak to a specialist.

The benefits of performing precision alignment at installation

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precision alignment

Measuring for precise alignment when installing a coupling driven asset is a smart and cost-effective way to help assure a longer machine life — right from the beginning of its active use.

Maintenance teams that measure alignment during initial machinery installation often see benefits in machine performance, efficiency, and health.

Using PRUFTECHNIK Adaptive Alignment systems can be especially valuable during machine installation because the results are highly accurate, getting measurements can be quick, and moving the machine may not be necessary.

Here are three alignment problems that can be minimized or resolved by measuring the alignment during installation phase.

1. Soft foot

Soft foot is a commonly used industry term describing distortion of the machine frame and “feet.” It occurs when a rotating machine set on its base, frame, or soleplate is off-kilter because one or more of its “feet” fails to make contact with all of the “foot-plates” on the frame.

It is the root cause of most alignment issues and a critical aspect to check before performing an alignment. Eliminating soft foot saves substantial time and money, especially since an estimated two-thirds of all rotating machinery have soft foot conditions. Addressing it right from the beginning typically makes subsequent alignments much easier.

Additionally, if the soft foot correction is successful, the bearing and motor typically have longer lives because the frame is no longer under tension and because there’s a better vibration signature when the soft foot is eliminated. Correcting soft foot improves seal and bearing life and reduces vibration—all of which contribute to a healthier machine.

Diagnosing and correcting soft foot when installing a machine enables maintenance teams to protect against further occurrences. The soft foot diagnostics tool in Adaptive Alignment systems provide a simple, convenient way to confirm the presence of soft foot and dirive and inform the user which type of soft foot and corrective action required to remove the soft foot.

2. Bolt-bound or base-bound

During initial machine installation, it’s essential to align the motor so there is some clearance in the bolt holes.

The most logical method for preventing a bolt-bound or base-bound condition is to install the stationary and movable machines properly before any piping, ductwork, or other attachments are added.

The absolute best time to use a laser shaft alignment tool to avoid this condition is during the initial installation.

3. Pipe strain

Pipe strain is likewise best addressed when machinery is first put in place. Pipe strain occurs when piping puts stress on the machine due to poor alignment of the pipes before they are bolted up.

The amount of this stress can be measured using the Live Trend feature of Adaptive Alignment laser tools. Measurements can also be performed by watching the pump during live-move or alternatively by taking an alignment measurement but instead of then moving the machine, unbolt the pipes, and taking another set of measurements and then compare the differences between the two sets measurement results.

The objective is to determine how much influence the pipes attached to the pump have on the alignment. It’s much more effective to address pipe strain when machines are being installed because teams can easily locate and correct pipes that are poorly aligned.

Using reports as a baseline for future inspections

Adaptive Alignment systems provide documented PDF reports about the condition of alignment and the presence of soft foot or pipe strain. Optional PC software is available for storing this information, making it easy to keep a running trend of machinery condition. This type of reporting tool is invaluable, especially in new installations, because it provides baseline data to reference when performing subsequent alignments.

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 on this webpage.

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.

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.

How to diagnose and correct soft foot (part 2)

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Eliminating soft foot before attempting machinery alignment will save you time and money

In the first installment of this two-part blog series about soft foot, you learned how to identify the symptoms, effects, and types of soft foot conditions. In this second post, you’ll learn how to diagnose and correct the condition and what types of tools to use.

It’s estimated that two-thirds of all rotating machinery have soft foot conditions. Soft foot is also the root cause of most alignment issues and is considered to be the most critical thing to check before performing an alignment. So why is soft foot one of the most overlooked machinery problems?

Granted, the process of diagnosing and correcting soft foot can be frustrating, and it often takes longer to fix than the actual machine alignment. However, if you can remain calm and think critically, the effort always has a huge payoff which is preventing machine destruction.

Soft foot toolkit (Diagnosing soft foot)

Several ways exist to diagnose and measure soft foot. It’s essential to apply the following methods during every machine alignment and installation to determine if there’s a soft foot condition.

Having the right devices on hand can make detecting soft foot go smoother and faster. Here’s a list of tools to help you measure for soft foot and eliminate any debris found under and around the feet to ensure machine alignment.

  • Image 1 – Feeler gauge
    Image 1 – Feeler gauge

    Feeler gauge: A feeler gauge is used to measure gap widths or the clearance between two parts. The tool has several steel blades with different thicknesses that can measure as little as 1/1000 of an inch or up to a quarter (¼) inch.

 

  • Micrometer or digital caliper: A micrometer can also measure gap thickness. The tool is used to verify shim thickness. A caliper is used to measure shim stacks before inserting them under the feet. This verifies that the shims are the thickness as labelled and not defective.

    Image 2 – Digital caliper
    Image 2 – Digital caliper
  • Wire brush: This clears away the debris or corrosion you may come across while checking machinery feet.
  • Cleaner/degreaser: Use a heavy-duty degreaser in combination with the wire brush to clean existing shims and contact surfaces during the soft foot correction. Brake cleaner works well, but you might also have success with other well-known commercial cleaners.

 

  • Laser shaft alignment system: A laser system can be helpful when measuring for soft foot and is easy to use. This sophisticated tool walks you through the measurement process via a series of screens and includes an auto diagnosis. Although you can use either a dual or single laser shaft alignment system, a dual system can be more challenging to use.

 

Correcting soft foot with shims

Using shims to correct machine foot issues is usually very effective. However, if the frame or mount is bent, twisted, or cracked, or other overall machinery destruction has occurred, correcting the condition can be quite tricky.

In most cases, the machine you’ll be working on will already be shimmed. It’s a good practice to clean any shims that are not new and also clean the base plates and feet to eliminate any dirt and debris. If you do not remove the corrosion, paint, and grime that can accumulate over time, it’s possible to form a new condition, squishy foot, during alignment.

5 rules to avoid squishy foot

Here are some good rules of thumb to follow to better ensure that you don’t create a squishy foot condition while trying to eliminate another soft foot condition.

  1. Use shims big enough to cover at least 80% of the footprint. Shims come in many sizes, and if the machinery requires large shims, they’re usually fabricated on site.
  2. ShimApply no more than four shims under each foot. If you add too many shims, you risk producing a spring-like situation, i.e., squishy foot.
  3. Sandwich thin shims in between thick shims. It makes placement easier and eliminates the potential for shim creasing.
  4. Measure stacks with a micrometer to verify shim thickness. Use it to make sure things add up as they should because errors or defects sometimes happen during manufacturing.
    Shim rules pic
  5. Measure shims over 0.030 to verify thickness. Some sources might recommend lower or higher thicknesses, but ultimately, it’s your decision.

By following these soft foot best practices, including applying the right methods and tools to accurately diagnose and correct the condition, you set yourself up for success. Always remember to check for soft foot before aligning shafts. It will save you time, money, and headaches.

For a more in-depth look at soft foot, watch the Fluke Accelix Best Practice Webinar, “A hard look at soft foot: detecting machine frame distortion before it causes major issues.”