Benefits from shaft alignment - vibrotech.co.uk · 1999-03 2 Fixturlaser Shaft50 Fixturlaser Shaft100 Fixturlaser Shaft200 Shaft alignment with Fixturlaser Shaft systems Benefits

1999-03 1

Fixturlaser Shaft50

Fixturlaser Shaft100

Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems Benefits from Shaft AlignmentBenefits from Shaft Alignment

When shafts are misaligned forces aregenerated at the coupling

1999-03 2

Fixturlaser Shaft50

Fixturlaser Shaft100

Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems Benefits from Shaft AlignmentBenefits from Shaft Alignment

• Studies over the past ten years indicate that 50% of allmachine breakdowns are due to poor alignment.

• Some surveys indicate that up to 90% of all machinesrun outside their recommended tolerances

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Fixturlaser Shaft50

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Shaft alignment withFixturlaser Shaftsystems Benefits from Shaft AlignmentBenefits from Shaft Alignment

¶ Vibrations· Energy savings¸ Wear of mechanical components¹ Production capacityº Product quality

1999-03 4

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Shaft alignment withFixturlaser Shaftsystems ¶¶ VibrationsVibrations

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Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems ¶¶ VibrationsVibrations

When measuring vibrations:• Horizontal vibrations indicates imbalance (H)• Vertical vibrations indicate a weak or loose foundation (V)• Axial vibrations indicate misalignment (A)

1999-03 6

Fixturlaser Shaft50

Fixturlaser Shaft100

Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems ·· Energy savingsEnergy savings

• The correct alignment can reduce energy consumtionwith anything up to 15%, sometimes more.

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Fixturlaser Shaft50

Fixturlaser Shaft100

Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems ·· Energy savingsEnergy savings

To calculate savings• Measure amperage before and after alignment• Find the difference• Get motor data• Find cost of energy• Calculate kW savings with formula below:

(volts * amps * pf * 1,732)1000

kW=

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Fixturlaser Shaft50

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Shaft alignment withFixturlaser Shaftsystems ¸̧ Wear of mechanical componentsWear of mechanical components

Bearings• Increasing the load will

result in exponentialbearing life reduction

• Doubling the load willreduce the bearing lifeto one eight of itsdesign life.

Bearing constantBearing load[ ]3

L =10

• Expected bearing lifetime is calculated according to:

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Fixturlaser Shaft50

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Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems ¸̧ Wear of mechanical componentsWear of mechanical components

Seals• Poor alignment can cause a

50%-70% reduction ofcalculated life time.

• Lubrication problems areoften caused by leakage inthe seals

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Fixturlaser Shaft50

Fixturlaser Shaft100

Fixturlaser Shaft200

Shaft alignment withFixturlaser Shaftsystems ¸̧ Wear of mechanical componentsWear of mechanical components

CouplingsIndications of misalignment:• Coupling is getting hot• Stacks of rubber or plastic under the coupling or

coupling guard• Excessive wear of teeth in gear type coupling

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Fixturlaser Shaft50

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Shaft alignment withFixturlaser Shaftsystems ¹¹ Production capacityProduction capacity

• Today a modern production process isdepended on high runability.

• Production stop, 5-25 thousand USD/hour• Exceeds by far the cost for the replacement of

components.

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Shaft alignment withFixturlaser Shaftsystems ºº Product qualityProduct quality

• Decreased vibration levels, reducedloads on mechanical components willhave a positive impact on the productitself.

• Alignment of drives: Paper, Steel, Plasticfilm