Engineering Dynamics Blog

Laser Alignment - Top FAQs over last 10 years

Thu, 10 May 2012 09:22:00 GMT

1. How accurate is your Easy Laser Systems?

Accuracy requirements differ due to the application and the ambient conditions being experienced during the measurement task. In machine tool applications we can be stable within a few microns in normal workshop conditions. The laser line is absolute straight. An excellent machine tool can be straight within 0,01mm. For shaft alignment we have suggested tolerances based on the shaft speed. Although we can be a lot more accurate there is a trade-off between time spend and the accuracy required. More important is how quickly the system can assist you to get to the accepted tolerance value. Operator experience plays an important role here too.

Note:

Accuracy is not to be confused with “measurement error”. With our systems you must allow for errors of ± 1% + 1 digit. This is very small.

2. How repeatable are measurements with your lasers?

For shaft alignment you can repeat within 0.01mm or better if you measure in the same 3 points. The same applies for other types of measurements like straightness, flatness, bores, spindle, etc. If you want to repeat your results, you have to repeat your measurement actions as well!

Note:

Not to be confused with the Resolution of the Easy Laser systems. Resolution is 0.001mm.

3. How sensitive is your lasers?

Sensitivity should not be confused with Resolution. For resolution, please see point 2 above. However, if you really interested in the ruggedness of our systems, then we can say the following: Our new lasers/detector is calibrated/paired together. All measurements using lasers must consider the influence of ambient conditions and specifically the presence of air turbulence. All our equipment is built for industry use and are very rigid. We offer the D550 Extreme system with an IP67 and drop test rating.

4. What is the maximum distance of your laser?

Shaft alignment up to 20meters (E710), E530 up to 10m. D22 and D75 laser up to 40m. D146 up to 20m. Our laser are designed to cover specific applications and distances matched for that.

5. Can Easy Lasers handle uncoupled shafts?

Both the E530 and E710 can do this without any problems. The E710 using a laser dot and the E530 using a line. The E710 will be more accurate over long distances further than 2 meters.

6. Why are dual beams as used in the Easy Lasers beter than a single beam?

Dual beams gives you an improved accuracy when measuring on longer distances like cooling towers, cardan applications, etc. which is almost impossible to do using one beam. For normal coupling alignment one beam or two beams gives fairly the same result. Click here for a graphic explanation.

7. How often should I really check the calibration?

The calibration should be checked every year. Most companies follow some type of ISO standard for their measuring equipment as part of their quality standards. As a distributors we can assist in giving a conformance check and issue a certificate to provide proof that the system works within the specifications. Factory calibration is always available and varies from 2-5 years.

8. Can you do a repair locally on the laser head?

To get any repair on the Easy-Laser system, you have to send it to our service centers. Do not open any device since this could damage the components by static electricity. By opening any unit, transmitter or display yourself, you will not have the right for warranty claims. At the moment In South Africa, we send our units to Sweden for repair with very fast turn-around times. A full repair and calibration certificate is provided.

Christo van der Walt
0764221768

Easy Laser S&M Units for Machine Base Checks

Tue, 17 Apr 2012 08:12:00 GMT

In all our training sessions we always discuss the importance of ensuring the soundness of the machine base before tackling the shaft alignment. A very common problem we encounter is the so-called "twist" of the fabricated type of bases as found on many smaller pumpsets. In most cases the pumpsets leave the factory perfectly aligned, but due to wrongly positioned lifting points, the base gets twisted during loading and offloading. Everybody assumes the alignment is perfect until the vibration measurements during commissioning are captured. When an alignment check is called for, it quickly becomes clear that something is wrong with the base. Below we present a quick method to check the base.

Step by Step Method:

The idea is to use the laser beam as one would use a straight edge.

Mark Points ACED on the structure. Point B represents a support pillar on the same height as points A and D. Base twist is traditionally checked using the diagonal ABC by placing a straightedge on points A and B and measuring the gap with a feeler gauge between C and the bottom of the straightedge (if point C happens to be lower).

The same method is followed for the diagonal using points DBE. If points E and C are found to be higher, then redo and use E and C as starting points. It is always preferable to add material for height compared to have to take material away with grinding or machining.

The laser beams from your Easy Laser system can be used in a similar fashion and one can do longer bases compared to a standard length straightedge by following the steps below.

1. Build support B so that it is level with points A and D respectively. If A and D differs - fix first.

2. Use the Values program. Mount the S (Stationary) unit on base point D. Mark the position with a permanent marker around the base of the S unit. Make sure that the S unit is on the same spot with every measurement for the chosen diagonal.

3. Mount M (Movable) unit close to S unit and press "zero" on the display unit. Move M unit to point B and zero with the laser beam by adjusting first on the rods and then using fine adjustment screws on the M unit. We are only interested in the vertical direction.

4. Now move the M unit to point E and record the vertical measurement value. The value obtained here is similar to the feeler gauge value discussed earlier.

5. For the second diagonal use the Values program again. Mount the S unit on base point A. Mark with permanent marker around the base of the S unit. Make sure that the S unit is on the same spot for every measurement.

6. Now move M unit to point C and record the vertical measurement value. The value obtained here is similar to the feeler gauge value discussed earlier.

7. Example - If measured result on point C is -2.3mm and point E is -3.0mm, one needs to add 0.7mm at point E to be equal with the height of point C and to eliminate “twist”.

Read more about our Shaft Alignment systems that use this method here.
For other types of geometric flatness measurements, please read here.

Christo van der Walt

076 422 1768

Laser Flatness Measurement with a twist

Wed, 28 Mar 2012 13:46:00 GMT

One of the important objectives of our blog is to educate and inform. To this end, I would like to share a recent flatness measurement project we completed using standard Easy Laser Geometric equipment.

Background
The client has two instrumentation test floors of approximately 35 square meters each, but here's the twist. The floors consist of individual granite, 2m x 1m, slabs to be flat to 0.05mm/m across slabs and then 0.05mm for the complete floor. The reason for the tight specification is that they move heavy equipment across these floors by using an air cushion. (Lead blocks on the photos are providing a stable surface since the cavity below the slabs still have to be filled with concrete after adjustments)

Test Procedure:
The laser measurement equipment used was a D23 Spinning Laser with a single D6 detector. Since this was not a proper "flatness" measurement, we used the Values Program with an older D-series display. The motivation for using the D23 and D6 was for a faster measurement process. We knew we were losing accuracy compared to using a D22 Swivel Laser and D5 detector, but the tolerances achieved were still within the client specification.

At each floor a reference slab was selected and its flatness referenced to points outside the floor before we arrived on site. The reference slab was used to level the laser using the trusted old "L" method of setting a reference plane using 3 corner points on the slab. After establishing the plane, the Detector was moved from slab to slab and adjustments made. Each slab has 3 adjustment points and the detector is placed close to it and adjustments made. There is a small amount of "trial and error" work required after adjusting each bolt on a slab, but it did not take long time to get each point to 0.05mm. (A great help would have been three D6 detectors at each bolt with 3 people ready to make adjustments - but that's only in a perfect world!)

Results

The client called for 0.05mm/m but in the end we achieved 0.03mm. The total measurement and adjustment took only 4-5 hours for each floor where previously this measurement took approximately 5 days per floor with results up to 0.05mm very difficult to achieve.

We have a satisfied client and we could demonstrate the benefits of using the Easy Laser equipment ie.:

1. Versatility of the components in the Geometric system
2. Ease of use, quick results and within specified tolerance.

If you want to know more about the different applications and system, please visit our Geometric Products Page on our website.

Christo van der Walt

Combine Laser Alignment and Vibration in one tool

Thu, 08 Mar 2012 14:20:00 GMT

Vibration Measurements with an Easy Laser

Shaft misalignment is a major cause of high vibration on rotating machines - some experts state the occurrence as high as 50%. Alignment practitioners know that it is common practice to take vibration measurements before and after an alignment job. A reduction in vibration levels to conform to a client or ISO standard usually gives the client peace of mind and confidence in the contractor to solve the misalignment problem. Easy Laser makes life easier for the contractor and uniquely incorporates overall vibration and bearing condition measurements into the shaft alignment instrument and the reporting capability of the E530 and E710 systems.

Figure 1 E-Series Vibrometer Probe E285

The optional Vibration probe as shown in Figure 1 above comes standard with a magnetic base and a measuring probe tip 65 mm long. The overall vibration level is measured using Velocity in mm/s RMS in 2 user selectable frequency ranges:

10-3200 Hz for medium and high running speeds
2-3200 Hz for running speeds down to 120 RPM

These values only give an indication and can be compared with the ISO 10816-3 standard. If machine rotating speeds and KW size are known, the system plots the values on the ISO table. See Figure 2 below. If a more detailed analysis is required using a vibration spectrum, then we recommend our range of portabe vibration instruments like the Viber X5 with Spectra Pro software.

Figure 2. Result screen from E710/E530 after measurements

A second helpful measurement with the same probe is the Bearing Condition Measurement as measured in g’s RMS. This measures in a range between 3.2 kHz and 20 kHz. If the running speed is known, then the Easy Laser E710/E530 systems will plot the point on the graphs. One does not need specialist vibration training to understand the operation of the vibration probe and it adds a great deal of value by reducing the number of portable systems the artisan has to carry around.

Both these measurements and the summary are available as reports in PDF or XML format stored on the supplied memory stick which can then be printed from any PC.

Figure 3. Screenshot from E-series while capturing Vibration data

It is reassuring to know that Easy Laser always keep their users in mind when designing the laser measurement systems.

See our other products on our website.

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Christo van der Walt

Basic Handheld Vibration Tools

Mon, 20 Feb 2012 07:55:00 GMT

In the entry level market where people need a basic handheld vibration tool to indicate vibration severity, two new instruments the Viber X2 and Viber X3 fit into this category.

These battery operated instruments measure the following:

Vibration measurements in 3 selectable frequency ranges
Bearing Condition measurement in wide frequency range
Audible noise on headphone for Bearing condition measurement – X3 only
Built-in IR temperature sensor – X3 only
Highest peak frequency and amplitude for troubleshooting
Colour LEDs for alarms
High quality sensor on 1 meter cable with magnet or spike attachment.

Detail specifications of the Viber X2/X3 here.

Typical end users:

X2 – Maintenance or repair people who needs a reliable, fast and easy to understand tool for the basic checks in rough conditions.

X3 – Same as for X2, but with additional IR temperature sensor, internally charged NiMH batteries and earphones for bearing condition troubleshooting.

My verdict:

I like the 3 frequency ranges and highest peak calculation – nice for troubleshooting and the Viber X3 with IR Temperature measurement. The accelerometer on the cable, as found on both instruments, makes it easy to get into tight spots ensuring a good quality and repeatable measurement. (Unlike vibration pens). The headphones used for bearing sound will go a long way in convincing sceptics about the true consition of a bearing and its lubrication. The present range from VMI starting at the Viber A, X2, X3, Viber X and Viber X5 and X6 is fairly complete and there is a handheld vibration solution for every budget.

Laser Bore Alignment made Easy!

Tue, 31 Jan 2012 13:59:00 GMT

A range of new geometrical application instruments from Damalini was released recently using the same colour screen display unit and wireless technology already well established in the E710 shaft alignment system, but now for geometrical measurent systems. This blog will review the main new points of the Easy Laser E950-A and B for Bore or Bearing pocket alignment applications.

The E950-A above is primarily designed for diesel engines (crank and camshaft bearing pocket alignment), but also for gearboxes and compressors. This system builds on the industry-leading D series instruments but now with wireless detectors and versatile brackets. See the unique "gokart" type brackets above. I have used it myself and these brackets make the movement in the bore of the detector very easy.

The E950-B is in the same family, but designed for propeller shaft installations on ships with stern tubes, support bearings, bearboxes and engines.

The E950-B differs from its E950-A family member with a self-centering detector bracket which gives a range of diameters to be handled between 100 and 500mm.
I like the addition of 2 additional calculation methods "best fit around zero" and "waviness" to be done on existing data. An additional application program, Ovality check, allows one to calculate wear rates. We also have a Shipping Applications Guide in PDF and it provides step-by-step examples in how to use the equipment in different shipping applications.

More detailed information on these 2 systems are available here.

These Bore Alignment systems can also be expanded for shaft alignment and they build on the very popular E710 platform. By choosing the correct shaft accessories, the complete machine train and foundations can be checked. The shaft programs are already loaded into the system, so no extra costs from us.

More information on the E710 can be seen here.

Christo van der Walt

Easy Laser with a new Turbine Alignment System

Thu, 09 Feb 2012 10:38:00 GMT

If you are using dummy shafts, piano wire and feeler gauges to obtain the true centreline of a turbine, there is a smart solution using laser technology that just got better.

The Easy-Laser E960 makes the measurement and adjustment of diapraghms and bearings easier thanks to the wireless detector unit and measurement programs that guides you through the measurement process. The versatile design solves the straightness measurement problems quickly and with precision for any kind of application. Objects up to 40m can be measured and the detector reads measurement values with a resolution of 0.001 mm.

A visible red laserbeam is the reference to which the straightness of the bores is measured. Compared to older methods, e.g. piano wire, the work is done much faster, easier and more accurately.

The laser transmitter support beams that come with the system are solid allowing for a stable mounting and accuracy. Rigid aluminium beams with 2 or 3 magnets are used.

The detector bracket comes in two versions.
A: Measuring probe with a stroke of 10 mm. The slidable tube makes it possible to measure several positions in a row without moving the bracket. Suitable for gas turbines and smaller steam turbines.
B: Measuring probe with a stroke of 60 mm. Suitable for larger turbines.

In summary:

EASY-LASER E960-A
This system is suitable for gas turbines and smaller steam turbines. Measures diameters 150–1700 mm. The detector bracket comes with a slidable tube, making it possible to measure several positions in a row without moving the bracket.

EASY-LASER E960-B
System suitable for larger turbines. Measures diameters 200–1700 mm as standard, and up to 4500 mm with accessory brackets. The detector bracket has a probe stroke of 60 mm, which is convenient when nearby bore diameters vary a lot.

More Information on the geometric systems here.

Viber X5 - New Multi-Channel Instrument to Rock Vibration Industry

Mon, 30 Jan 2012 12:54:00 GMT

In this industry where progress has been very incremental over the last decades, our latest offering from VMI, the Viber X5, is set to change the industry.

The X5 is the latest handheld vibration instrument from VMI, Sweden. The family of portable instruments that we offer include the Viber-A, Viber X2 and X3, X-Viber and is further extended with this state-of-the-art instrument. When combined with Spectra Pro software and the optional items added, one will have an instrument that is difficult to beat on price and performance.

What comes with the system:

2 Accelerometers, 100 mV/g with magnets and cables standard

Internal IR temperature meter for quick measurements while in route
IP68 rugged carrying case for heavy industrial use
Hand straps for both sides for comfortable use

The following measurements are standard:

One- and two- plane balancing, hardware kit extra
Route based data collection from a list in Spectra Pro
Multimeter, process parameters to capture with vibration data
Data logger for long-term recording waiting for that transient event
Run up/Coast down and Orbit for the advanced analyst
Bearing condition, Amplitude and Phase for troubleshooting
Envelope, Spectra, Waveform as standard for everyday analyses

Optional - Listen to bearing noise while measuring with head phones.

I Like:

Price/performance
High resolution screen
Advanced applications as standard
Included standard accessories
SpectraPro software

I Dislike:

Weight of instrument
Screen can be bigger for analysis, but good for data collection

Final Verdict

The X5 shows that all the advanced features reserved for higher priced systems, is something of the past now. VMI is very innovative and their instruments deserve a larger cut of the vibration instrument cake.

View More Details Now and Download the PDF

Exciting Mid Range Laser System - E530

Fri, 11 Nov 2011 14:16:00 GMT

Simple and Efficient Shaft Alignment

The Easy-Laser® E530 is a very powerful laser shaft alignment system, with the ideal balance between performance and price. Programs that guides step-by-step with both icons and text makes the system very easy to use for everyone, regardless of prior knowledge. The measuring units are pre-mounted for rapid machine set-up. With the barcode reader the user can save many key operations where all machine dimensions, tolerances and compensation values are entered in one single operation, and the measurement can be started directly. Start with the measuring units positioned anywhere through 360 ° around the shaft, then take any three readings down to 20° in-between. Then adjust the machine with the live-values in both horizontal and vertical directions. A PDF report is generated automatically when the measurements are saved. Simple and efficient!

Technology that gives the best performance in demanding industrial environments

The shaft alignment system has a large 5.7", bright colour display that clearly shows all the steps of the measurement. The measuring units have TruePSD-technology, which gives unlimited resolution. Twin laser beams, twin PSDs and twin inclinometers give you superb control of the measurement in all situations. The wireless units (accessories) have a very long operating time and give full freedom of movement around the machine. Display unit, measuring units and fixtures are all very robust for the highest accuracy in demanding industrial environments.

Large expansion possibilities

It is possible to connect two very useful accessories to the system. With Vibrometer E285 it is possible to check the vibration level and bearing condition of the machine. Using E170 BTA you can check and align sheaves and pulleys with digital precision. You can document the measurements for vibration checks and belt alignment in the same way as for the normal shaft alignment programs. There is also a wide range of accessory brackets, such as magnet bases, axial magnet brackets and brackets for non-rotating shafts. The transportation case is equipped with recessed compartments for the accessories, which means that you can carry everything in one case.

CHARACTERISTICS AND FUNCTIONS (** with accessories):

Barcode system reduces key strokes and starts the measuring work quicker
TruePSD technology for unlimited resolution
Twin PSD detectors, laser beams and angle sensors for superb measurement checks
Icons combined with program in your language make it easy to use
Programs for Horizontal and Vertical shaft alignment
Program for aligning sheaves with digital precision**
Program for checking the machine’s vibration levels (mm/s, g-value)**.
Bluetooth® wireless connection - enables you to work more freely**
EasyTurn™ function – offers down to 20° between measuring points
Alignment “live” anywhere around the shaft (360°)
Expandable – adapt the system to your needs, now and in the future

My opinion:

The launch of this midrange laser system is long overdue by Damalini since the launch of the E710 almost 2 years ago. The same ease-of-use and practical approach like in the rest of the range can be found here as well. The use of a single transmitter as an upgrade option to make the display unit "wireless" is an unique approach and we will have to see how the market reacts to this. The PSDs used where the width of the detector is fairly narrow but allow for large offsets in the direction of mounting can cater for medium offsets, but in extreme cases the E710 will still be the answer. In summary, a much welcomed addition to the E-series platform. How about an entry level E-series now! See more details here.

Oil Analysis - The Perfect Screening Tool

Mon, 07 Nov 2011 12:15:00 GMT

After doing training today on our Oilview Quickcheck oil analysis system, I once again came under the impression of this powerful little portable instrument. In this mini lab for a mining company, hundreds of samples are tested every month. They have all the expensive and sophisticated equipment you will find in a commercial lab, yet the Oilview will be used as a first screening tool to direct traffic after the initial tests were done. This is because the Oilview measures these basic values taking not more than 3 minutes per 50 ml sample:

1. Large Ferrous Particles > 60 microns
2. Large Non-Ferrous Particles > 60 Microns
3. Droplets - water or other fluid droplets
4. Ferrous Index - checking for small wear particles
5. % Water Estimate
6. Dielectric Number

If the trends and alarms show a problem, then more sophisticated instruments are used. The software allows for trending and reporting with alarm limits that can be added or standard ones used from the software. Values can be exported for use with other software like CSI, LIMS etc.

My Opinion:
I have come across many portable systems in recent years. Some units provide one or two absolute measurement types with varying testing times using up to 500ml of oil. The OIlview look at the basics to be encountered in used oil which can influence the life of your machines at an affordable price in a small portable format with quick testing times.
Read more on the Oilview.

Preventing machine failure through laser shaft alignment equipment

Sun, 09 Oct 2011 10:44:00 GMT

Mining Weekly.com

Vibration monitoring and laser shaft alignment technology is being supplied by machine condition monitoring systems company Engineering Dynamics (ED) to several mines around South Africa to prevent machine failure.

The company offers solutions to machine monitoring require-ments, including vibration, hand-held, online, protection and sensor systems as well as laser shaft alignment equipment.

ED MD Christo van der Walt says that the company identifies the need within mining and manufacturing organisations to limit damage to machines and prevent expensive down time and then supply the correct technology or service solution.

Laser Shaft Alignment

The company’s Easy-Laser range of laser shaft alignment equipment measures all types of rotating machines, regardless of size and shaft diameter, with a measurement distance of up to 20m.

The company’s entry-level laser shaft alignment system, Easy-Laser D450, is designed for users that only need alignment of horizontally installed machines. It is typically installed onto horizontal pumps, fans, motors and gearboxes.

In addition, the Easy-Laser D480 provides alignment to rotating equipment, such as horizontal, vertical-mounted and cardan-shaft-coupled machines. The imbedded EasyTurn programme allows alignment with as little as 40° rotation of the shaft. Coupled with further accessories, vibration measurement and digital pulley alignment are possible.

Further, the Easy-Laser D525 builds on the D480’s programmes and functions by including programmes for geometrical measurements, allowing for the measurement of straightness, flatness of machine foundations, parallelity and perpendicularity with the addition of acces- sories.

Van der Walt says that the Easy-Laser Extreme, the D550 Ex, is a measurement and laser alignment system for potentially explosive areas. The entire system is impact resistant and durable. The D550 has the same measurement functions as the D480.

Accessories to further extend the range of laser alignment applications include pulley alignment equipment applicable to belt drives; a vibration measurement probe to monitor vibration level and bearing condition value; and geometry measurement accessories.

Van der Walt says that all Easy-Laser systems’ measurement values are displayed live, allowing users to make adjustments to the machinery accordingly.

Various mines within South Africa have applied Engineering Dynamics’ technology to crucial areas, such as in mills.

“It is important to align the mill drivetrain properly. Mechanical components like bearings and gears are designed for normal operating loads and any additional external forces exerted on these components will reduce its life expectancy. Accurate laser shaft alignment will reduce the effect of some of these forces due to misalignment,” says Van der Walt.

Meanwhile, he says that the company has not seen a decline in the need for its products and services in the present economic climate and has forecast a growth of more than 10% for the year.

He adds that mining and manu- facturing companies have seen the benefits of using condition monitoring and laser shaft alignment on their machinery, even when production is low.