Machine Alignment and Rotor's Equilibration

About machine alignment in general:

As all operating equipments, rotors also constitute a vibration system so vibration and resonance - deriving from the movement of all mechanical objects - goes together with their operation. Due to the wrong setting of these mechanical objects or because of their loosening during operation, their vibrating system becomes activated, their vibration level increases, so their equipment gets damaged. Actually we can differentiate between two activities, which basically influence the condition of the machine: the coupling's alignment and the balancing of the rotor.

The alignment of the coupling:

Coupling setting is controlled by extremely strict rules, norms and instructions, and to fulfil these with ocular estimation, hair bars, clocks, waste blades or lever lids is virtually impossible. The accurate, standardized alignment can only be performed with the aid of laser coupling setting equipment.

Thermo-analytical image of accurate setting

Thermo-analytical image of misalignment

What can accurate laser coupling alignment provide?

• It increases the lifetime of the components, accessories and abutments
• It increases the accessories 'reliability, improves the machine's condition
• It decreases vibration, noise, the damaging forces effecting axes and bearings
• Reduces the energy consumption of the machine

The aplicability of laser shaft alignment:

• The accurate alignment of the coupling
• The level adjustment of motors, air blowers and pumps with gap shooting
• Demonstrating the angle error of the runners
• Demonstrating axis deflection

The alignment of the band pulleys:

Belt-driven machines due to their structure or rather by virtue of their construction which demands more accurate alignment and more precise assemblages, fail more frequently than the other dead joint machines. Their most characteristic defect is the recurrent abruption of the band pulleys, the quicker wear of the bearings, the greater current drain and heating of the electric motor. Owing to the above listed phenomena the most precise alignment of such devices has to be insisted on. It is also essential to choose the right belt tension, the control of the discs' snug and the exact setting of the band pulleys' position.

What does the laser band pulley alignment provide?

• It increases the operating time of the accessory parts, fittings and snugs
• It enhances the reliability of the equipment, and improves the condition of the machine
• It decreases vibration, noise, and the damaging forces affecting the bearing and the axle
• It decreases the energy consumption of the machine
• It decreases maintenance costs

To perform machine alignment Kalkon Ltd. applies the Fixturlaser Shaft 100 laser shaft setting system which makes the most accurate coupling alignment possible

The rotor's equilibration:

Equipments that rotate greater loads such as fans, turbo generators, electric motors, belt-pulleys, clutches are in some significant cases imbalanced. Inaccuracies coming from their design, construction or inadequate operation parameters as well as too flexible or too rigid basements also can result in the ceasing of circular symmetric mass distribution which gives rise to the imbalance of the rotor. This phenomenon is not perceptible and this is just where its gravity comes in. It is not detectable during the decomposition of the house and visual check however its effects are the following:

• It increases vibration and noise level
• Due to the abnormal loading, the loaded appliances and components wear harder, and they need to be replaced more frequently.
• Degradation of the bearings is more extensive and the dead time can be fatal.
• The chance of lamings grows.

To resolve balancing tasks, our company uses the equalizing function of Schenck Vibroport 41, the two-channel vibration analyzer.

Dismembering and installation of machines:

The Kalkon Ltd. undertakes dismembering and installation of industrial equipments like pumps, ventilators, compressors, as well as moving and positioning of heavy components.