OPTALIGN
Introduction:
OPTALIGN is a “Class 1 Laser Product”.
Operaing Range: Since the OPTALIGN is independent of mechanical bridging devices,
and a beam of light diffuses linearly, alignment jobs with spans upto 2m are no problem.
Longer spans may be bridged if the machines are not excessively misaligned, or with a
special detector for very long spans, which is presently under development.
Precautions: Problems may arise if strong sources of heat or steam are present in the
immediate vicinity of the OPTALIGN system which lead to uneven heating of the air
between the laser/detector unit and the prism reflector. This uneven heating distorts the
laser beam by varying degree of refraction which lead to erroneous results. Over short
spans of up to about 1m, however, this will have practically no influence on the
measuring results unless a leaking or poorly insulated steam pipe is located under the
laser beam.
Shield the system from strong incandescent light sources such as torch lights or sunlight.
Avoid direct exposure of optical aperture to light beams.
Do not operate portable intercom equipment near the control unit or transducer system.
This might lead to mis readings.
Preparation: Essential to optimal alignment is the perfect condition of the contact
surfaces between the machinery and its base or foundation.
Lack of planar parallelism in these surfaces, leads to mounting stresses on the machine
feet when tightening the anchor bolts. Uneven height of base surfaces, dirty or corroded
undersides of the feet, or other irregularities will all lead to the machine standing on only
three feet, a condition known as soft foot. The soft foot function of the OPTALIGN is
activated by the keys F , I.
Additionally, all connections must be completed before beginning with alignment.
However, it is not absolutely necessary that the coupling halves be joined, as an
alternative measurement process can be used.
Torsion play of the coupling (backlash) can lead to measuring errors. Therefore this play
must be eliminated before entering measured values. This may be accomplished through
the use of adhesive tape or small wedges, tightening the two coupling-halves together in
such a way that any radial play between the two is eliminated for the duration of
alignment work. It can also be handled by always rotating in the same direction from the
same input point, with drag on the driven end to prevent gravity overswing.
Tolerances
Excellent Acceptable
Mils 1/100mm mils 1/100mm
Soft foot 2.0 5.1 3.0 7.6
Short
Coupling
Parallel
Offset
1200 rpm 3.0 7.6 4.0 10.2
1800 rpm 2.0 5.1 3.0 7.6
3600 rpm 1.0 2.5 2.0 5.1
Angularity
(per
inch/cm
dia.)
1200 rpm 0.5 0.05 1.0 0.10
1800 rpm 0.3 0.03 0.5 0.05
3600 rpm 0.25 0.025 0.3 0.03
Coupling
with Spacer
Parallel
Offset (per
inch/cm
spacer
length)
1200 rpm 1.0 0.10 1.5 0.15
1800 rpm 0.5 0.05 1.0 0.10
3600 rpm 0.25 0.025 0.5 0.05
Principles of Measurement using OPTALIGN
In the OPTALIGN system, a laser beam is emitted from a laser/detector unit mounted on
the shaft of the stationary machine. It is aimed at a prism mounted on the shaft of the
machine to be moved, where it is reflected back into a detector, again mounted on the
shaft of the stationary machine. When misalignment is present, rotating the shafts causes
the laser beam to change its reception coordinated in the detector. These changes permit
the calculation of the actual alignment configuration.
The calculations are performed by a controller that automatically draws the data from the
detector and figures the correction values for the feet of the machine to be moved. When
desired the controller can also give the centerline offsets at any desired measurement
plane(s) along the shaft axes.
Major Components:
Brackets, Laser/Detector, Prism, Controller, Beam finder, Inclinometer/Level
OPTALIGN Measurement:
When measuring, the laser/detector unit is mounted on the shaft of the stationary
machine, and the prism-reflector is mounted on the shaft of the machine to be moved.
From at least three of four position, 0o, 90o,180o, and 270o, the coordinated in the
detector are entered into the controller (direction of view is toward stationary machine).
Leveling to the clock positions must be performed on the side where the prism is
installed.
The detector yields the reception coordinates of the laser beam, but only within its inner
linearized range.
Switching the System On
ON The display will immediately show the serial number of the unit.
To work in inches, press the key /
Now press the key M
The sender control lamp (red) blinks when the laser is in operation.
The detector control lamp (green) blinks when the reflected beam enters the detector
(display shows either two sets of numbers X.X Y.Y or END ).
Measurement Procedure (“Zero-Zero” Alignment):
a) Adjust shafts in the 12:00 position (viewing toward the stationary machine, i.e.toward
laser/detector). Enter the data in the 12:00 position as M O ENT
b) Rotate the shafts clockwise by 90o to the 3:00 position. Enter the data from the 3:00
position as M 3 ENT
c) Rotate the shafts clockwise by 90o to the 6:00 position. Enter the data in the 6:00
position as M 6 ENT
d) Rotate the shafts clockwise by 90o to the 9:00 position. Enter the data from the 9:00
position as M 9 ENT
These measurements may also be entered in any other order, as desired. Furthermore,
only three measurements are sufficient, since the controller can determine the fourth from
these three. However, four measurements yield a more accurate result.
