FIGURE 6.58 Observe the amount of sag on the dial indicator as you rotate the assembly to the six o’clock position. T B 0 T B 0 Motor Fan Ϫ64 Ϫ48 +16 +55 +77 +22 Field readings T B 0 “Sag” readings T B E E EE W W W EWW 0 T B 0 Motor Fan Ϫ58 Ϫ36 +22 +61 +89 +28 “Compensated” readings To compensate for the sag, add the amount of the sag observed at the bottom to each bottom reading and the amount of the sag observed on the each side to each side readin g Ϫ6 Ϫ12 Ϫ6 (Ϫ48 + 12 = Ϫ36) (+16 + 6 = +22) ( Ϫ64 + 6 = Ϫ58) FIGURE 6.59 Mathematically compensating for sag. Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 270 26.9.2006 8:51pm 270 Shaft Alignment Handbook, Third Edition that the centerline of rotation of the spindle and chuck is perfectly in line with the centerline of rotation of the live center. 6.14 ZERO SAG BRACKETS Is it possible to defy gravity and construct a cantilevered beam that compensates for the elastic bending due to the force of gravity? You bet, within limits. Figure 6.63 shows a bracket design where a second span bar holds a weight so that its position is on the opposite side of the clamping point on the shaft, thereby counterbalancing the overhung weight. Figure 6.64 shows another arrangement for long spans where a different type of counterweight is placed on a coupling spool that ‘‘lifts’’ the span bar. Neither of these prototype ‘‘anti-sag’’ devices are included in any of the dial indicator based alignment measurement systems. Another long span bracket system fabricated from lightweight carbon tubes is shown in Figure 6.65. T B EW 0 T B EW 0 Motor Fan Field readings −6 −12 −6−6 −12 −6 When the motor and fan shafts are perfectly aligned, you should have these field readings FIGURE 6.60 Ideal ‘‘shoot-for’’ readings (assuming no OL2R movement occurs). FIGURE 6.61 Xmas tree bracket. Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 271 26.9.2006 8:51pm Shaft Alignment Measuring Tools 271 6.15 DIAL INDICATOR SHAFT ALIGNMENT SYSTEM MANUFACTURERS The ensuing pages cover the currently available dial indicator based shaft alignment systems. There are currently 7 manufacturers offering 19 different models. A talented person could fabricate his own shaft alignment fixtures, purchase dial indicators, and perform very satisfactory shaft alignment. The Xmas tree brackets shown in this chapter were custom fabricated and work very well. Small to medium size fixtures can be made that clamp around the outside of a shaft or coupling hub using roller chain or hose clamps. The bracket body can be machined out of a block of steel or fabricated with pieces of angle iron. Span bars can be made with tubing or round stock and can be cut to various lengths to suit the users needs. Dial indicator sleeves can be purchased to clamp on various diameters but the ones typically used clamp on 1=4, 5= 16, or 3=8 in. rods with metric sizes available also. It may take several hours for some experiments (also known as prototypes) to get what you need. On the other hand, the following tools have already gone through a development cycle and are commercially available at relatively modest prices. Xmas tree bracket (bolt to plate steel) Plate steel Angle iron gusset support Weld Sch. 80 pipe (support on roller stands) Weld Post 0 50 10 40 20 30 + _ 10 40 20 30 0 50 10 40 20 30 + _ 10 40 20 30 FIGURE 6.62 How to measure sag when using an Xmas tree bracket. Counterweight FIGURE 6.63 Turvac Inc. sag compensation bracket design. Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 272 26.9.2006 8:51pm 272 Shaft Alignment Handbook, Third Edition 6.15.1 ACCUSHIM SYSTEMS Accushim offers five different dial indicator based systems as shown in Figure 6.66 through Figure 6.70. The REACT SA-2 system includes a pocket computer with alignment software. Chain, brackets, posts, targets, and rods can be purchased separately to extend the capabil- ities of the systems. SK-1 system cost: $425.00 SK-2 system cost: $575.00 REACT HA-3 system cost: $825.00 REACT HA-2 system cost: $1500.00 FIGURE 6.64 Sag compensation fixture design. (Courtesy of Murray & Garig Tool Works, Baytown, TX. With permission.) FIGURE 6.65 Long span carbon tube. (Courtesy of Murray & Garig Tool Works, Baytown, TX. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 273 26.9.2006 8:51pm Shaft Alignment Measuring Tools 273 REACT SA-2 system cost: $2250.00 Manufacturers Web site: http:== www.accushim.com= 6.15.2 A-LINE SYSTEMS A-Line Mfg. Inc. A-750 system as shown in Figure 6.71 is designed for smaller, hard to fit equipment, and ANSI pumps. The A-1000 system is designed to clamp directly onto the shafts and reach over the coupling as shown in Figure 6.72. The A-2000 model is designed to clamp onto the coupling hub and reach over the hub flange as shown in Figure 6.73. The A-3000 system combines both the A-1000 and A-2000 components (Figure 6.74). An optional Palm OS computer is available with alignment software. A-750 system cost: $875.00 A-1000 system cost: $1025.00 A-2000 system cost: $1225.00 A-3000 system cost: $1675.00 Palm OS with software cost: $750.00 Manufacturers Web site: http:== www.alinemfg.com= FIGURE 6.66 SK-1 system. (Courtesy of Accushim Inc., Lyons, IL. With permission.) FIGURE 6.67 SK-2 system. (Courtesy of Accushim Inc., Lyons, IL. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 274 26.9.2006 8:51pm 274 Shaft Alignment Handbook, Third Edition FIGURE 6.68 REACT HA-3 system. (Courtesy of Accushim Inc., Lyons, IL. With permission.) FIGURE 6.69 REACT HA-2 system. (Courtesy of Accushim Inc., Lyons, IL. With permission.) FIGURE 6.70 REACT SA-2 system. (Courtesy of Accushim Inc., Lyons, IL. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 275 26.9.2006 8:51pm Shaft Alignment Measuring Tools 275 6.15.3 BENCHMARK SYSTEM The Benchmark PAS-1 alignment kit is shown in Figure 6.75 and Figure 6.76. PAS-1 System cost: $1200.00 Manufacturers Web site: http:== www.withinspec.com= 6.15.4 MURRAY &GARIG SYSTEM If you have not been noticing, there are several references in this book to describe the owner of this company, Malcolm Murray. Malcolm is one of the foremost experts in shaft alignment and holds seven patents, including a patent for several reverse indicator brackets as well as FIGURE 6.71 A-750 system. (Courtesy of A-Line Mfg. Inc., Liberty Hill, TX. With permission.) FIGURE 6.72 A-1000 system. (Courtesy of A-Line Mfg. Inc., Liberty Hill, TX. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 276 26.9.2006 8:51pm 276 Shaft Alignment Handbook, Third Edition many other machinery alignment products shown in this book. He has been a consultant to many of the manufacturers and users of dial indicator and laser-based shaft alignment measurement systems shown in this book. The Murray & Garig K-5 shaft alignment system is shown in Figure 6.77 and Figure 6.78. K-5 system cost: $2300.00 to $2900.00 depending on options. 6.15.5 PETERSON ALIGNMENT TOOLS CO.SYSTEMS Peterson Alignment Tools Co. offers two different alignment kits, the 20RA and 30RA, as shown in Figure 6.79 and Figure 6.80. Also offered is the Alignment Managery 2002 FIGURE 6.73 A-2000 system. (Courtesy of A-Line Mfg. Inc., Liberty Hill, TX. With permission.) FIGURE 6.74 A-3000 system. (Courtesy of A-Line Mfg. Inc., Liberty Hill, TX. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 277 26.9.2006 8:51pm Shaft Alignment Measuring Tools 277 software program that operates on Windowsy operating systems that can be purchased separately. Another version (Alignment Manager 3.1a) can be loaded onto a TI-86 scientific calculator. 20RA system cost: $795.00 (includes Alignment Manager 2002 software program) 30RA system cost: $995.00 (includes Alignment Manager 2002 software program) AMTI-86 scientific calculator cost: $199.00 Alignment Manager 2002 or 3.1a cost: $79.95 Manufacturers Web site: http:== www.petersontools.com= FIGURE 6.75 PAS-1 system set up for reverse indicator method. (Courtesy of Benchmark Maintenance Services Inc., Toronto, Ontario, Canada. With permission.) FIGURE 6.76 PAS-1 system set up for face–rim method. (Courtesy of Benchmark Maintenance Services Inc., Toronto, Ontario, Canada. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 278 26.9.2006 8:51pm 278 Shaft Alignment Handbook, Third Edition 6.15.6 TURVAC INC.SYSTEMS Turvac Inc. offers five different systems. Figure 6.81 shows the miniature bracket that is used for small couplings. Figure 6.82 shows the standard bracket kit. Figure 6.83 is the Journey- man system which includes two standard bracket kits, a magnetic base, and the Shaft Alignment Software Program or Technical reference library (the book Basic Shaft Alignment FIGURE 6.77 K-5 system. (Courtesy of Murray & Garig Tool Works, Baytown, TX. With permission.) FIGURE 6.78 K-5 system components. (Courtesy of Murray & Garig Tool Works, Baytown, TX. With permission.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C006 Final Proof page 279 26.9.2006 8:51pm Shaft Alignment Measuring Tools 279 [...]... À0.5 11 Yes Yes No Twin spirit level Yes 12 Yes 25 Yes Yes Yes Yes No Macintosh 5995.00 Turvac Inc Professional Yes (addtn’l parts req’d) Yes Yes (addtn’l parts req’d) Yes (addtn’l parts req’d) Yes (addtn’l parts req’d) 0. 625 12 2.5 23 3 12 Yes No Yes Spiral level Yes 12 35 Yes Yes Yes Yes Yes No 24 90.00 Update Int’l Proaction Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof... ϫ 3.5 in footprint 3 in ϫ 3 in footprint 21 / 32 in hole diameter 1 /2 in bolt 15 6 mils total diametral clearance 17 / 32 in hole diameter 3/8 in bolt 15 6 mils total diametral clearance FIGURE 7 .2 NEMA foot pad specifications Bolt 5 /16 in 3/8 in 1 /2 in 5/8 in Diameter 0. 313 0.375 0.5 0. 625 Hole 13 / 32 in 17 / 32 in 21 / 32 in 13 /16 in Hole diameter 0.406 0.5 31 0.656 0. 813 FIGURE 7.3 Bolts, hole diameters, and... Optional 12 20 Yes Yes Yes Yes Optional No Optional 12 17 Yes Yes Yes Yes Optional No Optional 12 7 Yes Yes Yes Yes Optional No Optional 12 32 Two Two Yes Yes Yes No Yes 36 Yes 32 Two Two Yes Yes No No No 36 Yes 15 Two Two Yes Yes No No No 36 Yes 12 Two One Yes Yes No No No 36 Yes 10 One One Yes Yes No No No 36 Yes 28 4 0.375 3.5 2 6 3 7 Yes No No Level 16 75.00 A-Line A-3000 12 2 5.00 A-Line A -20 00 1 025 .00... DK4 322 _C006 Final Proof page 28 5 26 .9 .20 06 8:51pm Shaft Alignment Measuring Tools 28 5 Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 28 6 28 6 26 .9 .20 06 8:51pm Shaft Alignment Handbook, Third Edition 3 What is the distance from the point where the bracket touches the shaft to the center of the span bar? If your bracket system can change the height of the span bar, what is... Hills, IL, June 26 28 , 19 84 Piotrowski, J.D., The graphical alignment calculator, in: Machinery Vibration Monitoring and Analysis, Vibration Institute, Clarendon Hills, IL, 19 80 Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 28 9 Shaft Alignment Measuring Tools 26 .9 .20 06 8:51pm 28 9 20 03 Precision alignment and balancing guide, Maintenance Technology, 16 (11 ), 20 03 Samzelius,...Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 28 0 28 0 26 .9 .20 06 8:51pm Shaft Alignment Handbook, Third Edition FIGURE 6.79 Peterson 20 RA system (Courtesy of Peterson Alignment Tools Co., Channahon, IL With permission.) FIGURE 6.80 Peterson 30RA system (Courtesy of Peterson Alignment Tools Co., Channahon, IL.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006... No 12 1 1, L.S Starrett Co., Athol, MA Two Step Dial Indicator Method, Bulletin No MT-SS-04-0 01, Rexnord, Thomas Flexible Coupling Division, Warren, PA, 19 79 Yarbrough, C.T., Shaft alignment analysis prevents shaft and bearing failures, Westinghouse Engineer, May 19 66, 78– 81 Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 29 0 26 .9 .20 06 8:51pm Piotrowski / Shaft Alignment. .. Macintosh computer (Professional system) (Figure 6.84) Miniature bracket cost: $495.00 Standard system cost: $14 95.00 FIGURE 6. 82 Standard alignment system (Courtesy of Turvac Inc.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 28 2 28 2 26 .9 .20 06 8:51pm Shaft Alignment Handbook, Third Edition FIGURE 6.83 Journeyman alignment system (Courtesy of Turvac Inc.) Journeyman... 4 10 3.5 6 .25 Yes No No Twin spirit level No 12 Yes 24 Yes Yes Yes Yes No No 5 Yes Yes Yes Yes Optional No Optional 12 Yes 9 Yes Yes Yes Yes Optional No 23 00.00– $29 00.00 Murray & Garig K-5 12 0 0.00 Benchmark PAS -1 Shaft alignment method capabilities Face–rim method? Shaft bracket fixtures Minimum shaft diameter (in.) Maximum shaft diameter (in.) Minimum shaft- to -shaft span (in.) Maximum shaft- to -shaft. .. baseplate As you can see, there is not much 29 1 Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C007 Final Proof page 29 2 29 2 26 .9 .20 06 8:43pm Shaft Alignment Handbook, Third Edition Shaft alignment in a three-dimensional world Axial position Horizontal position Vertical position FIGURE 7 .1 Moving in the X, Y, and Z planes room between the shank of the bolt and the hole drilled into the machine . No No No DOS-based laptop Apple Macintosh No Alignment software included? Optional No Optional Optional No No Yes Yes Yes Yes Warranty period (months) 12 12 12 12 12 12 12 12 12 12 Purchase parts separately? Yes Yes Yes. (in.) 2 2 2 3 3 1. 5 1. 5 1. 5 1. 5 Maximum shaft- to -shaft span (in.) 6 6 12 14 14 9 18 18 18 Minimum span bar height (in.) 3 3 3 3 3 2. 2 3.5 2. 75 3 .2 Maximum span bar height (in.) 7 7 9 12 12 2 .2 3.5 75 3 .2 Brackets attach around shaft. Master or Professional alignment system. (Courtesy of Turvac Inc.) Piotrowski / Shaft Alignment Handbook, Third Edition DK4 322 _C006 Final Proof page 28 2 26 .9 .20 06 8:51pm 28 2 Shaft Alignment Handbook,