Alignment Calcs

Reverse Indicators method (solved Example):Draw a simple diagram in you alignment sheet to show how the dial indicators are fixed, distances of inner and outer boards (IB, OB). Plane A is the position of indicator tip at adjustable machine while plane S is at stationary machine.

Stationary and Adjustable machines

Dial indicator readings:To ensure perfect alignment, dial readings must be carefully recorded.Write down Rim readings for Adjustable (i.e motor) and Stationary (i.e pump) machines.

Adjustable MachinePlane (A)

Stationary MachinePlane (S)

Applying Validity Rule:Applying validity rule is very important to check your readings, errors in readings will effect the results of your alignment calculations.

Top reading + bottom reading (must equal to) Left reading + Right reading

The allowable difference should not exceed 0.001″

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Rim readings check for Adjustable Machine: Rim readings check for Stationary Machine:T+P= (+5) + 0 = +0.005L+R= (-0.005) + 0.011 = +0.006

T+P= 0 + (-0.019) = - 0.019L+R= -0.006 + (- 0.012) = -0.018

Calculations to be done:In these calculations you will cancel the amount of indicator bar sag and zero the (Top and Left) readings at S plane, and (Bottom and Left) readings at A plane.



Net results after all Calculations:Write down the net results after all calculations as following:



Data Analysis:Logically analyze the above results as following:

Vertical AnalysisAdjustable Machine is Lower by 2 The Face Gap is 4 wider at Top

Horizontal AnalysisAdjustable Machine is 10.5 to LeftThe Face Gap is 16 wider at Left

Vertical solution:Draw the graph of vertical solution based on the data analysis:

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Note: Drawing is NOT to scale

CALCULATIONS FOR (VERTICAL): -Mathematically find the values of X and Y:

(X / 10) = (0.008 + 0.001) / 6

X = 0.015

IB = 0.015 + 0.001 = 0.016"

(Y / 30) = (0.008 + 0.001) / 6

Y = 0.045

OB = 0.045 + 0.001 = 0.046"

Actions to be taken for vertical:

Lower IB 0.016" (Remove 0.016" of shims from the IB foots of the adjustable machine).Lower OB 0.046" (Remove 0.016" of shims from the OB foots of the adjustable machine).

Horizontal solution:Draw the graph of horizontal solution based on the data analysis:

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CALCULATIONS FOR (HORIZONTAL): -Mathematically find the values of X and Y:

)X / 10) = (0.008 - 0.003 / (6X = 0.008IB = 0.008 + 0.008 = 0.016"

)Y / 30) = (0.008 - 0.003 / (6Y = 0.025

OB = 0.025 + 0.008 = 0.033 "Actions to be taken for vertical:

PUSH IB 0.016˝ TOWARDS LEFT.PUSH OB 0.033˝ TOWARDS LEFT.

Two Indicators method (solved Example):Draw a simple diagram in you alignment sheet to show how the dial indicators are fixed, distances of inner and outer boards (IB, OB). Plane A is the position of indicator tip at adjustable machine while plane S is at stationary machine.

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Dial indicator readings:To ensure perfect alignment, dial readings must be carefully recorded.Write down Rim readings for Adjustable (i.e motor) and Stationary (i.e pump) machines.

Dial indicator readings

Applying Validity Rule:Applying validity rule is very important to check your readings, errors in readings will effect the results of your alignment calculations Top reading + bottom reading (must equal to)Left reading + Right reading

The allowable difference should not exceed 0.001″

Rim readings check: Face readings check:

T+P= 0 + (-7) = -7L+R= (-14) + 7 = -7

T+P= 0 + 4 = +4L+R= +10 + (-6) = +4

Calculations to be done:In these calculations you will cancel the amount of indicator bar sag and zero the (Top and Right) readings, then write down the net results after all calculations as following:

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Calculations to be done: Net results after all calculations:

Data Analysis ExampleLogically analyze the above results as following:

Vertical AnalysisAdjustable Machine is Lower by 2 The Face Gap is 4 wider at Top

Horizontal AnalysisAdjustable Machine is 10.5 to LeftThe Face Gap is 16 wider at Left

Vertical solutionDraw the graph of vertical solution based on the data analysis:


CALCULATIONS FOR (VERTICAL):-Mathematically find the values of X and Y:

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(X / 10) = (0.004 / 4)X = 0.010IB = 0.010 + 0.002 = 0.012"(Y / (10+30)) = (0.004 / 4)Y = 0.040OB = 0.040 + 0.002 = 0.042"


Add IB 0.012" (Add 0.012" of shims from the IB foots of the adjustable machine).Add OB 0.042" (Add 0.012" of shims from the OB foots of the adjustable machine).

Horizontal solutionDraw the graph of horizontal solution based on the data analysis:



(X / 10) = (0.016 / 4) X = 0.040 IB = 0.040 + 0.0105 = 0.0295" (Y / (10+30)) = (0.016 / 4) Y = 0.16 OB = 0.16 + 0.0105 = 0.1495


PUSH IB 0.0295˝ TOWARDS LEFT.PUSH OB 0.1495˝ TOWARDS LEFT.

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Three Indicators method (solved Example):Draw a simple diagram in you alignment sheet to show how the dial indicators are fixed, and the distances of inner and outer boards (IB, OB).


Dial indicator readings:To ensure perfect alignment dial readings must be carefully recorded.Write down Rim and Face readings. Face reading taken by two indicators in one time. Zero both indicators at Top and Bottom, then turn them half rotation and record both readings to Top and Bottom of the circle. Remember (two indicators on face will terminate the error may occur from the axial movement of the shaft.

Dial indicator readings

Calculations to be done:In these calculations you will cancel the amount of indicator bar sag and zero the (Top and Right) readings, then write down the net results after all calculations as following:

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Calculations to be done Net results for all calculations

To get the net results for all calculations you have to Zeros Top and Right sides as following:Net Reading at Bottom = (B-T)/2 = (+0.004 - (-0.010))/2 = +0.007Net Reading at Left = (L-R)/2 = (-0.008 - (+0.010))/2 = - 0.009

Data Analysis:Logically analyze the above results as following:

Vertical AnalysisAdjustable Machine is Lower by 0.004The Face Gap is 0.007 wider at Top

Horizontal AnalysisAdjustable Machine is 0.01 to Right

The Face Gap is 0.009 wider at Left

Vertical solution:Draw the graph of vertical solution based on the data analysis:

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CALCULATIONS FOR (VERTICAL): -Mathematically find the values of X and Y:

(X / 15) = (0.007 / 4)X = 0.0263IB = 0.0263 + 0.004 = 0.030˝(Y / (15+40)) = (0.007 / 4)Y = 0.0963OB = 0.0963 + 0.004 = 0.100˝


Add IB 0.030" (Add 0.016" of shims at the IB foots of the adjustable machine).Add OB 0.100" (Add 0.016" of shims at the OB foots of the adjustable machine).

Horizontal solution:Draw the graph of horizontal solution based on the data analysis:



(X / 15) = (0.009 / 4)X = 0.0338IB = 0.0338 + 0.010 = 0.0438˝

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(Y / (15+40)) = (0.009 / 4)Y = 0.1237OB = 0.1237 + 0.010 = 0.1337˝

Actions to be taken for Horizontal:

Push IB 0.0438" (Push the amount of 0.0438" at the IB foots of the adjustable machine towards left).

Push OB 0.1337" (Push the amount of 0.1337" at the OB foots of the adjustable machine towards left).

BEST REGARDSFALAH ALHUMRANI

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Alignment Calcs