Centralized alignment management system

• US 5,621,655 A
• Filed: 02/01/1995
• Issued: 04/15/1997
• Est. Priority Date: 06/03/1993
• Status: Expired due to Term

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Inventors: King, Willie T., Piety, Kenneth R., Nower, Daniel L.
• Primary Examiner(s): Voeltz, Emanuel T.
• Assistant Examiner(s): KEMPER, MELANIE A
• Application Number:
  US08/382,270
• Time in Patent Office: 804 Days
• Field of Search: 364/507, 364/508, 364/506, 364/551.01, 364/580, 364/474.34, 364/474.35, 364/474.37, 73/460, 73/462, 73/459, 356/400, 356/153, 250/231.16, 250/231.18, 250/561, 33/228
• US Class Current: 700/279
• CPC Class Codes: G01B 21/24 for testing alignment of axes
• CPC Class Codes: G01B 5/25 for testing the alignment of axes

Abstract

A system for managing the alignment of a plurality of machine sets includes a portable alignment analyzer for calculating machine moves tending to bring the shafts of a machine set into alignment, and a base computer. A database of alignment documentation for the machine set is maintained in the base computer, the database including alignment fixture setup data, machine dimensions and tolerances, by way of example. A data link at least periodically enables communication between the base computer and the portable alignment analyzer. When the data link is active, alignment documentation for the machine set may be selectively Loaded into the portable alignment analyzer, and measured misalignment data may be selectively Dumped to the base computer for storage in the database. The system allows previously entered and stored machine-specific setup information to be used for a current alignment job, requiring only minor changes in the field.

Claims

1. A shaft alignment system comprising:

a base computer having a memory, a data port, and an input device,

alignment documentation corresponding to at least one alignment job residing in a data base in the memory of the base computer,

a portable alignment analyzer having memory, a data port, and an input device,

a data link for communicating between the base computer data port and the analyzer data port,

means for transferring the alignment documentation from the data base in the memory of the base computer, through the data port of the base computer, through the data link, through the data port of the analyzer, and into the memory of the analyzer,

means for editing the alignment documentation transferred to the analyzer, while the alignment documentation is in the analyzer, and means for reconfiguring the analyzer in automated response to the alignment documentation stored in the analyzer'"'"'s memory to produce a reconfigured analyzer.

2. The shaft alignment system of claim 1 wherein the analyzer further comprises:

the memory having a stored job area and a current job area,

means for transferring the alignment documentation corresponding to one alignment job from the stored job area to the current job area of the memory of the analyzer,

the means for reconfiguring the analyzer for further reconfiguring the analyzer in automated response to the alignment documentation in the current job area,

means for acquiring a first set of alignment measurement s from an alignment fixture having measurement means attached to first and second rotating shafts,

means for calculating alignment adjustments based on the alignment measurements, the configuration of the analyzer, and the alignment documentation, and

means for transferring the alignment documentation from the current job area to the stored job area.

3. The shaft alignment system of claim 2 wherein the reconfigured analyzer further comprises:

means for taking a second set of alignment measurements in response to an alignment method variable, and

means for acquiring the second set of alignment measurements into the current job area of the memory of the analyzer as a part of the alignment documentation stored there.

4. The shaft alignment system of claim 2 wherein the reconfigured analyzer further comprises:

means for acquiring data from the measurement means via the analyzer data input device if a fixture configuration variable indicates that the measurement means has no other data communication option,

means for acquiring data from the measurement means via a cable if the fixture configuration variable indicates that the measurement means communicates via a cable, and

means for acquiring data from the measurement means via an infrared link if the fixture configuration variable indicates that the measurement means communicates via an infrared link.

5. The shaft alignment system of claim 2 wherein the reconfigured analyzer further comprises:

the means for calculating for further performing calculations based on a combination reverse dial alignment procedure if a fixture configuration variable indicates that a combination alignment fixture is to be used and an alignment method variable indicates that a reverse indicator method is to be used,

the means for calculating for further performing calculations based on a general reverse dial procedure if the fixture configuration variable indicates that a general fixture is to be used and the alignment method variable indicates that a reverse indicator method is to be use, and

the means for calculating for further performing calculations based on a face-and-rim alignment procedure regardless of the setting of the fixture configuration variable if the alignment method variable indicates that a face-and-rim alignment method is to be used.

6. The shaft alignment system of claim 2 wherein the reconfigured analyzer further comprises:

means for acquiring data from a combination alignment fixture if a fixture configuration variable indicates that a combination alignment fixture is to be used, and

means for acquiring data from a general fixture if the fixture configuration variable indicates that a general fixture is to be used.

7. The shaft alignment system of claim 2 wherein said reconfigured analyzer further comprises

means for acquiring a second and a third set of data from the fixture if an alignment method variable indicates that a three point method is to be used.

8. The shaft alignment system of claim 2 wherein the reconfigured analyzer further comprises:

the means for calculating for further operating on data taken in-phase if a fixture configuration variable indicates that the measurement means will take the data in-phase, and

the means for calculating for further operating on data taken out-of-phase if the fixture configuration variable indicates that the measurement means will take the data out-of-phase.

9. The shaft alignment system of claim 1 further comprising:

an alignment fixture having an attachment means, and a measurement means for producing alignment measurements corresponding to offset and angularity between first and second rotating shafts which are coupled together with a coupling,

means for acquiring the alignment measurements into the memory of the analyzer as a part of the alignment documentation, and

means for calculating alignment adjustments based on the alignment measurements, the configuration of the analyzer, and the alignment documentation.

10. The shaft alignment system of claim 1 further comprising:

means for transferring the alignment documentation from the memory of the analyzer, through the data port of the analyzer, through the data link, through the data port of the base computer, and into the data base in the memory of the base computer.

11. The system of claim 1 wherein the alignment documentation further comprises sag variables indicating the deflection and height of mounting means which mount the measurement means to the fixture.

12. The system of claim 1 wherein the alignment documentation further comprises a move variable indicating which one of the first and second shafts can be moved relative to the other, and which is immobile.

13. The system of claim 1 wherein the alignment documentation further comprises a rotation direction variable indicating the direction in which the shafts rotate.

14. The system of claim 1 wherein the alignment documentation further comprises an orientation variable indicating the vantage point from which other variables, such as the rotation direction variable, are referenced.

15. The system of claim 1 wherein the alignment documentation further comprises thermal growth variables indicating the horizontal and vertical shift experienced by the first and second shafts as they heat up during rotation.

16. The system of claim 1 wherein the alignment documentation further comprises an alignment method variable indicating which set of a plurality of alignment equations are to be used during the alignment calculations.

17. The system of claim 1 wherein the alignment documentation further comprises a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure.

18. The system of claim 1 wherein the alignment documentation further comprises fixture size variables indicating the size of the fixture to be used during the alignment procedure.

19. The system of claim 1 wherein the alignment documentation further comprises machine dimension variables indicating locations of points of adjustment, and locations of reference points on the first and second shafts.

20. The system of claim 1 wherein the alignment documentation further comprises a speed variable indicating the speed at which the first and second shafts rotate.

21. The system of claim 1 wherein the alignment documentation further comprises notes variables containing comments input by a technician.

22. The system of claim 1 wherein the alignment documentation further comprises tolerances variables indicating maximum allowable differences in horizontal and vertical offset and angularity between the first and second shafts.

23. The system of claim 1 wherein the alignment documentation further comprises efficiency variables which can be used by the analyzer to calculate the effect which the alignment procedure has had on the efficiency of the rotating shafts.

24. The system of claim 1 wherein the alignment documentation further comprises dial orientation variables indicating the position of the measurement means.

25. The system of claim 1 wherein the alignment documentation further comprises a machine description variable indicating the type of equipment in which the rotating shafts operate.

26. The system of claim 1 wherein the alignment documentation further comprises a station variable indicating the location of the equipment in which the rotating shafts operate.

27. A shaft alignment system comprising:

a base computer having a memory, a data port, and an input device,

alignment documentation corresponding to a plurality of alignment jobs residing in a data base in the memory of the base computer, said alignment documentation further comprising;

a rotation direction variable indicating the direction in which the shafts rotate;

an alignment method variable indicating which set of a plurality of alignment equations are to be used during the alignment calculations;

a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure;

machine dimension variables indicating locations of points of adjustment and locations of reference points on the first and second shafts;

tolerances variables indicating maximum allowable differences in horizontal and vertical offset and angularity between the first and second shafts; and

a machine description variable indicating the type of equipment in which the rotating shafts operate;

a portable alignment analyzer having memory, a data port, and an input device, the memory further comprising a stored job area and a current job area,

a data link for communicating between the base computer data port and the analyzer data port,

means for transferring the alignment documentation from the data base in the memory of the base computer, through the data port of the base computer, through the data link, through the data port of the analyzer, and into the stored job area of the memory of the analyzer,

means for transferring a portion the alignment documentation corresponding to one alignment job from the stored job area to current job area of the memory of the analyzer,

means for performing alignment calculations, and

means for reconfiguring the operation of analyzer in automated response to the alignment documentation stored in the current job area of the memory of the analyzer so that the alignment calculations automatically correspond to the direction in which the shafts rotate, the set of alignment equations which are to be used during the alignment calculations, the type of fixture which is to be used during the alignment procedure, the locations of points of adjustment, the locations of reference points on the first and second shafts, and the type of equipment in which the rotating shafts operate.

28. A shaft alignment method comprising:

providing a base computer having a memory, a data port, and an input device, entering alignment documentation corresponding to at least one alignment job into a data base residing in the memory of the base computer using the input device,

providing a portable alignment analyzer having memory, a data port, and an input device, the memory further comprising a stored job area and a current job area,

communicating between the base computer data port and the analyzer data port using a data link,

transferring the alignment documentation from the data base in the memory of the base computer, through the data port of the base computer, through the data link, through the data port of the analyzer, and into the stored job area of the memory of the analyzer,

transferring the alignment documentation corresponding to one alignment job from the stored job area to the current job area of the memory of the analyzer,

editing the alignment documentation in the current job area of the analyzer,

reconfiguring the operation of the analyzer in automated response to the alignment documentation in the current job area,

providing an alignment fixture having an attachment means, and a measurement means for producing measurements corresponding to offset and angularity between first and second rotating shafts which are coupled together with a coupling,

connecting the fixture to the first and second shafts using the attachment means, rotating the first and second shafts,

taking alignment measurements on the first and second shafts, corresponding to at least three different rotational orientations, using the measurement means,

acquiring the alignment measurements into the current job area of the memory of the analyzer,

supplementing the alignment documentation stored in the current job area with the alignment measurements,

calculating alignment adjustments using the analyzer, based on the alignment measurements, the configuration of the analyzer, and the alignment documentation,

moving one of the first and second shafts relative to the other based on the calculated alignment adjustments,

transferring the alignment documentation, which has been edited and supplemented, from the current job area to the stored job area,

transferring the alignment documentation from the stored job area of the memory of the analyzer, through the data port of the analyzer, through the data link, through the data port of the base computer, and into the data base in the memory of the base computer.

29. The method of claim 28 further comprising:

the steps of transferring the alignment documentation further comprising;

transferring an alignment method variable indicating which set of a plurality of alignment equations are to be used during the alignment calculations, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to the alignment method variable to perform the additional steps of;

taking a second set of alignment measurements on the first and second shafts after moving one of the first and second shafts relative to the other, to confirm the affectivity of the alignment process, and

acquiring the second set of alignment measurements into the current job area of the memory of the analyzer as a part of the alignment documentation stored there, before transferring the alignment documentation from the current job area to the stored job area.

30. The method of claim 28 further comprising:

the steps of transferring the alignment documentation further comprising;

transferring a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to the fixture configuration variable by;

configuring to acquire data via the analyzer data input device if the fixture configuration variable indicates that the measurement means has no other data communication option,

configuring to acquire data via a cable if the fixture configuration variable indicates that the measurement means communicates via a cable, and

configuring to acquire data via an infrared link if the fixture configuration variable indicates that the measurement means communicates via an infrared link.

31. The method of claim 28 further comprising:

he steps of transferring the alignment documentation further comprising;

transferring an alignment method variable indicating which set of a plurality of alignment equations are to be used during the alignment calculations, and

transferring a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to a combination of the fixture configuration variable and the alignment method variable by;

configuring for a combination reverse dial alignment procedure if the fixture configuration variable indicates that a combination alignment fixture is to be used and the alignment method variable indicates that a reverse indicator method is to be used,

configuring for a general reverse dial procedure if the fixture configuration variable indicates that a general fixture is to be used and the alignment method variable indicates that a reverse indicator method is to be use, and

configuring for a face-and-rim alignment procedure regardless of the setting of the fixture configuration variable if the alignment method variable indicates that a face-and-rim alignment method is to be used.

32. The method of claim 28 further comprising:

the steps of transferring the alignment documentation further comprising;

transferring a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to the fixture configuration variable by;

configuring to acquire data from a combination alignment fixture if the fixture configuration variable indicates that a combination alignment fixture is to be used, and

configuring to acquire data from a general fixture if the fixture configuration variable indicates that a general fixture is to be used.

33. The method of claim 28 further comprising:

the steps of transferring the alignment documentation further comprising;

transferring an alignment method variable indicating which set of a plurality of alignment equations are to be used during the alignment calculations, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to the alignment method variable by;

configuring to acquire three sets of data from the fixture if the alignment method variable indicates that a three point method is to be used, and

configuring to acquire four sets of data from the fixture if the alignment method variable indicates that a four point method is to be used.

34. The method of claim 28 further comprising:

the steps of transferring the alignment documentation further comprising;

transferring a fixture configuration variable indicating which type of fixture is to be used during the alignment procedure, and

the step of reconfiguring the operation of the analyzer further comprising reconfiguring the analyzer in automated response to the fixture configuration variable by;

configuring to calculate alignment adjustments using data taken in-phase if the fixture configuration variable indicates that the measurement means will take the data in-phase, and

configuring to calculate alignment adjustments using data taken out-of-phase if the fixture configuration variable indicates that the measurement means will take the data out-of-phase.