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Alignment Definition
Shaft alignment is a process in which machines can be positioned in a manner that when transferring
power from shaft 1 to shaft 2 the rotation axes of these shafts are collinear as the machine is running at its
normal conditions. An example of machines which need shaft alignment is the motor and hydraulic pump.
The exception to this definition is the gear coupling which requires some degree of misalignment to
Alignment Measurement.
Shaft alignment has to be measured and subsequently corrected, and therefore it is necessary to have a
method for quantifying and proofing alignment condition. The traditional method of shaft alignment is
by use of dial indicator. It is done by taking readings of the dial indicator at the coupling face or by
taking position values at the machine feet. The values obtained from both of these methods depend on the
dimensions of the particular machines. Since some various methods are used to mount dial indicators,
there is a likelihood of problems when comparing measurements and when applying tolerances. A more
convenient way is to describe the condition of shaft alignment in terms of angle, offset and a gap in the
vertical side view and horizontal plan view. By using this approach, there are four values which can be
Figure 2: angularity a.
Angularity is used to describe the angle between the two axes of rotation.
Figure 3: angularity b.
Angularity can be described in terms of: degrees or mrads slope in mm/ m or thousandths/inch. This latter
approach is useful because the product of angularity and coupling diameter will result in an equivalent
gap difference on the rim coupling. Thus the angle is oftenly described in gap per diameter. The gap
itself becomes more meaningful when divided by the diameter. This diameter is oftenly referred to as
working diameter and sometimes known as coupling diameter. Any value convenient can be used as the
working diameter.
Figure 3: working diameter, gap and angle relationships.
For a 152.4 mm coupling which is open at the top by a value 0.127 mm will give angle of 0.83 mrads.
For a working diameter of 254 mm the corresponding gap will be 0.21082 mm.
The distance between rotating axes at a given point is known as the offset. As illustrated in the following
figure, the offset value will vary depending on the location at which the distance from one shaft rotation
axis to the other is measured. Off set can also be determined in mm or thousandths inch at the center of
coupling if there are no further instructions given. This definition is applicable to the short flexible
couplings but for spacer couplings the offset is determined at the coupling power transmission planes.
These are the couplings in which flexible element axial length is equal or smaller than diameter of
coupling. Because the alignment entails combination of offset and angularity, then it is necessary to
correct the machine in both horizontal and vertical planes to obtain four values which are essential for
Vertical offset
Horizontal offset.
Figure 6: sign convection and notation.
Spacer shafts
These are the shafts used in a when significant alignment variations are expected during machine
operation for instance as a result of thermal growth. Angular change which occurs at the end of the spacer
shaft will be small through the spacer shaft length. Four angles are necessary when describing the
alignment condition. These angles can be determined by measuring the angle existing between the axis of
rotation of the spacer shaft and axis of rotation of the respective machine. These angles are:
i. Vertical angle
ii. Horizontal angle
iii. Vertical angle
i. Vertical offset B
The above offsets are determined between the axes of rotation of the machine shaft at the end of the
The following diagram illustrates the relationship between various angles and offsets.
Trial and error method is used where shaft float and bracket sag are ignored. It is done by rotating one
shaft during the measurement which adds more errors to the alignment resulting from run-out of coupling
The machine coupling is clocked using the rim and face indicators. The indicators ae set to 12 oclock and
the machine shaft to be aligned is perpendicularly to make a half turn to the 6 oclock position. The
nearest foot to the coupling is either lowered or raised by a given amount which is equal to half reading of
the indicator reading. Shims are placed repeatedly far from the coupling under the foot up to a time when
the face indicator readings remain unchanged when the shaft is rotated. Similarly, at 3 oclock position
the indicators are zeroed and then rotated to the position of 9 oclock for horizontal correction. This
method is inefficient as it results to significant errors at the planes of the transmission coupling.
b) Calculation method.
The device used to measure alignment is a dial indicator. The device points or indicates on the dial face
the increments marked. By pushing the foot in to the body enables the dial to rotate in clockwise
direction. The total number of indicator marks made by the hand is equal to the distance that the hand
travelled while it was pushed into the body. Similarly the dial indicates the same travel distance when the
foot travels out of the body. When the foot travels in there is positive dial count and negative dial count
After finishing mounting, the shafts are rotated together and then the dials reading are read at position
12:00, 6:00, 3:00, and finally at position 9:00. Formulas for calculating alignment corrections
R 6 R 0 RS
VO
2
F6 F0
VA
Dia
R9 R3
HO
2
F9 F3
HA
Dia
Where:
S-span between measurement plane and machinefoot.it is either a negative or positive value.
The clockwise is given by looking in the direction along shaft from MTBM to STAT.
( F 6 F 0 FS ) *s R0 R6 RS
Shim
dia 2
( F 9 F 3) *s R3 R9
Move
dia 2
The position of dial indicators at 12:00 is set to zero and read at 6:00, the shim calculations will be:
( F 6 FS ) * S R6 RS
Shim=
dia 2
If the result is positive then more needs need to be added while if the result ids negative then it means
remove shims. By setting the dial indicators to zero at position 3:00 and then reading at position 9:00 the
If the result is positive it means that move towards position 3:00. If the result is negative it means move
towards position 9:00. The sum of the readings at 3 and 9 oclock should be equal to sum of the readings
at the 12 and 6 oclock readings. The major source of error in this method is the spanner bar slag. It can
cause misalignment of the machine shaft. To compensate for the slag, it is measured and then it is added
a) Calculation method.
This is the most advanced method of indicator shaft alignment. The American petroleum institute
After mounting, the dials are read at 12:00, 3:00, 6:00 and 9:00 when the rotating shafts are rotated
simultaneously. The misalignment at the center of coupling is determined using the following formulas.
0.90
0.45mm
2
Where:
SO= reading of the left rim at position 12 oclock
The corrections for the right machine feet are calculated as follows:
If the result is positive add shim and if negative it means you need to remove shim.
oclock.
sR = distance between coupling center and the right feet of the mce
Setting the dial indicators to zero at position 12 oclock and reading at position 6 oclock the calculations
HO
S 9 S 3 (S 9 S 3 M 9 M 3)* C
2 2D
HA
S 9 S 3 M 9 M 3
2D
For positive results shim is added and for negative results shim is removed.
Setting the dial indicators to zero at position 3 oclock and then reading at position 9 oclock the
When the results are positive then move towards position 3 oclock and for negative results move towards
position 9 oclock.
b) Graph method.
In this method a graphical solution is used to avoid numerous mathematical computations and help
engineers resolve alignment problems and to achieve move and shim corrections.
For bracket sag the total indicator readings (TIR) after correction are:
Figure 24 b.
Values for the true shaft offset are obtained by dividing the TIR values by 2.
0.70
Offset S= 0.35mm -
2
1.40
Offset M= 0.70mm .
2
Figure 14 c: graph 1.
The right machine is the machine to be moved (abbreviated as MTBM). At position 12 oclock both
indicators are set to zero. The view direction is from MTBM to the machine at rest. The shaft needs to be
rotated through angle of 1800 in the same direction as the normal shaft angle of rotation. The dial
readings are taken and recorded. The following example can be considered:
Figure 14 d.
TIR values are divided by 2 in order to calculate the true offset values of the shaft in the dial indicator
planes.
0.50
Offset S= 0.25mm
2
0.90
Offset M= 0.45mm
2
Figure 14 e.
The amount of sag is measured by mounting the entire fixtures on a straight pipe. The fixtures are
adjusted until the distance between the brackets is the same as when they will be mounted on the
machine. Also the indicators need to be positioned the same way they will be mounted on the machine.
When the indicators are held at position 12 oclock the dials are zero. The pipe is then rotated until the
indicators are at position 6 oclock. The readings are taken and recorded.
Factors considered before alignment of shaft and coupling.
1. Indicator bracket sag-this factor should be determined before actual shaft alignment readings are
2. Internal friction/hysteresis: this is necessary because sometimes the gauge needs some tapping to
3. Readings errors-errors can occur for example when readings are taken under difficult conditions
4. 1/100 mm resolution-rounding error of up to 0.005 mm can occur when taking the readings. The
5. Mechanical linkage play-slight plays in linkage may end up resulting in reading values with
errors.
6. Axial shaft play- this factor will alter the face readings recorded to determine angularity unless
7. Titled dial indicators-sometimes reading is lost when the gauge is not perpendicularly mounted to
A shaft is said to be straight in a given length when the distance variation of points from two
perpendicular planes to each other and parallel to the direction of the shaft remains in the specified
tolerance limits. Straightness tolerance can be used to control straightness of cylindrical surface, planar
surface and a center line or center plane. An axis is perfectly straight when all points of an axis are on a
straight line. Straightness control (u) shows by how much an axis of a certain part may vary from
reference ideal straight line. The following procedure can be followed to locate and inspect an axis
i. The part has to be placed in apparatus so that the ends of the part are held and allow
ii. On opposing sides dial indicators are mounted to locate median point.
iv. Average of the median points for each angle is calculated to determine the center
point at point x.
v. The center points are used to plot graph in three dimensions to create the axis.
vi. If it is found that the axis is within the tolerance zone then it will be in the required
specifications.
Figure 15: straightness inspection.
Well aligned machinery will have many benefits. Some of the benefits are:
It reduces cost of operation by reducing cost spare parts used like bearings and seals.
Reference
1. http://www.engineeringessentials.com/gdt/straightness/straightness-axis.htm
2. An engineers guide to shaft alignment, vibration analysis, dynamic balancing and wear debris
analysis.
4. http://www.maintenancetechnology.com/2002/12/understanding-shaft-alignment-basics.