Precision engineering plays a critical role in modern manufacturing by ensuring the consistent production of high-quality products with minimal variation. Industries such as aerospace, aircraft automotive and medical rely on precision engineering to produce accurate components that meet or exceed quality and performance standards.
Effective precision engineering relies on the accurate measurement and alignment of machines, which is vital for smooth production performance, equipment longevity and quality output. Misalignment of machine components and subassemblies can place undue stress on equipment, leading to quality issues, shorter component life and even production machine failure. For example, if a machine is misaligned and running incorrectly, parts may be cut or machined in the wrong dimension, or with errors resulting in poor quality parts. Fabricated parts for rotating machinery may be out of specification and balance intimate ultimately failed in the field.
Types of Machine Misalignment
Misalignments are common in rotating equipment including:
- Shafts
- Drives
- Rollers
- Lathes
- Spindle
- Turbines
- Compressors
- Motors
- Pumps
- Bearings
Studies indicate that 90% of all rotating machinery operates outside of the manufacturer’s alignment tolerances. CNC machines, in particular, are susceptible to axis alignment issues, which can result in product defects. Regular calibration is necessary to ensure machine components are properly aligned and running correctly.
Misalignment Types
Two common types of misalignment are centerline (offset) and parallelism (angle) misalignment:
- Centerline misalignment. This occurs when the centerlines of two components or subassemblies, such as a rotating spindle, chuck or tool holder, are displaced from one another and do not align on the same centerline.
- This arises when the rotational axis of a part and movement axis of a tool are not parallel. Angular errors change with distance. The farther the tool, such as a chuck or spindle, is moved from the source, the greater the angular error.
A machine may exhibit both types of misalignments. For instance, when comparing the machine bed and tool axis, the chuck or spindle is likely to experience both offset and angular misalignment.
Laser Alignment
Laser alignment systems, such as Pinpoint’s Laser Microgage systems, are user-friendly, versatile and cost-effective tools that provide exceptional precision in industrial alignment. These systems employ a transmitter that projects a laser beam in a straight line and a receiver that measures offset and angular errors. In addition to displaying real-time alignment information, data from the laser systems can be downloaded onto laptops to calculate offset and angular errors, providing guidance on how to correct machine misalignments.
Pinpoint offers 2D and PRO versions of its advanced Laser Microgage alignment systems. Both capture precise measurements as small as 0.0001 (2.5 microns) up to distances of 165 feet across various alignment applications.
- Laser Microgage 2D. This system measures in two perpendicular axes simultaneously, addressing the complexities of alignment challenges. It can check for straightness, parallelism, flatness, squareness and other alignment requirements.
- The Laser Microgage PRO Plus. This model offers the same capabilities as the 2D but also utilizes smart technology to provide users with step-by-step instructions for completing alignment tasks. A smart display also allows users to view and store alignment measurements, run applications and upload data to a PC. The system offers wireless capabilities, enabling conductance of alignment tasks without the hassles of running cables and cords.
The Pinpoint Microgage Laser Alignment tools support precision engineering by checking the alignment of machine tools as part of preventative maintenance and during new installations. From machine shops to aircraft manufacturers, the Microgage systems are employed in a diverse range of industrial measurement and alignment tasks.
