Challenge
An electric motor manufacturer required precise alignment of a reduction gearbox. The gearbox design incorporated two electric motors and drive shafts that transmitted power to a single output shaft. Proper operation depended on accurate alignment of three internal bores through which the drive shafts would pass.
Because the gearbox casing had to be fully assembled during measurement, there was no physical access to the interior for conventional alignment tools. The manufacturer required a method capable of measuring the internal bore alignment with a high degree of accuracy under these constraints.
Solution
To align the three internal bores, Pinpoint Laser Systems engineers collaborated with the customer’s engineering team to develop a tailored alignment solution using Microgage laser alignment technology.
A Microgage cylindrical laser transmitter was mounted to a custom made fixture designed to locate securely within one of the internal bores. A Microgage two-axis receiver was mounted in a custom bracket attached to a handled bar, allowing it to be inserted sequentially into the remaining two bores while the gearbox remained fully assembled.
As the receiver was positioned in each bore, alignment data was transmitted to the Microgage Pro PLUS display. Using the capture program, engineers monitored real-time X and Y positional data to evaluate the relative alignment of all three bores. This configuration enabled continuous measurement and immediate feedback, allowing adjustments to be made with quantifiable, real-time data throughout the alignment process.
Results
The completed gearbox assembly achieved an alignment resolution of of 0.0001 inches and an alignment accuracy of 0.0005 inches, exceeding the precision attainable using conventional mechanical measurement methods.
The process significantly improved measurement repeatability and allowed alignment verification to occur immediately. Real-time feedback enabled rapid corrections, increasing overall efficiency and confidence in the final assembly.
System Capabilities
The alignment system utilized a Microgage PRO Plus 2-axis digital receiver capable of simultaneously measuring X and Y positional data. The setup maintained measurement accuracy within the enclosed gearbox and allowed for the collection of multiple data points to generate a quantitative alignment profile of the internal bores.
Conclusion
This custom alignment solution demonstrates the effectiveness of precision laser-based measurement for internal bore alignment in enclosed assemblies. By enabling accurate, repeatable measurement within a fully assembled gearbox, the process supported proper shaft alignment and overall gearbox performance.
Such measurement capability is applicable to gearbox manufacturing and other assemblies where internal alignment must be verified without direct physical access.
