Monition Ltd

Welcome to GearboxAlignment.co.uk from Monition Ltd

The Fixturlaser XA Gearbox Alignment System can be upgraded with a range of Software Programs and specially designed Fixtures to tackle the most demanding gearbox alignment measurement and correction tasks.

Click on the following links for further information: -

• Offset Gearbox Shaft Alignment
• Offline to Running Gearbox Alignment
• Machine Train Gearbox Alignment
• Alignment of Gearbox Spacer Shafts
• Gearbox Hot Check Alignment Measurement

Offset Gearbox Shaft Alignment

Offset, or Cardan shafts are an excellent way of power transmission, when it is impossible to configure two machines, such as a motor and gearbox, in line. There is the general misunderstanding, however, that offset mounted cardan driven gearboxes do not require precise alignment.

A misaligned cardan shaft rotates with an uneven angular speed over a full turn. This generates vibrations with harmful forces throughout the drive chain, which will cause adverse load and wear on gearbox components. The risks with misaligned cardan shafts in a drive train are similar to other misaligned machines, with the addition of the safety risks for damages caused by a broken cardan shaft.

The Fixturlaser XA Gearbox Alignment System combined with the Offset Shaft Alignment fixture expansion kit makes precision alignment of offset mounted gearboxes possible. The payback time for an Offset Gearbox Alignment system such as this is very short considering the costs for replacing a broken cardan shaft, or a damaged motor and gearbox assembly.

The XA Offset Gearbox Alignment Expansion Brochure can be downloaded by clicking here

ABOVE: Fixturlaser Offset fixtures for alignment measurement of offset Gearboxes. The Expansion kit includes the cardan shaft extension arms, specially designed 'turrets' for mounting the XA System laser heads, along with a range of fixing screws, all contained within a heavy-duty carry case.

Benefits of the Fixturlaser XA Offset Gearbox Shaft Expansion Kit:

• Allows for a fast and accurate alignment measurement of offset mounted gearbox shafts
• The fixtures are equipped with point laser, hence no need to use the alignment system during the set up of fixtures
• Inclinometers in each laser unit will locate the right position of the lasers

ABOVE: Screenshot for the Fixturlaser XA Offset Gearbox Shaft Alignment program - the colour LCD touchscreen and live data screen instantly displays movement of the laser or shafts.

Benefits of using the Fixturlaser XA Gearbox Alignment System with the Offset Expansion upgrade to Conduct Offset gearbox shaft Alignment Measurement:

• Reduced wear on gearboxes, motors, bearings and cardan joints.
• Full documentation of alignment measurement result.
• Minimised risk for cardan shaft breakdown.

Offline to Running Gearbox Alignment

Fixturlaser OL2R - Offline to Online Running Application for express alignment measurement of Dynamic Movements in gearbox position.

If your process operates within large temperature differences or other conditions affecting gearboxes and other machinery, you might have a need to measure the dynamic movements. This is indicated by a high level of vibrations, persisting even after having performed gearbox alignment in cold condition. After measuring the dynamic movements of the motor and gearbox in cold as well as in hot condition, the calculations are made and the target values for true running alignment are obtained.

Fixturlaser OL2R (Off-line-to-Running) is the perfect tool for measuring gearbox shaft movements due to e.g. Thermal Growth, Process Forces, Background Vibration Levels, etc. The Fixturlaser XA is the only system on the market that includes this application for advanced gearbox alignment.

OL2R, a gearbox and motor alignment measurement accessory for the Fixturlaser XA Gearbox Alignment System, makes it possible to receive the exact compensation data required for a precise alignment of gearboxes and motors by making it possible to measure in both hot and cold conditions.

Fixturlaser OL2R (off-line-to-running) fixtures combined with the Fixturlaser XA gearbox alignment system puts a stop to guesswork in gearbox position-measurement and alignment. With OL2R, changes in gearbox shaft alignment are mirrored by changes in position of the OL2R brackets. By simply measuring and documenting the initial position of the brackets, the actual changes in the alignment of the gearbox and motor shafts and position can be measured as alignment positions change.

To download our Brochure for the Gearbox Alignment OL2R system click here

Factors affecting Gearbox Dynamic Movements:

• Thermal growth
• Pipe strain
• Movements in foundations
• Surrounding machines and processes
• Air pressure, pressure in liquids, etc.
• Sun light, wind and other environmental factors
• Cooling systems (fans, oil cooling, etc.)

Gearbox Alignment Measurements:

• Measurement of gearbox and motor position in operating and cold condition
• Gives you the real alignment compensation values in a fast, easy and precise way
• Calculates the correct shaft offset and angularity values to be used during the gearbox shaft alignment process

Features:

• The XA: OL2R system makes it possible to calculate exact and precise offset values for a specific motor and gearbox assembly

Benefits:

• Reduced gearbox shaft vibration levels
• High availability of operating plant
• Trouble free operation
• Faster installation for gearbox and motor refits
• Minimised gearbox downtime
• Reduced energy consumption
• Reduced gearbox maintenance cost
• Documentation of gearbox installations and reconstructions

Machine Train Gearbox Alignment

A machine train consists of several units, such as a motor, gearbox and pump, with rotating shafts connected to one another. Conducting the alignment measurement of machine trains with gearboxes can be difficult, but with the Fixturlaser XA Gearbox Machine Train Expansion Kit you will be surprised how convenient it can be.

The Fixturlaser Machine Train XA Expansion Kit is a software upgrade for the standard XA Gearbox Alignment system - no additonal fixtures or equipment is required to conduct machine train gearbox alignment.

The Machine Train Expansion Kit includes:

• 3-D Macromedia® Flash™ animations which will guide you through the machine train and gearbox alignment measurement process
• The software produces a large color display which gives you a clear overview of the whole machine configuration
• Shows both the horizontal and vertical view
• Has a unique “minimal moves” function, which automatically helps you to determine the best reference machine in order to make as few and small changes as possible

ABOVE: Fixturlaser XA Gearbox Machine Train Software screenshots

The Fixturlaser Machine Train XA software guides the user throughout the alignment process. After the alignment, the result screen showing the whole machine configuration can be transferred to external units via a USB stick.

Alignment of Gearbox Spacer Shafts

Spacer Shaft is a function for measuring misalignment between diaphragm couplings, i.e. checking for misalignment in two coupling planes. As shown below, the measurement results are displayed as two angular errors in the horizontal and vertical view. If you wish, you can then proceed directly to the gearbox alignment process.

The Gearbox Spacer Shaft alignment function is a software upgrade for the standard XA gearbox alignment system. No additonal fixtures are required to conduct alignment of gearbox spacer shafts.

Gearbox Hot Check Alignment Application

The Gearbox Hot Check Application offers the ability to record a gearbox and motor shaft alignment measurement from a machine whilst cold, and to record an alignment measurement quickly after a machine has been run-up to operating temperature and then stopped.

Hot Check allows you to retrieve the two saved measurements, one in the gearbox’s cold condition and one in its hot condition, and to calculate the difference between the two measurements. This will give you an indication of the true alignment condition of the gearbox and motor by taking into account the differences in hot and cold shaft alignment due to thermal expansion.

Fixturlaser offer a range of Advanced Gearbox Alignment upgrades to enable the XA Gearbox Alignment System to tackle the most demanding and complex of gearbox alignment tasks. Monition Ltd – Fixturlaser UK is the official main distributor for Fixturlaser Laser Gearbox Alignment systems here in the UK. For additional information, to discuss the system range and to obtain details of current prices, please telephone Monition on 01909 722000. Alternatively you can email us at sales@monition.com.