What is Machine Alignment, and Why is it Necessary?

Machine alignment is the process of aligning rotating shafts on horizontal and vertical planes; if these shafts are not aligned correctly, it causes a machine misalignment.

There are two types of machine misalignments: unparalleled shafts and angular misalignments. These misalignments can happen separately or simultaneously. Both types of misalignments are problems with a machine’s shaft.

Unparalleled shafts are offset vertically (vertical offset misalignment) or horizontally (horizontal offset misalignment). Angular misalignments are shafts at the wrong angle on the horizontal plane (horizontal angle misalignment) or the wrong angle on the vertical plane (vertical angle misalignment).

Solving horizontal misalignment requires repositioning center lines by moving the machine side to side; vertical misalignment requires adding or removing shims from the feet.

A number of reasons, such as human error, pipe strain, thermal expansion, and shaft deformation, cause these misalignments.

Knowing the problems that different types of machine alignment create enables personnel to identify faults fast and implement the right fixes. Every kind of misalignment produces varying symptoms and calls for different approaches to treatment. Early detection of these trends keeps small problems from turning into big failures.

Equipment operators should look for signs of misalignment during routine inspections. High noise levels, unusual vibration patterns, or variations in operating temperature are frequently indicators of alignment issues. Equipment longevity is increased, and optimal performance is maintained by routine monitoring.

When discussing how machine alignment is conducted, there are two sides to the coin. Some alignment techniques produce successful results, and some add to the prevalence of misalignment. For instance, some manufacturers use flat devices or laser technology for securing parallelism, while others use methods that find misalignment rather than alignment.

Some of these methods are proactive and prevent misalignment, while others are reactionary to fixing misalignment. Let’s review some common methods technicians use.

Proactive machinery alignment measures are methods that prevent misalignment, while reactive machinery alignment fixes the misalignment after the fact.

Choosing proactive measures is always better than reactive ones. With reactive machinery alignment methods, the damage is already done when a machine is misaligned—that is irreversible. Proactive machinery alignment saves time and money by preventing misalignment before it can damage your machine or process.

Laser alignment, thermography, and vibration analysis are all productive ways to achieve machine alignment; however, because they give data on the problem without the solution, these methods are sometimes only a reactive measure. On a shop floor where technicians are relying on subpar measuring methods to set up the machine in the first place, these methods are only a band-aid on the issue.

KEYENCE makes tools to assist with proactive machinery alignment, the XM and WM coordinate measurement machines (CMMs). These CMMs are handheld machinery alignment equipment that use GD&T inspection to determine alignment. The XM and WM work by touching their probes to the machine, collecting X, Y, and Z coordinates, and analyzing essential alignment data like parallelism, squareness, and position.

The XM and WM confirm machine alignment by showing you the exact coordinates of shafts, as well as defining parallelism for a perfect fit beyond what the naked eye can see. These devices require fewer than five steps and have no operator training. They are so simple that KEYENCE clients report handing CMMs out on the shop floor without technicians needing instruction. The XM can inspect a shaft up to 2 m horizontally and 1 m vertically; the WM aligns shafts as long as 25 m. Faster and more accurate machine alignment reduces labor costs and downtime and helps machines produce better parts, reducing scrap rates and increasing productivity.

Staying on top of your machine’s alignment before, during, and after manufacturing is the best way to prevent and fix misalignment quickly. Without it, you risk constantly repairing and replacing your machines while also suffering time loss from bottlenecks. Be a proactive machine alignment technician and study machine alignment all the time.

If your alignment process is reactive instead of proactive and is another hassle for your manufacturing plant, contact us today to learn about how KEYENCE’s machine alignment solutions can help you.