Leveling and alignment of machinery and process equipment are essential for long-term performance, calibration, and accuracy. SLA’s highly trained technicians are experts in leveling and aligning machine bases, integrated production lines, rollers, conveyors, motors, shafts, couplings, bearings, and drives. Manufacturing industries such as automotive, printing, aerospace, metal stamping, injection molding, machining, and food processing require proper alignment and leveling to maintain production efficiency.

SLA’s Machine Alignment Services:

• Reduces Scrap and Waste
• Decreases Machine Downtime
• Improves Equipment and Process Line Efficiency
• Lowers Operating Costs

Select Laser Alignment Provides:

• Alignment, Inspections, and Analysis
• Advanced Tooling Including 3-Dimensional Metrology Tools—Laser Trackers, Laser Scanners, Measuring Arms
• Mechanical Services and Machine Installations

SLA will level and align injection mold machines, CNC lathes, tanks, extrusion lines, heat treating lines, conveyor packaging lines, and more.

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Rolling metal under tension, heat, and pressure transforms ingots, billets, blooms, and slabs into sheets and various profiles. At the same time, the precision alignment of the parts in your rolling mill will play a major influence on productivity and product quality, whether you are producing steel, aluminum, or other metal sheets or coils.

The machinery used in a rolling mill must withstand extreme conditions and lengthy durations of usage. Settling, vibration, abrasion, and even forklift strikes may all cause components to diverge from acceptable operating tolerances and parameters over time, leading to issues including misalignment, deterioration of roller surface cylindricity, bearing wear and tear, and more.

Roll and component precision alignment in a rolling mill is crucial to the quality of the finished product, the reduction of scrap, and the enhancement of operational efficiency, regardless of whether the process is hot rolling or cold rolling or what configuration the rolls are in.

Problems Resulting From Improper Alignment

Precision alignment is a critical factor in metal rolling mills, and any misalignment can result in several issues. One of the most significant problems is inconsistent or out-of-spec products. When the rolls are not correctly aligned, they can produce products that do not meet the required specifications, leading to wasted materials, time, and resources.

Besides that, misalignment can cause uneven rolling thickness, resulting in products with varying thicknesses that are unsuitable for their intended purposes. This issue can lead to tension problems, faulty rolling direction, excessive vibration, chatter, and reduced rolling speed, which eventually results in unplanned downtime and increased energy consumption.

Another problem caused by misalignment is higher scrap rates. When the rolls are not correctly aligned, they can produce scrap metal instead of usable products, leading to increased scrap rates and decreased efficiency. Misalignment can cause premature component wear and failure, such as rolls, bearings, and chocks, which results in costly repairs and replacements.

Innovative Tools and Technologies for Precision Alignment

The development of 3-dimensional precision measurement has benefited the rolling mill industry by allowing for the rapid, accurate, and thorough examination of rolling mill components previously impossible or impractical to achieve. In addition, modern metrology instruments are built to resist severe working conditions, making them perfect for metal rolling mills.

Meanwhile, our metrology experts can help rolling mills with various tasks by using several modern laser-based 3D measurements technologies, such as laser scanners, laser trackers, portable coordinate measuring arms, and the corresponding metrology software.

• Constructing and installing mill reference points.
• Inspecting the mill’s centerline.
• Alignment and parallelism of the rolls.
• Analysis of wear and roll profiles.
• Inspection of rails and pass line.
• Verification of chocks.
• Parallelism and location of platens.
• Motor and gearbox positioning.

Equipment Installation and Precision Alignment

One of the most common causes of misalignment in rolling mills is the result of improper alignment during equipment installation. The layout and location of critical components need pinpoint accuracy during installation. With the use of laser trackers, metrology experts may swiftly assess a space’s architecture, as well as get the accurate spatial placement of components and guide modifications throughout the installation process. Installation as a whole may be sped up, allowing for a shorter total time spent on the project. The same applies to component upgrades and rollovers.

Final Words

Metal rolling mills, both hot and cold, are highly efficient manufacturing processes that process large tonnages of metal. Nevertheless, due to the heavy workload, the rolls and components of these mills experience significant wear and tear over time. To ensure smooth and efficient operations, planning for precision alignment inspections and adjustments during scheduled downtime is important. Routine inspections for alignment and wear should be a part of your preventive maintenance program to avoid costly issues resulting from misalignment.

By adopting these practices, you can enhance your operational efficiency and minimize the impact of wear and tear on your metal rolling mills. Please get in touch with us, and one of our representatives would be pleased to talk to you about how cutting-edge 3D metrology technologies and equipment may improve productivity at your metal rolling mill.

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When the manufacturing process is stopped due to machine misalignment, companies risk losing a significant amount of investment in the form of time delay and scraps. However, these costs can be avoided if companies take careful ownership of preventative maintenance, minimizing the likelihood of equipment failure or downtime drastically.

In fact, by adopting the preventative maintenance approach, quality management departments can also better ensure that products leaving the facility meet quality benchmarks, as well-maintained machines are the foundation of manufacturing processes. Besides, machine alignment significantly increases the lifespan of tools, which can be expensive to replace. For these reasons, companies have found it necessary to perform machine alignment regularly and efficiently.

Single-use tools vs. multi-function device

In the past, companies used to rely on traditional alignment methods that involved tools such as machinist levels, piano or tight wires, and optics (e.g., bore scopes, theodolites, etc.). While these tools worked well in most cases, they often served only single, dedicated function. Using these methods, calibration, and alignment would typically take days or even weeks to complete. It was also common to involve multiple instruments, which translated to higher costs and more time spent on setting up in each step.

Naturally, companies sought out better and faster ways for machine alignment to be done. In the early nineties, the use of laser trackers for industrial measurement became widespread. Compared to traditional methods, the laser tracker is a powerful device that can perform multiple measurement tasks in a much shorter time. By gathering X,Y,Z coordinates with the click of a button.

This device combines the capabilities of several traditional tools in one, including the ability to: check for plumb, level, squareness, and parallelism; verify and conduct positional checks of rotary axes and multi-axis heads; reposition a part on a table without a rotational bed; perform real-time adjustments of machine beds, rails, and ways; as well as measure bore alignment, coupling, and shaft alignment. More importantly, the laser tracker captures data points in a three-dimensional (3D) space, which provides users with higher precision and versatility in data usage.

Basic mechanics of a laser tracker

The laser tracker is a portable coordinate measuring machine (CMM) that is based on 3D coordinate technology. Fundamentally, these devices provide the benefits of CMMs with the added versatility of being portable, which allows the user to deploy wherever there is a need. Designed to handle larger working volumes, laser trackers offer extremely accurate measurements over long ranges. Put simply, a laser tracker establishes the precise location of a target in spherical space by measuring two angles and a distance, each time it takes a measurement. It does so by sending a laser beam to a retro-reflective target, which must be held against the object being measured. The return beam re-enters the laser tracker where the distance to the target can be determined using interferometry or phase shift analysis.

The horizontal and vertical angles to the target probe are determined using precision angular encoders attached to the mechanical axis of a gimbaled beam steering mechanism. Using the two angle measurements and distance determined by the laser, the laser tracker can report the coordinate location of the target probe to extremely high accuracy levels.

In addition, the laser tracker can follow or track the target probe as it moves in real time. This unique feature, coupled with the laser tracker’s ability to internally sample up to 16,000 times per second, enables the user to digitize data on complex surfaces or measure the location of moving objects.

In fact, laser trackers today have impressive measurement ranges and accuracies that provide users with more versatility and better results. For instance, the FARO^® Laser Tracker Vantage’s distance measuring range is 80m both ways (160m coverage), and at that range, it captures data at typical accuracies of up to 39 microns (0.039mm / 0.001”). Weighing just under 18kg, the Vantage offers portability and flexibility on measuring large parts, no matter where production is located within the plant. Manufacturers can achieve unprecedented speed and efficiency by capturing more with fewer device moves and shorter routines.

Laser Tracker in Machine Alignment Scenarios

The American Society of Mechanical Engineering established a set of standards for the correct and accepted methods to check and align machine tools with a laser tracker. Here are some documented scenarios of alignment being performed on a variety of machining centers, machinery, and other equipment.

American Society of Mechanical Engineering, ASME B5.54-2005 Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers, 2005.

1. Machining Centers

Horizontal/Vertical Machines, Bridge, Column, or Gantry-type Machines

On these machines, the laser tracker can be used to check for surface level, straightness, flatness, and squareness. The target is placed on the machine bed to capture measurements, and users can either adjustments in real-time, or obtain a complete set of points before adjusting the machine bed afterwards.

For tool alignment, the target can be placed in the spindle, chuck, or quill of the machining center. Measurements can also be obtained by placing the target on a pin nest that gets mounted directly into the drill of the machine. Alternatively, it can also be placed in a ‘puck’, or a drift nest, which can be glued on to a moving bed. As the target sits on its respective locations, 3D data points are collected while the machine travels through a range of movements to check for alignment issues. Apart from checking the machine bed, the laser tracker can also be used to check for plumb, level, or ensure parallelism in the rails. Additionally, conducting 3D volumetric accuracy checks and re-mapping the machine are possible functions.

Boring Mills, Jig Borers, Gantry Drills, Routers, and Lathes

The same checks of levelling, squareness, alignment, and 3D volumetric accuracy checks can be made on these machines. For lathes laser trackers can perform turning center alignment by tracking a target that is affixed on to the headstock with a drift nest. Much like how machine beds are measured, data points are collected as the headstock turns, moving incrementally towards the tailstock in a circular fashion. Adjustments are then made to align the tailstock with the headstock accordingly.

2. Machinery

Presses – Platen, Stamping, and Brake Press

With presses, laser trackers are useful for checking perpendicularity and parallelism of posts, as well as platen parallelism. The ends of each pole on each side of the planes are measured and compared to ensure it lines up square (between pole and plane) and parallel (between planes) respectively. Any deviation can be corrected based on the readings acquired.

Rolls

Laser trackers are also effective at conducting shaft alignment checks in roller mill machinery. Shafts need to be in proper alignment and orientation in order to function well, and the laser tracker allows such checks to be performed easily on a roll (or series of rolls). Real-time adjustments can be made as measurements are being taken. Data points at both ends of a shaft are acquired by placing the target on the cylinder. The information collected by the software allows users to identify the movement that is required to put each roll back into alignment.

3. Other Equipment

Calibration of Robots

In this application, the target is ‘held’ by the robot while measurements are being taken. The laser tracker dynamically tracks the target as the robot moves through its programed path. By analyzing the data points, a user can tell how much the robot has deviated from its nominal path, thereby directing him on remapping, calibration, or error compensation actions that will allow the robot to move properly through its range of motions.

Drivelines – including Gearboxes, Shafts, and Couplings

In the assembly of power generation equipment like a driveline, the laser tracker can ensure that components are lined up correctly, according to design. The laser tracker is mounted with a magnet to hang off the side of a machine, so that it has a direct line of sight to all the features of interest. In this manner, the laser tracker can take measurements of the driveline while it remains on the machine tool. As checks are being made right on the shop floor, adjustments can be made without taking the set-up apart, which saves time and eliminates the need for rework.

Evidently, the laser tracker is an effective complement for the practice of preventative maintenance, which reduces downtime, enables cost-savings, and improves the quality of output. It is a robust tool that can be deployed anywhere on the shop floor, the laser tracker’s multiple functions can suitably replace a variety of hand tools. At Select Laser Alignment we have vast experience in utilizing laser trackers to their full capabilities and can align anything, anywhere, anytime. Give us a call.

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Select Laser Alignment utilizes the latest measurement technology to achieve the tolerance set by our customers. Every installation job is different, and Select Laser Alignment has the necessary skills, experience, and equipment to achieve accurate and precise installations for all forms of machinery. This could be levelling bed plates, alignment of large machinery or test equipment, even positioning complex particle accelerator components to incredibly accurate tolerances.

Select Laser Alignment installs Equipment in all environments from construction sites to temperature controlled clean rooms in precision manufacturing environments.

All our installations will be accompanied by a detailed measurement report on completion of the work, showing nominal data, actual locations, and delta data in graphical and tabular formats. The final reports are fully customizable and tailored to the customer’s specific requirements on each installation. Contact us to discuss your needs!

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How often should alignment checks be performed?

There are guidelines for how often the alignment should be checked. According to Mr. John Piotrowski and his Shaft Alignment Handbook, for newly installed machinery the alignment should be checked following 500 to 2000 hours of off and on operation, or 1–3 months of nonstop operation. If there was no found shift in the alignment, then the following check should be made between 4500 and 9000 hours of off and on operation or 6 months to 1 year of nonstop operation. If no found shift occurred at any time, then measurements should be made every 2–3 years. This pace can of course be influenced by factors such as equipment importance etc.

If a mediocre shift in alignment happened at any time, then the equipment should be aligned to within tolerances. If a massive shift happened, then additional research should begin to determine what is causing the movement (root cause analysis). For example, any sign of excessive wear will also be a sign of “inadequate” machinery installation.

The importance of reporting.

To have reports on alignment checks is critical to avoid repeating the same install errors, or to find and follow up on the same problems over and over. As you of course know, there is no precise answer to the headline question. But the reporting will give you a solid understanding of what occurs on the way and help to keep your machinery aligned in optimal conditions as long as possible. We will provide you with an in-depth written report and drawings on every alignment check to compare as the equipment ages.

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