Reverse Dial Indicator Shaft Alignment Techniques

Understanding Shaft Alignment:

Shaft alignment refers to the process of aligning machines' rotating shafts to ensure they are in a straight line. This means that the shafts are parallel to each other and have the same centerline. Properly aligned machinery leads to enhanced performance, minimal vibrations, reduced wear on components, and increased machinery longevity. Conversely, misaligned machinery can lead to damage to the bearings, seals, couplings and other components, leading to downtime and reduced output.

Shaft alignment is especially critical for machines with high rotational speeds and those that transmit heavy loads between components. Proper alignment helps to optimize the machine's reliability and reduce the probability of component failure due to misalignment.

There are different methods of aligning the shafts, including straight edge alignment, reverse dial indicator alignment, laser alignment, and others. The choice of the method depends on the machinery's accuracy requirements, the available equipment, and the type of equipment in use.

Benefits of Reverse Dial Indicator Shaft Alignment:

1). Accuracy: The reverse dial indicator shaft alignment method offers a high degree of accuracy, ensuring that each shaft component is aligned correctly. This precision helps to prevent machinery vibration, which can cause wear and tear on components and reduce the lifespan of the machine.

2). Precision: With the reverse dial indicator shaft alignment method, we can achieve a precise alignment of shaft components. This precision ensures that the shafts are perfectly aligned, reducing the likelihood of premature wear and tear on the machinery. Precise alignment also helps to improve the overall performance of the machinery, resulting in more efficient operation and reduced downtime.

3). Cost Savings: By using the reverse dial indicator shaft alignment method, we can save money on maintenance costs in the long run. Accurate and precise alignment of shafts reduces the likelihood of machinery breakdowns, which can be costly to repair. Additionally, machinery that operates efficiently uses less energy, resulting in lower operating costs over time.

Tools for Reverse Dial Indicator Shaft Alignment:

Reverse dial indicator shaft alignment requires specific tools to achieve accurate results. These tools not only help align the shafts but also ensure that the machinery operates efficiently. In this section, we will discuss the different shaft alignment tools required for reverse dial indicator alignment.

Tool	Functionality
Dial Indicator	Measures the degree to which the shafts are misaligned and guides the alignment process.
Base and Targets	Provide a stable platform for the dial indicator and enable accurate measurement of shaft misalignment.
Gauge Blocks	Used to calibrate the dial indicator, ensuring it measures accurately and consistently.
Shims	Inserted between the base and the machinery to adjust the height of the equipment and achieve proper alignment.

Reverse Dial Indicator Shaft Alignment Procedure:

Performing reverse dial indicator shaft alignment involves several steps that must be adhered to for accurate results. Below is a step-by-step guide on how to perform the alignment procedure using a dial indicator.

Remove any existing coupling: Before starting the alignment process, remove any coupling that may be present on the shaft.
Mount the dial indicator: Mount the dial indicator on the stationary shaft in a vertical position so that the plunger of the dial indicator is in contact with the other shaft.
Set the dial indicator: Set the dial indicator to zero. This can be achieved by using the calibration procedure provided by the manufacturer.
Rotate the movable shaft: Rotate the movable shaft in 90-degree increments and note the readings indicated by the dial indicator on each turn.
Perform calculations: Use the readings obtained from the dial indicator to calculate the horizontal and vertical misalignment values.
Make adjustments: After calculating the misalignment values, make adjustments to the movable machine so that the readings are within acceptable limits.
Recheck alignment: Recheck the alignment after making adjustments to ensure that it meets the required specifications.
Reinstall the coupling: After completing the alignment process, reinstall the coupling on the shaft.

Reverse Dial Indicator Alignment Technique:

By using the reverse dial indicator alignment technique, we can accurately measure the misalignment between the two shafts. This method involves measuring the movement of one shaft in relation to the other while the machinery is still in operation.

"The reverse dial indicator method is highly effective for measuring the misalignment between two precision shafts."

The reverse dial indicator technique involves four basic steps:

Mount the dial indicator on the machinery housing using the magnetic base and bracket.
Place the indicator in contact with one of the shafts, ensuring that the contact surface is perpendicular to the shaft axis.
Rotate the shaft and observe the movement of the dial indicator needle. Record the maximum reading on the dial indicator and the position of the shaft at this reading.
Rotate the shaft in the opposite direction and repeat the process. The maximum reading should occur in the same position as before. If it does not, the alignment needs adjustment.

Reverse Dial Indicator Alignment Technique in Action:

First, need to establish a reference point. This reference point serves as the baseline for our alignment measurements. It will begin by mounting the dial indicator on the stationary shaft and setting it to zero.

Next, rotate the movable shaft until the dial indicator shows a reading. This reading represents the initial alignment offset. It will then record this value as measurement A.

After that, We will rotate the movable shaft 180 degrees and take another reading. This reading represents the opposite alignment offset and we will record it as measurement B.

Using these two measurements, we can calculate the vertical and horizontal adjustments required to align the shafts accurately. We will use the following formula to determine the required adjustments:

(Measurement A - Measurement B) / 2 = Adjustment

Once we have the required adjustments, we can proceed to make the necessary changes to the movable shaft until it aligns perfectly with the stationary shaft. We will repeat this process until the dial indicator shows zero readings, indicating that the shafts are aligned perfectly.