Our services are a combination of two key factors:
- the most modern technology available on the market: devices such as Laser Tracker, Measuring Arms, 3D scanners and specialised measuring software,
- combined with many years of experience gained during the implementation of complex measurement projects in the energy, chemical, shipbuilding, metallurgy, foundry and automotive industries.
Services offered for the levelling and positioning of machinery and equipment:
- precise levelling of machines with laser tracker
- verification of the variation of the foundation over time
- setting up support elements with very high precision
- analysis of the geometry of the foundations prior to placing machinery
LEVELING
Machine leveling is a broad term used in industry when assembling machines, machine tools, presses, guides, etc. In some applications it is very important that the machine base, guides and tables are perfectly level with the direction of the gravity vector. This is due to the large mass of these devices and the type of work performed.
Rapid component movements of high-speed presses, when leveled badly, will damage the bearings of the slide rails and damage the machine. Failure to level large machinery and structures well will result in gravity warping and stresses in the structure, which will eventually lead to cracks and damage.Precise leveling of machines ensures:
- proper functioning of devices and stability of the foundation
- correct wear of the sliding elements of bearings and seals
- reduction of stresses and vibrations that may arise during work
- reduction of operating and servicing costs
ALIGNMENT
Compared to traditional methods, our services are distinguished by the speed and precision achieved thanks to the real-time generation of results and the ability to measure large-size elements such as raceways and ball mill drives, plotter rolls or steam generator casings in power plants.
We offer alignment:- determining the axis of the shafts
- drive rollers, rotating tracks
- a series of machines and production lines
- bearing series and their seatings
- pulleys, gears and machine drives
Accurate alignment of machine components ensures:
- correct bearing wear and smooth running
- lower power consumption by reducing drag
- reduction of vibrations due to improper balance
- reduction of operating and servicing costs
SETTINGS & ADJUSTMENT of machines
There are many cases where it is necessary to set the correct geometry of the machine so that the mating elements are perpendicular and parallel. Failure to maintain the geometrical relationships may lead to stress concentrations which lead to increased deformation or increased friction and, consequently, damage to machine components such as guides or bearings. Thanks to our services, we can answer the questions which elements of the machine or the entire system need to be corrected. Minimal falsehoods invisible at first glance, we can precisely identify and eliminate
We offer settings and adjustments of machines and devices:
- welding and production fixtures,
- automated mechanisms and robots
- tools, jigs, fixtures and gages
- machine side guides and all other engineering structures where precision plays a critical role
In addition, thanks to the well-arranged geometry of machines, devices and their components, many positive effects can be achieved, such as: lowering energy consumption, lowering the level of vibrations and noise as well as the wear of individual elements of the crane,
Machines settings and alignment
A failure-free machine is the dream of every industrialist. Unfortunately, in this case it usually ends with dreams, because many people prefer to wait for the first failure than to prevent it. The most common victims of such failures are bearings and couplings that cannot withstand vibrations. Surfaces wear off quickly when the machine set is not properly adjusted.
So what to do to be one step ahead of damaging any of the assemblies? It is enough to correctly set the coupled elements together and prevent their misalignment. This is what this text will be about. The dangers of misalignment of equipment and how to properly couple them.
Misalignment and its effects
Misalignment is negative for the condition of the devices. On average, half of the premature failures are caused by their incorrect alignment. The main effect of this condition is an increase in machine vibration, which significantly accelerates the wear of bearings, shafts, seals and couplings. Ultimately, this leads to greater failure rates and damage to machines. After that, production stops and we have a breakdown. It is very dangerous because losses of break at production are higher than the cost of preventive actions. Wrong machine setting and alignment is very risky for Your company!
Alignment and position adjustment
You can prevent all of the unplanned breakdowns. Of course you need to take care about proper on-site measurements. Machine alignment not only reduces failure rates, but also leads to shorter, scheduled service downtimes. The alignment itself comes down to setting the machine shafts in such a way that they are parallel to each other and the axes are their extension. Devices position adjustment like straight line setting negates all the previously described negative effects, at the same time leading to quieter, more productive operation of the device.
The easiest way to achieve such an effect is to position the devices so that the shafts are ideally facing each other. Unfortunately, it is rarely possible at all. Additionally, there are machines both stationary and mobile. The different sizes also effectively negate the possibility of direct connection. It is then a good idea to use alignment shims that are able to align the levels so that the shafts meet parallel. Their different sizes allow for proper leveling, and thus – for better work.
It is worth to make devices position adjustment!
It not only increases their performance, but also reduces the chance of failure. You can easily control the time when you need to replace the machine parts. This increases control over the entire production process. However, it is important that the alignment is done professionally and with high precision. This is why for all devices position adjustment project we are using best in class Laser Tracer FARO. This device is very accurate and can measure form 0 meters up tu 80 meters in radius direction (160 meters of diameter) with very high accuracy at about 0,01 mm at close distances.
If You are interested in proper alignment of machinery in your factory let us know!