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KOHTECT(c) 2013
CONTENT
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1. General and introduction
The KOHTECT AVV-701 alignment system is the class II laser device at typical wavelength of
670nm, delivered output power of less than 1 mW and maximum radiant energy per pulse of
0.1 mJ. The Class II laser comply with requirement outlined by USAs FDA as well as
international ANSI, BS 4803 and IEC 825 standard.
Be sure to follow the following safety precautions to avoid personal injuries and damage to the
system
ATTENTION!
Do not try open / dismantle measuring units and the display unit this can damage the system,
and your after-sales service warranty will come void.
Warning!
Be sure the machines to be measured, cannot be started unintentionally as this can cause
injuries. For this purpose, before the mounting of equipment, either block the power switch in
the Off position or remove the safety fuses. These precautionary rules must be followed until
the measuring system is dismantled from the measured machine.
Neither the NPP KOHTECT enterprise nor our authorized dealers are liable for the damages
caused to machinery or equipment by use of the AVV-701 system. We carefully check text of
this manual to eliminate errors, nonetheless there may be mistakes or inaccuracy involved. We
will be grateful for your reporting to us about any error, and we will be able to correct them in
the subsequent editions of the manual.
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2. Technical Description
2.1. Designation
The checking of shaft alignment means adjustment of the relative position of two coupled
machines (e.g. motor and pump) so that the centre line of the axis will be concentric when the
machines are running during normal working conditions.
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2.3. System Package.
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2.4 Misalignment Parameters
Misalignment of any rotating machine is expressed in parallel (Offset) and angular (Gap) of the
shafts. Most frequently in practice, both of them are present simultaneously. Different kinds of
misalignment of axes are shown in Fig. 2.
Fig 2
The parallel (Offset) and angular (Gap) misalignment of axes is determined in two mutually
perpendicular planes. For the purpose of elimination of the parallel and angular misalignment
of axes, in each of the planes a correction of position of the movable machine (M) will be done.
For the horizontal mounted machine the movable machine (M) position is adjusted in the
horizontal and vertical planes.
For the vertical mounted machine, operator determines arrangement of the correction planes,
basing on considerations of the convenience and technological effectiveness of moving of the
movable (M) machine.
Stationary machine (S) - in the process of eliminating of the axes misalignment the position of
this machine stay static, i.e. it does not move.
Movable machine (M) the machine, which position is adjusted for eliminating of the parallel
and angular misalignment of axes.
The measurement system calculates the values of the angular and parallel misalignment of
axes in the plane of the coupling (in two mutually perpendicular planes), and the adjustment
values for the machine feet on the movable (M) machine, that is necessary for elimination of
this misalignment of axes. Fig. 3 shows misalignment of axes and the values for its correction
just for vertical plane.
Fig 3.
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3. Machine Alignment
Mount the Measuring transducer units on the shafts of the (S) and (M) machines
Select program according to the application of machine to be measured
Input the distances between the (S) and (M) units, the coupling and the movable
machine feet
Press to record readings from the measuring units at three different positions of
the shafts
Adjust the machine feet position of the movable machine in accordance with
correction results of the calculated value on control screen
Save the measured result into the file
While making the measurement, it is may be necessary to observe and understand the
orientation and rotation direction of the shafts with the (S) and (M) measuring transducer units
with regard to the relative position of the (S) and (M) machines as in Fig.4.
Fig 4.
Fig. 4 shows the view of (S) machine from the (M) end view, at the 12:00 oclock position. The
measuring transducer units have marking (S) and (M) on the top of each unit, should be
mounted with brackets onto the shafts of the (S) stationary and (M) movable machine
respectively.
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3.1 Input Measurement Data
AVV-701 system function is based on the measurement of the laser beam movement on the
detector receivers window during the turning of shafts with the measuring units mounted.
To enable the System to carry out the shaft alignment calculation, it is necessary to record the
measurement data in at least three positions of the shafts rotation. Turning the shafts in the
range of 180 is sufficient, but for the best results turn as wide as possible recommended.
If design features of the machines do not make it possible to carry out rotation of the shafts
with the measuring units mounted up to 180, the instrument also provides smaller shaft
rotation angle measurement mode that allows possibility to enter the measuring data when the
shafts rotation angle constitutes as low as 60, note turn as wide as possible always
recommended. Systems advanced multipoint mode allows shafts rotation in any direction and
up to 36 points.
Before the beginning of the work, check the battery voltage and charge it if necessary.
Battery voltage is indicated on the display of the device in the main menu.
The device is automatically turned off when the voltage is lower than 4.6 V.
Check and clean if necessary the surface of detectors and aperture of laser.
Use soft tampons, moistened with alcohol, for the cleaning. Solvents must not be used!
Check and setup if necessary, date and time of the system clock.
To enable the AVV-701 to carry out accurate calculations it is necessary to input the distances
between the measuring transducer units, the coupling and the machine feet.
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Fig. 6 shows the dimensions input for the horizontal plane alignment.
Fig. 7 shows the dimensions input for the alignment of vertical flange mount machine.
Fig 6.
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Fig 7.
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Fig 8.
Fig 9.
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4. Getting Started
To start AVV-701:
In Main Menu by using the arrow keys move the selection bar to Alignment then press
.
The display shows alignment menu screen with programs option
as in Fig.10.
The lower section display the day, date and time of system clock,
and the battery charge power within the device.
Mount the Measuring transducer marked with (S) on the shafts of the stationary machine and
Measuring transducer marked (M) on the moveable machine. Connect the cables as per
section 3.3, between the Measuring transducer units and Control Display unit.
Input dimensions
Dimensions between the two transducers(S-M), between S unit and coupling center
(S-C), between the S unit and the front feet of moveable machine (S-F1) and between the S
unit and the rear feet of moveable machine(S-F2) should be entered.
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measure units
MA means manual
angle IA means use
inclinometer
2D means biaxial
adjustment mode 1D
means uniaxial mode
Change parameters
2D means biaxial
adjustment mode 1D
means uniaxial mode
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Biaxial and uniaxial adjustment modes
When biaxial mode used both vertical and horizontal transducers data used in live
adjustment mode to perform live adjustment. Shafts rotation not needed and strictly prohibited
to adjust moveable machine in vertical and horizontal planes.
uniaxial means traditional live adjustment mode where you should turn shafts to predefined
transducers position to perform vertical or horizontal adjustment. The position should be 12 or
6 oclock for vertical adjustment and 3 or 9 oclock for horizontal adjustment.
Collect data
AVV-701 system does collect data in advanced multipoint mode. Up to 36 points using
any shafts rotation direction can be stored for the best results. At least three points should be
stored.
After the connection has been established data collect screen appears
Using fine adjusting screws on the Measuring transducers, adjust the laser beams to the
centers of detectors shutter cover one at a time, refer Fig. 1a & 1b. Once laser is centered on
both transducer, open the shutters. The screen starts display detectors coordinate position
readings for both transducers (S) & (M)
Face the stationary machine from the movable machine.
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Stored or manually
Main clockface
entered Y values
with stored points
showed
Stored or manually
Selected point
entered angle
index
To delete selected point press (you should not be in manual value edit state)
Delete confirmation dialog will pop up. To confirm point deletion press
To replace selected point in the manual data mode enter new manual data and confirm by
press Replace confirmation dialog will pop up. To confirm value replacement press
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Replace confirmation dialog
press to confirm
press . Then
To change display resolution between 2 and 3 decimal digits press
To enable or disable input data filter press you can change filter averaging number in the
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Calculate alignment results
When all of the desired points gathered press to go to view calculated results and to make
live adjustment
The alignment measurement result of calculations shows the values of the angular Gap and
parallel Offset misalignment in the plane of the coupling (in Horizontal and Vertical planes) as
well as the correction values for the machine feet F1 (machine front feet) & F2 (machine rear
feet) on the movable (M) machine that are necessary for eliminate the horizontal and vertical
misalignment.
STOP means live
adjustment now off
! indicates tolerances
violation
Note:
For the purpose of clarity the values of parallel Offset and angular Gap misalignment in the
plane of the coupling are shown in the view of the symbols of half-couplings.
The adjustment values of the position of the feet F1 and F2 of the machine (M) in the horizontal
plane indicate the value of horizontal shift. The positive values mean that the feet must be
pushed, the negative values the feet must be pulled.
The adjustment values of the position of the front feet F1 and F2 of the machine (M) in the
vertical plane indicate the value of vertical shift. The positive values mean that the feet must be
lifted, the negative values the feet must be lower.
Press to freeze the alignment result on screen to temporary jot down of coupling results,
Fig 19a, while prepare for live adjustment.
To resume live measuring mode, Fig 19b, on machine, press again and start shimming
and adjust horizontal movement with under the live adjustment mode.
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Note: To view option features(pop up) in Fig.19e, press and hold
For prompts screen message on the function key, press for
show following info:
to toggle resolution 0.01mm or 0.001mm
Shim simulator to check the shimming which size is
different from the results of calculation (Fig.19c).
Thermal growth to enter compensation values to thermal
growth (Fig.19d ).
to save the result. Enter My Documents. You may save this file in the old folder or
create a new folder.
Shim simulation
The shim simulation allows easy and convenient way to evaluate rest misalignment when shim
added or removed. To open shim simulation press .
See rest
misalignment here
Thermal growth
Most machines develop a certain amount of heat while running. In the best
case both the driving and the driven machine are affected equally requiring
no input of compensation values. But in several applications the driven
machine is either hotter, i.e. a pump for hot liquid, or cooler than the driving
machine. The machine manufacturers define the thermal growth of the
machines differently, but in most cases you will find it as a factor of
deliberately misalignment expressed in parallel offset and angular error
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To enter thermal growth press .
Setup tolerances
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4.3.3 To save alignment measurement data
Quit program
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4.4 Vertical Machine Alignment
The vertical machine alignment program shares many similarities with horizontal machine
alignment. See also: horizontal machine alignment
Mount the Measuring transducer units on the shafts of the machines (S) and (M) as shown in
Fig. 20a.
Note: Mark the clock positions 9-12-3-6 at the flange.
Using the connecting cables, connect Measuring transducer units and Control Display
Input dimensions
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Input the first dimension between the two transducer units, Fig.20a. Press. to start input
dimension then input the new dimension follow by to confirm input data.
Use or to move to 2nd dimension input, distance from Measuring transducer (S)
unit to coupling center, Fig 20b.
Use or to move to 3nd dimension input, distance from Measuring transducer (S)
unit to flange face, Fig 20c.
Use or to move to 4th dimension input, flange bolt center distance.
Use or to move to last dimension input, number of bolts.
Change parameters
Same lake in horizontal alignment program, to change program parameters press to call
popup menu
Note: inclinometers cannot be used in the vertical machine alignment
Collect data
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The display shows information of the serial number on both Measuring transducer units to
identify device is connected properly.
When connection established system switch to collect data.
When all of the desired points gathered press to go to view calculated results and to make
live adjustment
Press Screen message show Do not turn shaft while aligning before display shimming
values required for each individual bolts and make angular adjustment by adding in or remove
shims as per display values.
To freeze the result screen and LIVE adjustment mode, press to
toggle. Hand tight all bolts when shims adjustment done.
Press to toggle between offset adjustment (in 9-3 and 6-12
planes) and shims adjustment screen. Move the (M) machine along
9-3 and 6-12 direction as per offset adjustment values display on
screen.
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Press to repeat the entire vertical measurement task again to confirm machine alignment
has been done.
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4.5 Program for Soft Foot check and correction
Check the machine for the soft foot before fulfilling any alignment adjustments. Form the
alignment menu select Soft foot and press
Input dimensions
You must check/input all the required machine dimensions before continue. See horizontal
alignment input dimensions
Note: Dont select manual input of data or angle
Take measurement
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Follow screen prompts message, release 1st bolt and wait
approximately 5 second for soft foot value to measure. Then press
key to record the value.
Tighten the bolt as screen prompts message, and press to move
to next bolt and repeat procedure as per prompts message on the
display until all the four individual feet soft foot readings are taken on
display. The result shows the difference between the released and
tightened bolts of the foot. Set maximum shimming values.
Choose to repeat entire soft foot check after remove the soft foot
as per measured result.
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4.6 Bore Center Line Program
The AVV-701 laser alignment system uses a visible laser beam to determine the relative the
relative centerline of a series of bores. The laser transmitter(emitter of the laser beam) is
mounted a one end of the machine and is aimed at the laser receiver(detector of the laser
beam), which is mounted near the center of each bore in turn. The receiver is mounted on a
special bracket which allow the freely rotation of receiver within the bore.
Units configuration
S unit laser transmitter (fixed position)
M unit receiver (on bore bracket)
M label should be on top side at 6h oclock pos.
Measurement preparation
Thoroughly clean the bores to be measured
Ensure that the boring machine(or bores) are readily moveable horizontally and vertically
Set parameters
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Press to change measurement configuration number of receiver positions where data
will be taken. In case of 3 points configuration it is recommended to enter bores diameters
(3: Diam.) it improves result precision. However if diameters are not entered, result calculation
is still possible.
In case of 8 points result is calculated with higher precision due to averaging.
Press to set Horizontal or Vertical bores orientation. In case of Vertical inclinometer will
not work. One should check measurement position manually.
Press to switch between use sensor data or manual data input
Take measurement
Plane number
Measurement
position data
Inclinometer
data
Plane
If sensor position differs from number
proper measurement position
warning start blinking. (If Bore center
inclinometer is ON) displacement
Measurement position indicated on screen by radial line. Current receiver (M) inclination is
indicated by blinking radial line.
Place receiver into measurement position and press to take
readings for current position. When readings for all position will
be taken bore center displacement will be calculated.
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Use to select next next position or to return to the
previous position. Plane number changed automatically in regard
to measurement mode
Evaluate result
When all bore planes are calculated, press result will display
Press to switch between table or H, V plot.
Press to start enter reference points number, enter numbers for both points
confirmed by
Live adjustment
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2) When sensor is fixed in order to move together with
Save result
Press to enter data save screen and press again to save soft foot reading or press
to make new directory or select the existing directory to save.
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4.7 Flatness Program
This program for measurement of plane flatness relative to reference plane formed by laser
beam. The measurement points may be in the plane of circular or rectangular shape with
regular or variable grid step. The plane may contain cutouts. Up to 1600 measurement points
can be handled. The measurement values can be treated as absolute, recalculated to best fit
plane or three points can be set as reference plane.
Procedure: Plan the measurement and mark the points where the detector will be placed. Level
the laser within 0.5 mm [20 mils] in both X- and Y-direction. Start the Flatness program. Use S
or M unit as detector.
The detector unit should be installed with the label on top.
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Setup grid parameters
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Measured plane can contain some cutouts of arbitrary shape those nodes that are
within cutouts can be just skipped out during taking of measurement. The flatness
program correctly treats such cutouts.
Row and column index numbering starts from 0. E.g. first row is Y0.
When in grid setup use to switch between data from M Unit and manually entered data.
Taking measurements
Beam X position
indicator
Active Beam Y
node data
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The result display
BF best fit
Assigning 3 points of reference plane: ABS absolute
REF 3 ref. points
- press to choose REF option.
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Circle shaped plane
When new task started the menu screen to choose plane shape
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Taking measurements Active Beam X position Beam Y
node indicator data
Assigned node is indicated on the screen by Node data Node data not
recorded recorded yet or
blinking cursor. Use arrow keys or node is skipped
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Press to switch between plane data representation absolute, best fit, 3 points reference
plane.
Three of the measurement nodes can be selected as reference points, which will set
them to zero. The measurement value of the rest of the nodes will then be
recalculated. Reference points can be re-assigned as required.
To save data
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4.8 Squareness Program
Set parameters
Enter the distances between the 1st, 2nd and 3rd, 4th
distance in mm confirmed by .
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Press to call popup menu where:
Taking measurements
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Place detector in the 3rd position. Press to record the
reading
Measurement result
When readings for all four positions are recorded, press key to
go to the result display.
To save data
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Data files can be transferred to PC software for report printing, or can be opened in the AVV for
review.
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4.9 Straightness Program
Straightness measurement
The laser alignment system use visible laser beam to measure the straightness of linear
objects. The laser transmitter (transducer that emits laser beam) is mounted at one end of the
object and then aimed in the receiver. Both the transmitter and the receiver are adjusted to
ensure receiver detects the laser. The receiver is moved along the object, and any changes of
the laser beam position in the receiver gives a measure of straightness. The laser beam is not
intended to be the absolute reference. The setup should be such that the laser beam always
strikes the detector throughout the entire length being measured.
Setup parameters
Splice number
You should define
overlap points quantity
when splice number
>1(2 or more)
Set dimensions
To set dimensions press to select between all distances equal or different distances for
each segment. Then sequentially define distances use arrow keys to move to next or
previous distance, press and enter desired value confirmed by . Note: when all
distances equal selected system automatically set all distances to entered value, so enter
distance only once.
After all distances defined splice concept(see splice concept) should be followed if splice usage
planned.
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Define a splice
When splices planned to be used the splice should be defined. Press and then enter splice
number(the first splice is number 1). Else leave splice none.
Press to switch between manual entered data and data collected from detector
Before measurement can begin the laser must be positioned such that the beam strikes the
approximate center of the receivers detector over the entire measurement path(whole splice or
whole object).
Adjustment procedure
Place the receiver at the closest(to transmitter) measurement position. Adjust beam position to
center the beam onto the detector. With the receiver at the far end of the measurement path,
adjust the horizontal and vertical angle of the beam to center onto the detector. Repeat above
steps as necessary until the beam remains centered on the detector in both the near and far
positions.
Carrying measurements
If showed means
overlap point
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Evaluate measurement results
To enter to results screen when you stands in data collect screen press
Measurement results screen appears
When reference points not selected and best fit
mode not choose measurement results is the plane
stored values
To select reference points press and then enter points numbers sequentially
(set value and confirm by for each of points) .
Note: overlap point should not be selected as reference!
To deselect reference points enter 255 value for both points
To switch between reference points/best fit plane mode press
Splice concept
Splices in straightness are partial overlapped parts of whole length of measured object.
Measurement divides by splices for the extension of the total length that can be measured,
where object length exceeds maximum allowed distance between transducers.
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After you store measurements for all the points belonging to the current splice, you can switch
to the next splice.
To do it: while first point of next splice selected press to return to the straightness main
screen and increase splice number by one. If splice number is not 1 you should define number
of overlapped points too. Number of overlapped points should not be less than 2. To input
Enter to collect data screen. Use for select(if required) the first point of new
splice(in example this is a point 6). Move receiver to its position(regards to currently selected
point; in example this is a point 6, note its distance on object is equal to point 4 distance).
Remember X,Y values, let me label them as V6). Move transmitter from its current position
to position, where point of last splice point minus overlapped points number minus 1 located.
In example this is a place of point 3. Do not touch receiver! Adjust transmitter so that X,Y
values on receiver became almost equal to the X,Y values indicated before the transmitter has
been moved. Move receiver to the closest overlapped point to the transmitter point(exact
position) (in example this is a point 6, note its distance on object is equal to point 4 distance).
Fine tune transmitters position, so that receivers X,Y values became almost equal to
receivers X,Y values that we previously labeled as V6. Repeat adjustment procedure if
needed. Move receiver to the closest overlapped point at the exactly point position (in
example point 6, note its physical place on object is equal to point 4 physical place, but point
number 6 should be selected on the screen). Store measurement data. Then move receiver to
the next overlapped point at the exactly point position (in example point 7, note its distance on
object is equal to point 5 distance, but point number 7 should be selected on the screen). Store
measurement data. Repeat measurements for the all overlapped points. Then continuously
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perform measurements for non-overlapped points of the current splice (in example there are
points 8-9).
About to how close should be values for the overlapped point pairs.
In example there are two point pairs 4-6 and 5-7, so how close should be X and Y values within
the pair. The answer is: as close as possible, but complete equality does not required.
AVV-701 system will automatically calculate and apply correction values for each splice, but
care should be taken on values difference, because if difference too big the beam can move
out of the target during measurement.
After all measurements has been carried and results calculated, it may be necessary to make
corrections in the live move mode. The devices live mode make it possible to monitor these
corrections.
Before switch to the live mode reference points or best fit result mode should be selected.
If you move transmitter from its last position, two point adjustment procedure should be
performed(see adjustment procedure).
Place receiver at point where you intend to make corrections. Press to enter live mode.
String LIVE STOP appears at screens top right side. When you ready to move press to
enable live move detection. The LIVE LIVE start blinking at top right side of screen.
The V and H values at screens center now shows difference between desired and real object
positions. Move object toward zero of each of these values. To stop live correction press
again LIVE STOP appears at screens top right side.
To save data
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Data saved in the file with default name created with date/time stamp.
Cardan Shafts, or offset mounted machines, need to be aligned just as much as an ordinary
mounted machines. The cardan shaft with its ball-joints admits an amount of offset mounting of
the machines, but it does not tolerate angular misalignment. To be able to perform an
alignment of an offset mounted machine you will need to use the optional brackets. See also
horizontal machine alignment.
Flange
Movable machine
Bracket rail
Swivel bracket
1. To compensate offset, mount the bracket rail on the shaft end of the stationary machine.
2. Mount the swivel bracket on the bracket rail. Mount S transducer on the swivel bracket
3. Mount the magnet fixture on the end of the shaft of the movable machine. Mount
M transducer on the fixture.
4. Connect the S- and M- transducer to the display unit and start the Cardan program to
switch on the lasers.
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5. Adjust the M transducer beam.
To adjust the laser beam: Turn the transducer into first position e.g. 9
oclock. Note the beam position on the opposite transducer (e.g. beam
hits position 1). Turn the unit half a turn (beam hits position 2). Adjust the
beam to the centre of rotation (beam hits position 3 in the middle between
point 1 and 2).
6. Adjust the brackets rail so the center of the S transducer is hit by the M transducer
laser.
7. Adjust the S transducer beam.
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To start program press
Input dimensions
As offset value is not used in cardan shafts only distance between transducers and distance
between front and rear feet of machine need to be entered
Use or to move from dimension to dimension to input or reconfirm all dimension
data.
To start input dimension use key,
when the blinking cursor appeared use
numeric key pad to enter desired value
then press to confirm.
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Collect data
Collect data for the cardan shaft shares many similarities with horizontal machine alignment,
see collect data. To start collect data press The laser beams turned on now.
Screen of wait connection to transducers appears. Note that Bluetooth connection need more
time for connection to be established.
If connection cannot be established during more than 90 seconds check if pin codes entered or
check transducers.
After the connection has been established data collect screen appears.
Face the stationary machine from the movable machine.
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Calculate alignment results
When all of the desired points gathered press to go to view calculated results and to make
live adjustment
Note: Screen message shows Do not turn shafts
The alignment measurement result of calculations shows the values of the angular Gap
misalignment in the plane of the coupling (in Horizontal and Vertical planes) as well as the
correction values for the machine feet F1 (machine front feet) & F2 (machine rear feet) on the
movable (M) machine that are necessary for eliminate the horizontal and vertical angular
misalignment.
Blinking LIVE at the top right of the screen indicates live adjustment
mode is on
Refer to horizontal alignment section corrections of the misalignment
Note that offset not used for the cardan shafts alignment
Use to switch between live and frozen mode
To save data
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Quit cardan program
When quitting the program:
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4.11 Spindle program
For spindle alignment S unit(transmitter) mounted in the spindle and the M unit(detector)
mounted at the part of the machine that can be moved along the working area of the machine.
Input distances
by
Taking measurement
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S unit Black shows S Unit
inclinometer data label position
Evaluate results
Angular error
showed numerically
and graphically
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To save data
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5.0 Standards Tolerance of Shaft Misalignment
This chapter provides the standards alignment tolerance of misalignment for standard industrial
machinery with flexible coupling that can be used under condition only if existing in-house
standards or the machine or coupling OEM have not given any blinding values, and must not
be exceeded.
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