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Cardan Case Study1

The document describes a case study where a mining company needed to align a machine train connected by two cardan shafts, including one that weighed over 7500 kg. Typically, aligning such shafts would require their removal, taking a full day and involving safety and logistical challenges. However, a new cardan shaft bracket from Pruftechnik allowed the alignment to be done without removing the shafts. Using the new brackets and updated software, the experienced alignment team was able to complete the task within 15 minutes, saving approximately two days of work and eliminating risks and costs.

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125 views2 pages

Cardan Case Study1

The document describes a case study where a mining company needed to align a machine train connected by two cardan shafts, including one that weighed over 7500 kg. Typically, aligning such shafts would require their removal, taking a full day and involving safety and logistical challenges. However, a new cardan shaft bracket from Pruftechnik allowed the alignment to be done without removing the shafts. Using the new brackets and updated software, the experienced alignment team was able to complete the task within 15 minutes, saving approximately two days of work and eliminating risks and costs.

Uploaded by

JJ
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Cardan Shaft Case Study

SCOPE

FLSmidth in Perth Western Australia contacted Aquip Systems for purchase of a cardan shaft
bracket to align a three machine train with two cardan shafts, with an arrangement of Conveyor
Pulley > Gearbox > Motor. They wanted to use one of their existing Pruftechnik Rotalign ultra iS units
for the job. The work was to be carried out at a gold mine in Western Australia.

One of the cardan shafts weighed over 7500 kg with a shaft length of around 4000mm, the other
was much smaller and lighter. Originally the plan was to perform the alignment uncoupled as this
was the only option.

Typically, removal of the shafts would have taken a full day with difficulties such as:

• Crane hire
• Crane access
• OH&S risks
• Replacement of shafts after alignment
• Possible machine damage during removal and replacement

It is feasible that the whole process would be up to a two day task involving a team of 4-5 people,
with considerable labour and crane hire costs.

NEW CARDAN SHAFT BRACKET and ALIGNMENT METHOD.

In September 2013 Pruftechnik announced the release of new cardan


shaft bracket options that allows cardan shafts to be aligned without
removal of the cardan shaft. Alignment can be performed with a
choice of two methods. Either by taking measurements 180 degrees
opposed using non rotatable brackets, or using the rotatable brackets
and “rotating plane” method for measurement.

Given the time frame for the job it


was required for Pruftechnik to
urgently dispatch a set of brackets
which had just been announced but
were not yet released. It was also
required that Pruftechnik made the
new version 3.03 firmware available
for the Rotalign Ultra allowing use of
the new functions.

All brackets and firmware were


ready and available for the job. After Bryan Rodgers of Aquip
Systems provided tuition to the team at FLSmidth the highly
experienced alignment team were more than confident to
perform the task with the new brackets and firmware on the
Rotalign ultra iS.

13/12/2013
ALIGNMENT PROCEDURE

Once the Alignment task began on site the


brackets were set up on the shaft and
measurements taken within 15 minutes.
Setting up is virtually the same as any normal
rotatable coupled alignment; mount the
brackets using the supplied chains, enter
dimensions, and take measurements. Using
the new cardan bracket is extremely easy. The
onscreen tutorial and instructions can serve as
a reminder and are very easy to understand.

At the movable machine end of the shaft, a


“rotating arm bracket” is used to mount the
receiver and at the stationary end a “non- rotating
arm” bracket is used to mount the laser. As the
coupled shaft is rotated to each new measurement
location the rotating arm bracket is rotated at the
base and the receiver is moved along the posts to
intersect the laser beam and a measurement is
recorded. This is repeated at several different
points of shaft rotation to capture alignment
condition.

The required moves were made and checked and the task was completed, all without removal of the
7500kg cardan shaft.

TIME AND COST SAVING

As the alignment was being performed as part


of a time critical shutdown the saving of
approximately two days was highly significant,
not to mention the reduced manpower and
eliminated crane hire costs and risks. There are
several more identical machines on this site
with all having scheduled shutdowns in the
near future. The combined time saving will
extend into weeks with possibly 150-200 man
hours saved.

For Further information please contact

Bryan Rodgers
Aquip Systems Pty Ltd
Ph: +61 8 9472 0122
E: bryan@aquip.com.au

13/12/2013

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