Misalignment or off-center equipment components equals unwanted stress to core industrial equipment. Misalignment is a particular condition where the machine parts that are supposed to be perfectly aligned are out of line or not parallel to each other as manufactured.

In Industries, misalignments are commonly seen in shafts, rolls, couplings, and bearings. Even the slightest deviations from the actual alignment position can cause unwanted vibrations, fatigue, heat, and uneven loads, which will eventually lead to reduced machine efficiency, production halts, and may damage the components permanently.

This is where ParAlign Roll alignment services come in handy. Designed particularly for improved precision in industries, ParAlign provides quick, precise, and non-intrusive solutions to identify and correct roll misalignment without the need for extensive machine maintenance or dismantling. ParAlign locates alignment faults via advanced inertial measurement technology that is often more reliable than the conventional methods.

In this blog, you will see the ParAlign Roll alignment process in detail, from the very first assessment and on-site measurements to final adjustments and verifications.

Need for ParAlign Roll Alignment Services

• Ensures accurate parallel alignment of rolls to keep consistency and enhance product quality.
• Detects underlying misalignments that are hidden and not easily traceable via traditional tools and techniques.
• Reduces the wearing of rolls, bearings, and machine frames.
• Lowers energy consumption by reducing unwanted resistance in mechanical components.
• Reduces unplanned downtime and enhances equipment performance.
• Suitable for industries such as paper, film, steel, printing, and battery manufacturing.

When Do We Choose ParAlign for Misalignment?

ParAlign is opted for when a roll misalignment is suspected but difficult to determine using old techniques and in complex, closed, or high-precision machinery. It is suggested that there are frequent defects, unexplained vibrations, and bearing issues despite regular maintenance. ParAlign is also beneficial at a new installation, overhauls, or for performance optimisation.

One big advantage of ParAlign roll Alignment is that by quickly identifying the slightest of deviations, it enables corrective action before that tiny misalignment becomes costly breakdowns or production losses.

What Actually Causes Misalignment?

Misalignment does not occur overnight; it gradually escalates as industrial machinery works under dynamic loads, heat, and constant motion. A machine may look and function normally on the outside. Still, hidden issues may compromise the efficiency, slowly changing the positions of the components from their actual positions and over time, until these minor deviations escalate, creating stress within the system, affecting the efficiency, creating wear, and unexpected failures.

Understanding the underlying causes of misalignment is the first and crucial step, enabling early and reliable maintenance for high-performance industrial equipment.

• Incorrect installation or setup of machines, shafts, or rolls.
• Foundation or structural issues over time
• Thermal expansion due to temperature fluctuations while in operation
• Wear and fatigue in bearings, couplings, or other related components
• Vibration and load variances during continuous operation
• Irregular maintenance and improper alignment checks
• Overloads, sudden impacts, and poor handling while in operation
• Manufacturing defects and machining errors of components
• Frame distortion due to constant stress or heavy loads

Alignment methods 

Roll alignment has constantly evolved over time, increasing to match the demand of complex machinery and precision needs. The following are the methods currently in use:

Plumb Bob: This is a simple and one of the most conventional roll alignment methods, where a mass is simply hung from a string. It is now used as a rough alignment tool to evaluate or set the centreline of the rolls. It is also used to set the horizontal alignment of a pair of rolls that are vertically on top of each other. A plumb bob is beneficial but not ideal for the complete alignment of complex equipment.

Precision level: The Precision level is ideal for setting the horizontal level of rolls. The perfection of levelling achieved will depend on the sensitivity of the precision level. These levels are available in a range of sensitivities from 0.5 to 5 thousandths of an inch per foot. They must be properly calibrated to achieve acceptable results. Precision levels are only ideal for correcting vertical alignment errors of rollers and may need other tools to horizontally align.

Pi Tape: Pi tapes are generally used to measure the diameter of the rolls and to ensure cross-width diameter profile uniformity. To check the parallelism of the roller, the Pi tape is wrapped around two rollers nearby, forming a roller belt. A Pi tape is ideal for measuring a single diameter and measures the error alignment twice. Pi tapes are only useful in specific configurations.

Optical Methods: There are two optical methods for roll alignment, A Precision Sight Level and The Theodolite/ transit Square method. The former is used to measure the vertical offset of rollers, and the latter allows for measuring the tram or the horizontal misalignment of the rolls. Optical roll alignment methods have several drawbacks; for instance, optical roll alignment requires major setup time and multiple setups for each roll, rolls have to be in line of sight, are susceptible to temperature fluctuations, and more.

Laser Tracker: A laser tracker uses a tracker head and a spherical reflector to measure precise positions by reflecting a laser beam to the device. The data is captured, triangulated using reference points, and exported to CAD/CAM software for reporting. While highly accurate, the system requires a skilled operator, has distance limits, and often needs repositioning to measure long or complex setups, each move potentially adding measurement error.

ParAlign Technology 

ParAlign uses inertial roll alignment technology supported by three-ring laser gyroscopes that measure the angular rotation in terms of pitch, roll, and yaw. It is a special, non-optical measurement method to measure the roll's parallelism in production industries such as paper, printing, steel, and web handling or roll-to-roll transfer processes.

Misalignment in rolling machinery can cause inconsistent or low-quality products, excess machine wear, and even lead to wasted material and resources. Well-aligned rolls work better, improving performance, creating more consistent products, and reducing wear and tear on machinery. 

ParAlign technology uses three laser-based gyroscopes to measure alignment in all three directions: roll, pitch, and yaw. As it does not rely on a line of sight, it gives accurate, repeatable results even in tight or enclosed machine areas.

To be clear, ParAlign precisely identifies and corrects roll misalignment without complex processes or equipment dismantling. ParAlign’s advanced technology ensures accurate alignment, creating smoother operations, higher product quality, and improved efficiency on the production side.

Types of ParAlign Services from Pruftechnik

The Pruftechnik team offers mainly two types of Roll alignment with the help of gyroscopic technology:

1. The ParAlign Service:
   

The ParAlign Service includes only ParAlign. While conducting the alignment, the equipment is kept on a roll and swept at 20 degrees about the roll’s circumference. The ParAlign can be placed anywhere along the roll’s circumference with enough clearance to do proper measurements using the SWEEP method. This allows for rolls to be measured on the top, bottom, and sides, which depends on the accessibility. This measurement process could take about half a minute, and the results achieved are transmitted wirelessly to a system.

2. The Peak RGA Service:

The Peak Roll and Geometrical Alignment (RGA) is a complete and comprehensive alignment service combining the ParAlign technology with laser trackers to align rolls and the nearby structures quickly, while giving accurate and instant visual results and reports. This is the only alignment method that combines gyroscopic and laser tracker technology.

Advantages Of ParAlign

1. Fast - One of the quickest roll-alignment techniques available, allowing for measuring up to 100 rolls in a day with minimal production disruption.
2. Comprehensive - Can align rolls and other associated components in confined, difficult-to-reach, or enclosed spaces where conventional tools fail to provide.
3. Accurate - Gives high-precision results with a resolution up to 4μm/m (0.05mils/ft)
4. Efficient - Proper alignment improves machine performance and material tracking, which leads to improved productivity, low operating cost, and optimum efficiency.
5. Visionary - ParAlign works without needing a clear line of sight, making it highly reliable in modern and complex industrial settings.
6. Foundational - ParAlign is flexible and allows repeatable measurements across a variety of machinery and production setups. 

 ParAlign Service: A Step-by-Step Guide

Step 1: Initial Assessment: The primary step done once you decide to book a ParAlign Service is the initial consultation. During the initial consultation, a team of experts will assess and evaluate the challenges, understand the equipment concerned, analyse the operating environment, review maintenance schedules, and identify any existing alignment issues. This is particularly beneficial to understand the scope of alignment needs and to choose the best strategy for the alignment team. For example, if the alignment may need ParAlign tools or Peak RGA service, and additional laser trackers.

Step 2: Pre-Service Preparation and Scheduling: After the initial assessment, the alignment team will work closely with the client to plan the procedure and ensure the maintenance aligns with the operational schedules to avoid unplanned operational interferences. Planned downtime is considered an ideal window to conduct ParAlign services as it doesn’t affect the regular production phase. It is also a cost-effective approach, as the industries could manage while the operations are on hold.

Step 3: On-Site Arrival and Setup: Once the plan and schedules are in place, the technicians arrive at the facility, and the actual measurement process begins. The ParAlign tool with advanced gyroscopic technology is placed to capture the alignment data instantly. This process comes in handy where the conventional methods fall short, such as in enclosed spaces or multi-level setups. The gyroscopes give accurate measurements without requiring a direct line of sight, providing quick and precise alignment evaluations.

Step 4: Aligning the Rolls: As the measurements are taken, the ParAlign team commences the alignment process based on the data gathered by ParAlign Tools.  Additionally, roll re-measurements are taken after initial measurements if needed to ensure precision and efficiency. Alignment time changes depending on the number of rolls and system complexity, but with the speed and expertise of ParAlign tools and service team, the process can be completed easily and efficiently.

Step 5: Reporting and Documentation: After the alignment process, the ParAlign team generates clear and detailed reports covering the measurements and adjustments done, including the before and after data, visual charts, summaries, and suggested maintenance. These details are documented to validate the work, support audits, compliance needs, and maintain optimal equipment condition.

ParAlign Service with Technomax

ParAlign services from Technomax, backed by Prüftechnik, provide the most accurate and fastest solution for roll alignment concerns across a wide range of production industries. Using advanced inertial technology in place of line-of-sight methods, ParAlign ensures precise alignment even in tight or enclosed and complex machine areas. Supported by Technomax’s experienced service team and Prüftechnik’s globally trusted technology, these services help improve your product quality, reduce machine wear, minimize downtime, and extend equipment life, making them a reliable choice for efficient and consistent production performance.

Book your Roll alignment service today and prevent breakdowns. Learn more about advanced ParAlign Services. Contact us now!