A common misunderstanding is that sheave/pulleys are not significantly affected by misalignments. This assumption means that the industry has unnecessarily high electricity bills. Several studies have shown that proper alignment can lead to savings of up to 10% in energy costs alone!
Transmissions with several wide belts are especially sensitive. It is easy to understand that the difference in belt tension between the inner and outer belts can differ greatly when aligned incorrectly. This reduces efficiency as not all belts are driven optimally. If one belt is worn then all belts must be replaced with new ones at the same time, which adds expense to the entire operation. Even wide belts are affected more as the tension is uneven over the entire width.
Extending service life thanks to correct alignment is easy. Large savings can also be made when it comes to the cost of these types of belts and pulleys. Whichever of our tools you choose for belt alignment it usually pays for itself within a few months.
The advantages of laser compared to traditional technology
Using lasers makes work faster and easier than with traditional methods such as rulers and cords. These methods usually require two people to carry out the work, one to hold the ruler and one to adjust the machine. Spotting small differences with the naked eye using these methods is both arbitrary and dependent on who is performing the alignment. Laser measurement systems are considerably easier to read. In addition, they are much more accurate. From the belt manufacturer’s side it is sometimes recommended that there is a maximum angular error between the pulleys of 0.5 to 0.25 degrees for optimal service life and efficiency. Such small angles cannot be seen with the naked eye without the assistance of a laser.
Find out more about savings under Advantages of laser alignment.
Correctly aligned machines mean great improvements
- Increased availability and productivity of the machine = assured production
- Increased service life of belts, pulleys and bearings = fewer removals of replacement parts
- Optimally utilized lubricant film = less risk of overheating and secondary damage
- Reduced friction = lower energy consumption
- Less vibration = reduced noise level
- Less risk of serious breakdowns = safer working environment
Greater overall savings with fewer spare parts, lower energy consumption and less unscheduled downtime.
Side mounting for greater accuracy
Easy-Laser XT190/D90 uses the pulley’s side surface as reference during alignment. This gives greater accuracy, as the contact surface for the tool is larger than if the tool was mounted against the radial surface. Any faults and damage on the pulley affect the result less on the side (see image). The risk of wear and damage on the pulley is obviously greater in and by the groove where belts run. A further advantage is that without extra accessories, all types of pulleys can be aligned, regardless of belt type. It is even easy to compensate for pulleys of varying widths. Magnetic mountings on lasers, detectors or targets make it easy to install the equipment. Even non-magnetic pulleys can be aligned as the units are extremely light and can be mounted against the side, secured by double-sided tape.
For small and large pulleys (A/B). A large mounting surface (C) as on the BTA affects accuracy less than a small one with the same fault on the pulley.