2010 Third International Conference on Intelligent Networks and Intelligent Systems

The Design for Portable Fixturlaser Shaft and Mathematical Model

Study
Mu Li, Wang Xinwei，Zhang XiuHeng
（Department of Mechanical Engineering Shenyang Ligong university LiaoNing
Shenyang 110168）
Email: muli98@sohu.com; wangxinwei1977@163.com；aeh25@126.com
Abstract： ：A design of laser shaft alignment purpose can be realized by adjusting shaft position
based on double LD-PSD is proposed in this paper.
according to the calculted result.
The mathematic model of shaft alignment is
established and hardware circuit is designed. The
2. The mathematic model of
laser shaft alignment equipment can carry out
measurement system
alignment measurement under various conditions.
And it can resolve the effect of soft ground pin and
There are two deviations in shaft misalignment.
temperture.Sampling machine testing indicates that
One is the parallel deviation. It means two jointed
the measurement precision, reliability are higher
shafts are parallel, but not collinear. Another is the
than similar products. It can meet the measure
angle deviation. It means two jointed shafts are not
requirement of coaxiality in shafting.
parallel and formed angle[3]. When Measuring,
Keywords: shaft alignment; Mathematic usually the two-axis spatial location are
model; Machinery; Spot
decomposed into two mutually perpendicular plane,
then the deviation can be calculted using the spatial
1. Introduction relationship of the two-axis, at last adjusting the
shaft alignment according to the calculation result.
Machine jointed by coupling would generate
The laser shaft alignment’s principle is changing
vibration in the running because of shaft
the data measured by PSD into the adjustment of
misalignment, the vibration affects the using life of
the slave shaft’s anchors.That is the process of
machine and damages the parts. So shaft alignment
building mathematical model.When installing,two
is an important process in power machinery
pillars were fixed vertically on driven shaft and
assembly[1].
slave shaft respectively, two pillars’s height are
The advanced Laser technology is the key
roughly equal and adjusted, as shown in figure
technology in measuring and adjusting shaft
misalignment. Laser shaft alignment producted in
china is used as alignment tools and the data
require manual calculation. And foreign products
are expensive[2]. So laser shaft alignment product
based on double LD-PSD is designed.And the
product can realize shaft alignment measurement
by various modes.In the actual measurement,the
relative position of the two shafts can be calculted
by measuring the spot’s coordinate of the double
Figure 1 Two-beam LD / PSD diagram
LD-PSD on three different angles.The alignment

978-0-7695-4249-2/10 $26.00 © 2010 IEEE 405

DOI 10.1109/ICINIS.2010.150
 1.Then fixed LD and PSD on each pillar,assuring
laser beam is parallel to driven shaft and slave shaft
respectively and sensor’s Photosensitive surface is
vertical to laser beam. The coordinates built
according to drive shaft and slave shaft is shown in
figure 2. xoy plane is vertical to drive axis and
D is approximate circle whose center is point A and
radius is R.point A is the intersection of z ′ and
xoy plane. σ is the polar coordinate of point
D,and its polar radius is CD, α is the rotation
angle.Supposing A ( e,β) is the point A‘s polar
coordinate,then its Rectangular is：

x′o′y ′ plane is vertical to slave axis.The angle A( x0 , y0 ) = A(e ⋅ cos β , e ⋅ sin β ) (1)

between drive axis and slave axis is very small,and

R2 = e2 + (L + σ ) 2 − 2e(L + σ ) ⋅ cos(β − α) (2)
the distance of two PSD is 1meter to several
meters,so we proposed xoy was parallel According to The Cosine Theorem,in ∆AOD ：
(R2 − L2 ) − (e2 − 2eL⋅ cos(β − α) + σ 2 ) + 2eσ ⋅ cos(β − α)
to x′o′y ′ .A ( x0 , y 0 ,0) is the intersection of σ=
2L
When measuring, R is approximately equal to L,
z ′ axis and xoy plane,and B ( x0′ , y 0′ ,0) is the
then formula (3) is：
intersection of z axis and x ′o ′y ′ plane.In
σ = x0 ⋅ cosα + y0 ⋅ sinα (3)
measuring,the key process is measuring the
coordinate of point A and B,then doing coordinate Similarly,the coordinate of point B is：
transformation.Various measuring modes were
σ ′ = − x0′ ⋅ cosα − y0′ ⋅ sin α (4)
designed in order to suit different measuring
conditions.The coordinate of point A and B was σ′ is the spot’s polar coordinate detected by
measured using Any 3 points measurement method. slave shaft’s PSD.
2.1 principle of any 3 points measurement
method Y
In figure 3,point C is the center of drive shaft’s
PSD.point D is the projection of laser beam from
R β
slave shaft’s LD to drive shaft’s PSD.When drive C D
e A R
and slave shafts turning a round simultaneously,the σ
L α
P2 (x2, y2,0)
X′ X
y O
x y′ Y′
Y

O′
O
A( x 0 , y 0 ,0) PSD2
X
z′
Figure 3 Measurement principle of arbitrary 3 points
B ( x0′ , y 0′ ,0)
z o′ When measuring any three points,the rotation
o

X
angle is α1 , α2 , α3 respectively,then
PSD1

O P1(x1, y1,0)
σ 1 , σ 2 , σ 3 is：
Y x′
h

Figure 2 Coordinate established σ 1 = x0 ⋅ cosα 1 + y0 ⋅ sin α 1

 （5）
by driving shaft and slave shaft σ 2 = x0 ⋅ cosα 2 + y0 ⋅ sin α 2
σ = x ⋅ cos α + y ⋅ sin α
track of point C on xoy plane is a circle whose  3 0 3 0 3

center is point O and radius is L；the track of point According to the least square principle the result

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 can be calculated, setting the distance between rear anchor to frant anchor on
3 slave shaft motor.
M = ∑ [σ i − ( x0 ⋅ cosα i + y0 ⋅ sin α i )]
i =1
Y-coordinate of E y and Fy can be cumulated by

Equations（5） can be soluted using Equations Geometrical relationship in figure 4.

（6）,the result is Equations （7）.

 ∂M ( x0 , y 0 )
 =0
 ∂x0
 （6） A B
 ∂M ( x0 , y 0 ) = 0 Y K
 ∂y 0 ky y0′
y0
 3 3 3 3

 ∑ sin 2 α i ∑ σ i cos α i − x0 ∑ sin α i cos α i ∑ σ i sin α i θy Z

 x0 = i =1 i =1 i =1 i =1
2
（7） Ey Fy
 3 3
 3 
 ∑ cos 2 α i ∑ sin 2 α i −  ∑ sin α i cos α i  d
 i =1 i =1  i =1  Z′


3 3 3 3
a b c
 ∑
i =1
cos 2
α i∑ i
i =1
σ sin α i − x0∑
i =1
sin α i cos α i ∑ i cos α i
i =1
σ
 y0 = 2

3 3
 3  Figure 4 The calculation of slide adjustment
 ∑ cos α i ∑ sin α i −  ∑ sin α i cos α i 
2 2

 i =1 
 i =1 i =1
and deviation of alignment

Similarly,the coordinate of ( x0′ , y0′ ) is：

The value of E y and Fy is the adjusting value
 3 3 3 3

 ∑ sin 2 α i ∑ σ i′ cos α i − x0 ∑ sin α i cos α i ∑ σ i′ sin α i

of frant and rear anchor on vertical plane.
 x0′ = i =1 i =1 i =1 i =1 （8）
2
 3 3
 3 


∑ cos 2 α i ∑ sin 2 α i −  ∑ sin α i cos α i 
 i =1   E = y 0 + (a + b)( y 0′ − y 0 )
i =1 i =1 (9)
 3 3 3 3  y α

∑ cos α i ∑ σ i′ sin α i − x0 ∑ sin α i cos α i ∑ σ i′ cos α i
2

 i =1 i =1 i =1 i =1 ′
 Fy = y 0 + (a + b + c)( y 0 − y 0 )
 y0′ =

3 3
 3 
2
 α
 ∑ cos 2
α i∑ sin 2
α i −  ∑
 i =1
sin α i cos αi 

 i =1 i =1

2.2 Deviation and adjustment calculation Similarly,The value of E x and Fx is the

After calculating coordinate of point A and B,
adjusting value of frant and rear anchor on Horizontal
get position relationship between drive shaft and
plane
salve shaft, next step , deviation of two shafts
alignment and adjusting of slave shaft’s anchor can be E = x + (a + b)( x0′ − x0 ) (10)
 x 0 α
calculated. Shown in figure 4, the calculation of the 
′
Fx = x0 + (a + b + c)( x0 − x0 )
vertical plane as an example, we can get the results  α
get the results.
θ y is angle deviation of two shaft on vertical
Point y0 、 y0′ is pioint A、B’s projection on
plane,
vertical plane, k y is coupling center’s projection on Z
k = y ′ + d ( y 0 − y 0′ )
axes on vertical plane. The projection of salve axes  y 0 α (11)

(
tan(θ y ) = 0y ′ − y 0 )
motor’s the frant and rear anchor is E y and Fy .A is  α
Positive and negative sign of the result indicate
distance between two PSD；b is distance between
the deviation direction on vertical plane.Similarly,the
PSD on salve shaft to frant anchor, d is distance
angle deviation on parallel plane can be calculated.
between PSD on salve shaft to coupling center, c is

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 k = x′ + d ( x0 − x0′ ) driven shaft and slave shaft respectively. A laser spot
 x 0 α emerged,when laser beam irradiated on PSD.The spot
 (12)
tan(θ x ) = ( x0 − x0′ ) position on the detected object coordinates can be
 α gained by PSD’s signal processing circuit.The signal

X1
2.3 Temperature compensation
D ( x, y )
Supposing H 1 and H 2 are the high of drive Y1
X2

and slave shaft,theLinear expansion coefficient of box LYY

is µ , t is working temperature, t 0 is air LX

O
Y22
temperature, ∆t is temperature changing by Figure 6 Schematic diagram of two-dimensional PSD
working.The temperature compensation would be
was collected to computerd A/D data acquisition
calculated according to the standard climate
card,then coordinate of point A and B can be
condition-20℃, so the effect of different seasons to
calculated by writing suitable software,it means the
temperature compensation would be smaller.
deviation and adjustment can be calculated[4].
3.2 The working principle and Signal Processing
∆ht = (∆t2 +t0 −20)⋅ µ2 ⋅ H2 −(∆t1 +t0 −20)⋅ µ1 ⋅ H1 (13) Circuit of The PSD
PSD is a new Photoelectric detecting device.It is
According to formula（13）and（9）,the new
composed of P substrate, PIN photodiode and the
adjustment is：

E y = y 0 + (a + b)( y 0′ − y 0 ) α + ∆ht

surface resistance,as shown in figure 6[5]. ( x, y ) is
 (14)
 Fy = y 0 + (a + b + c)( y 0′ − y 0 ) α + ∆ht the coordinate of point D,Photocurrent output of each

3. laser shaft alignment system based Electrode is X 1 , X 2 , Y1 , Y2 .the location coordinate

on double LD-PSD
of incoming spot is：
3.1 The system’s composition and principle
The system composition is shown in figure 5. the LX X 2 − X 1
x=
system has five parts:laser source,Optical 2 X 2 + X1
target,signal processing circuit,data acquisition
system,computer. LY Y2 − Y1
y= （15）
2 Y2 + Y1
Then the polar coordinate of point D can be
calculated：
Figure 5 The system block diagram of
fixturlaser shaft σ = x2 + y2 （16）

The signal processing circuit of the PSD is

3.1 The system’s composition and principle shown in Figure 7.
The system composition is shown in figure 5. the First, the output current would be amplified by
system has five parts ： laser source,Optical the operational amplifiers and be converted to the
target,signal processing circuit ； data acquisition voltage signal. At the same time, attention must be
system；computer. paid to selecting suitable feedback circuit to ensure
When measuring,LD and PSD were fixed on that the four circuits of the PSD have the same

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amplifying performance. Next, adder and subtraction plane- E x and Fx ,calculating deviation of the shaft
operation would be realized with operational
amplifiers. And division operation would be realized misalignment on and vertical plane- E y and Fy . At
with analog divider. Finally, we can obtain a voltage
the same time, calculating the angle between the
signal that is proportional to the positional signal.
And after linking to the computer by high speed A/D horizontal and vertical plane- θ x and θ y .
converter, we can calculate the shaft misalignment
value and the adjustment value.
4. The experimental results analysis

In this experiment, we adopted the infrared

semiconductor laser as light source, because the peak
value of PSD’s spectral response was in the infrared
region. PSD was the homemade position sensitive
Figure 7 Two-dimensional PSD photodetector and the type was GD3284Y. The size
Signal Processing Circuit of PSD’s photosensitive surface was 10 mm ×10mm.
3.3 The software design for the measurement system The output voltage of the sensor changed from +5V
The software is developed using language C. to －5V by adjusting the feedback resistance value of
The software diagram is shown in Figure 8. First, the operational amplifier and selecting a suitable
acquiring the data from the workpieces joined by the magnification.
same coupling and calculating. Then, integrating Table 1. The actual measured values
every result. Finally, calculating deviation of the shaft (a=300mm)
misalignment on horizontal
Parallel
angle deviation/rad
deviation /mm
Input coupling type and size of the machine D
X Y
（mm） horizontal vertical
direction direction
angle angle
deviation deviation
No
Test system debugging 300 0.058 0.059 0.011 0.011
is completed or not. 400 0.062 0.065 0.009 0.009
Yes 500 0.067 0.064 0.008 0.007
600 0.069 0.068 0.007 0.006
measureing average 0. 0.
0.064 0.064
value 008 75 00825
The diameter of the coupling was 300mm. The
Misalignment and re-calculation
angle deviation between horizontal plane and the
adjustment
angle deviation to vertical plane were both 1 degree.
And the coaxial position deviation was 0.30mm
Yes No Store and adjust (deviation in X--axis direction was 0.16mm, deviation
Whether remeasurement
or not the organ in Y--axis direction was 0. 254 mm). When the
distance between the laser and PSD was 300mm, the
Figure 8 Software system design flow measuring results—the shaft alignment deviation in
X-axis direction and the shaft alignment deviation in

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Y-axis direction were shown in Table 1. The parallel misalignment value met the precision demand of shaft
deviation and angle deviation in X-axis and Y-axis alignment-- tolerance Level T14 in geometric
direction were shown in Table 2, while changing the tolerance zone.
distance D.
Table 2. the actual measured values when the 5. conclusion
distances between the laser and the detector
changed This experimental system is simple and easy to
use, and can be used by manual or automatic
angle measurement methods. The system has automatic
deviation/mm
deviation/rad collection, transmission, storage data capabilities. It
count
Parallel Vertical horizontal vertical can calculate the data automatically and give the
deviation deviation angle angle adjustment quantity by software. And the system has
1 0.056 0.054 0.011 0.010 good repeatability and strong anti-jamming
2 0.053 0.051 0.010 0.010 characteristics. Through many times testing, the
3 0.059 0.052 0.011 0.010 alignment effect is good, and it is convenient in
4 0.051 0.058 0.010 0.011 adjustment, it owns promoting value and many
5 0.069 0.065 0.013 0.012 advantage compared with overseas similar product.
6 0.0576 0.056 0.011 0.0106

According to GB1187 － 96, the shaft

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