Textile And Rubber Mill Roll Alignment
Traditionally with lower-accuracy roll alignment applications, such as textile and rubber mills, alignments have been performed using cumbersome and time-consuming optical transits or theodolites. Not only are optics slow and heavy, but they also require at least 2 technicians to run the instrument, which is why most mills in the industry hire outside contractors. Now, that is starting to change with the introduction of the L-730 series of automatically sweeping lasers that are now priced competitively with most new optical instruments. In fact, when the extra manpower needed with optics is considered, our lasers systems are actually less expensive than optics.
The L-732 Precision Dual Scan® Roll Alignment System is one of only 2 lasers in the world (the other is the L-742) to offer 2 automatically rotating laser planes that are highly accurate and versatile. This creates a powerful tool to not only MEASURE but also FIX roll misalignment on almost any kind of process mill, all in less than half the time of conventional methods.
Accurate Alignment Increases Material Flow and Quality
With poor alignment, most roll-type machines, whether a textile line or rubber line, will produce a product that has wrinkles and other quality problems. The material may also wander or "walk" to one side of the roll or the other. This means a lot of down time and tons of scrapped product. The L-732 not only produces a highly accurate alignment, but it also does it in record time, saving enormous costs in reduced downtime, scrapped product and quality problems. In fact, most machines processes that can handle it can run at faster speeds after laser alignment. This increased productivity will pay for the laser in a matter months, in some cases.
Less Manpower Needed for Alignments
The L-732 Roll Alignment System reduces alignment manpower. Wireless targets and automatically rotating laser planes make setting up the laser at each machine section a one-man job, freeing up technicians for other critical work during shut downs. The R-1355 Wireless PDA readout displays both reference/measuring targets simultaneously, allowing the operator to quickly set up to the offset centerline reference benchmarks. Traditional optics usually require at least two men to work the instrument.
Laser Technology Reduces Optics' Variability Between Alignment Crews
PSDs, or position sensing detectors, are one of the critical components of our laser alignment systems. It is this PSD that senses the laser beam and turns it into a digital signal. This greatly reduces the man-to-man variability found in optical measurements because sophisticated electronics determine the measurement rather than the human eye. Anyone with optical experience knows that the quality of the measurement depends on having the same experienced person perform the entire alignment, which can create big problems when the job takes more than one shift to complete.
By relying on the PSD to produce highly repeatable measurements, our L-732 makes it much easier to hand off an alignment project from one crew to the next. This greatly reduces the need to have new crews backshoot the previous crews' work to "calibrate" to their readings.
No Need for Optic's Recalibration After Plumb Measurements
Unlike optics, that usually require time-consuming recalibration of the levels each time plumb is checked, the L-732 has a level built into the laser head, eliminating the need for recalibration just to check plumb. The levels usually only require calibration once a month.
Laser Planes Have 200' Range
One of the most powerful features of the L-732 is the automatically rotating laser plane with a range of 100' (30.5 M) in radius. That means the horizontal parallelism of rolls at almost any elevation can be measured simultaneously without having to move the laser vertically. This also allows the laser to be moved to more sections without having to change the location of the reference targets.
Competitive Laser Systems Use 10-Year Old Technology
Our competitors' roll alignment systems use point-and-shoot laser technology, along with remote beam-bending devices that are difficult to set up and re-locate. We abandoned that laser technology 10 years ago with the introduction of our multi-plane, continuously rotating lasers. Not only is this point-and-shoot technology difficult to set up, it also requires extra manpower and about 50% more time.
Factory-Built Benchmark Fixturing
The L-732 Precision Dual Scan® Roll Alignment System comes with fixtures to pick up floor benchmarks for aligning the laser to the machine's centerline. The L-732 also has the flexibility to easily use a reference roll to set up temporary offset centerlines. In fact, this is our preferred method of referencing the machine's centerline, as benchmarks are frequently in not much better shape than the floor they sit in. Cracks in the floor can seriously affect the position of the benchmarks and often result in poor alignments (see "Choosing a Reference" in How it Works).
Multiple Wireless Targets Speeds Alignments up to 70%
Hamar's L-732 utilizes up to 5 A-1519-2.4ZB targets, with up to 150 feet (45m) of range, to send their data to our R-1355-2.4ZB IP67 Rugged PDA Readout. The R-1355 can display up to 5 targets simultaneously, reducing alignment times by up to 70% over optics or other alignment systems.
Measure More Rolls With Each Setup
By using a laser plane, Hamar's L-732 has the ability to measure multiple rolls from the same setup. Rolls up to 100 feet (30.5 m) above the laser can easily be measured.
R-1355-2.4ZB PDA Readout with
laser aligned to reference targets,
showing a roll measurement.
Read9 Multi-Target Display Speeds up Laser Transfer
The setup process is easy and fast because our Read9 PDA Display program displays up to 5 wireless targets simultaneously, so when using the Laser Transfer Method, you simply look at the data for the 2 reference targets (usually #2 & #3) and adjust the laser until both numbers are the same. Then use the measuring target to measure the roll or rolls.
Tram Bar Measurement Method
For situations where it’s impossible to put the target on the side of the roll, we use the Tram Bar Method. Here you put a tram bar over the end of the shaft and put a target on it. Zero at 12:00 and measure at 6:00 to check roll levelness. Then zero at 3:00 and measure 9:00 to get the parallelism relative to the reference roll.
- Two continuously rotating laser planes with operational range of 100’ (30.5 m) in radius
- Laser planes flat to .00012 in/ft (0.01mm/m).
- Using a reference roll, the measuring laser plane is parallel to roll datum to .00018 in/ft (0.015 mm/m) at any location along the machine.
- Back-lit levels accurate to .00012 in/ft (0.01 mm/m)
- A-1519-2.4ZB Single-Axis Wireless Target with 1.3” (33 mm) PSD and .00002” (0.0005 mm) resolution
- R-1355-2.4ZB Wireless PDA displays up to 5 targets simultaneously
- Factory-built benchmark reference fixtures for easy laser transfers and referencing floor benchmarks
- L-106 X-Y Tripod Translation Slide to speed up laser transfers and target setup
- Typical setup time 15 minutes or less