Features and Applications of the AT-100 Shaft Alignment System

AT-100 Shaft Alignment system by ACOEM is designed to provide precise and efficient shaft alignment solutions for industrial machinery. This system stands out for its high-quality construction, user-friendly interface, and advanced technological capabilities that improve both alignment accuracy and operational efficiency.

Key features of the AT-100 Shaft Alignment System

High-Performance Sensors (M8 and S8)

• The AT-100 system incorporates two robust sensors, designated as M8 and S8. These sensors are constructed using anodized aluminum and ABS plastic, providing a durable and impact-resistant frame suitable for harsh industrial environments.
• The sensors operate within a temperature range of 0 to 50°C, with a high tolerance for varying storage conditions between -20 and 70°C. This versatility makes the system adaptable to different working environments.

Laser and Measurement Accuracy

• The system features a Class II laser diode with a wavelength of 650 nm, operating at less than 1 mW of power. This classification is crucial for safe usage in standard industrial settings.
• It has a maximum measurement distance of 2 meters, allowing for flexible setup and effective alignment over significant distances between machinery shafts.
• The digital line sensor integrated within the measuring units offers a 20 mm detection length, with a high resolution of 0.01 mm. This level of precision ensures that even minor misalignments are detectable and can be corrected efficiently.
• Measurement accuracy is rated at 1% ± 1 digit, ensuring reliable readings that facilitate optimal machine performance.

Inclinometer and Wireless Capabilities

• The sensors include an inclinometer with a resolution of 1° and an accuracy of ±3°. This feature supports accurate measurement and analysis of shaft angles, which is critical for comprehensive alignment tasks.
• The system utilizes Class I Bluetooth for wireless communication. This connection provides a reliable transmission range of up to 10 meters, allowing the sensors to communicate seamlessly with the accompanying tablet or device without the need for physical connections.

User Interface and Display

• The AT-100 system includes a dedicated application that supports a straightforward and efficient alignment process. Users can download the app from standard app stores, and it is compatible with both Android and iOS devices.
• The app guides users through the entire alignment process, from initial measurements to final adjustments. Key features of the software include real-time data feedback, an easy-to-navigate menu, and the ability to save and generate PDF reports for documentation.

Battery and Power Supply

• Each sensor is powered by a high-capacity, rechargeable lithium-ion battery, which provides approximately 12 hours of continuous operation. This duration is sufficient for most full-day alignment tasks.
• The batteries can be charged using a mini USB port, and the system allows for simultaneous charging while the units are in operation. The charging process is indicated by an LED light, which turns green when fully charged.
• To preserve battery life and ensure consistent performance, the system includes safety features that prevent overcharging and potential damage.

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Applications of the AT-100 Shaft Alignment System

The AT-100 Shaft Alignment system is employed across a range of industries where precise machine alignment is crucial for operational efficiency and equipment longevity. Key applications include:

Industrial Manufacturing

• In manufacturing facilities, misalignment between machinery such as motors, pumps, and gearboxes can lead to increased wear and tear, higher energy consumption, and unexpected equipment failure. The AT-100 system helps detect and correct these misalignments, thereby enhancing machine reliability and reducing downtime.
• The system’s ability to produce detailed reports allows maintenance teams to document alignment results, facilitating a more structured and data-driven maintenance routine.

Power Generation

• Power plants rely on the efficient operation of turbines, generators, and compressors. Any misalignment in these components can lead to vibrations, excessive heat generation, and reduced energy output. The AT-100 system’s precise measurement capabilities ensure that such critical machinery is aligned within stringent tolerances, maximizing performance and minimizing the risk of costly breakdowns.
• The system’s ability to handle harsh environments, such as those with high humidity or temperature variations, makes it particularly suitable for power generation applications.

Petrochemical and Oil & Gas Industries

• The petrochemical and oil & gas sectors require robust alignment tools that can withstand extreme conditions and ensure the safe operation of rotating equipment. The AT-100 system, with its IP54-rated sensors, is well-suited for these demanding environments.
• Its quick setup and efficient alignment process minimize maintenance time, allowing critical equipment to be brought back online swiftly. Additionally, the wireless communication feature enables remote operation, which is beneficial in hazardous areas where safety is a top priority.

HVAC and Facility Management

• Proper alignment of HVAC systems, including pumps and fans, is essential for energy efficiency and maintaining a comfortable environment in large buildings. The AT-100 system simplifies the alignment process, making it easier for facility managers to maintain optimal performance.
• The system’s user-friendly app ensures that even less experienced technicians can carry out alignment tasks with confidence, reducing the need for extensive training or specialist knowledge.

Marine and Shipping

• The maritime industry requires precise alignment of propulsion systems and auxiliary machinery. Misalignment in these systems can cause severe operational inefficiencies and damage. The AT-100 system is ideal for use in shipyards and onboard vessels, providing accurate measurements even in challenging sea conditions.
• The system’s portability and rugged design make it a practical choice for the marine sector, where space and durability are often critical considerations.

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Workflow and Process Efficiency

The AT-100 Shaft Alignment system is designed to streamline the alignment process from setup to completion. The standard workflow involves several key steps:

1. Pre-Alignment Checks
   • Before initiating alignment, the system recommends performing various pre-alignment tasks, such as checking the foundation of the machine, assessing the condition of shims and bolts, and ensuring there are no restrictions on machine movement.
   • Pre-alignment checks also include ensuring that the operating environment, such as temperature and humidity, is suitable for precise measurements.
2. Sensor Setup and Calibration
   • The M8 and S8 sensors are mounted on the shafts using V-brackets and chains. The system allows for height adjustment of the sensors to ensure a clear laser path between them.
   • Proper tensioning of the chains is necessary to secure the sensors and prevent slippage during rotation. The user interface provides feedback on laser alignment and ensures that both sensors are correctly positioned.
3. Measurement and Data Collection
   • The AT-100 system employs the Tripoint™ method, which involves taking three measurements at different rotational angles (spaced at least 45° apart) to calculate the alignment condition. This method ensures a comprehensive analysis of both angular and parallel misalignment.
   • The system’s software automatically processes the data, presenting the results in a clear and intuitive format. Users can view misalignment values in real-time, along with indicators showing whether the measurements are within acceptable tolerances.
4. Alignment Adjustments
   • For vertical alignment, the system provides precise guidance on adding or removing shims to achieve the desired position. The real-time feedback feature allows users to make adjustments efficiently, minimizing the need for repeated measurements.
   • Horizontal alignment is similarly guided, with arrows and visual cues indicating the direction and magnitude of adjustments required. The app’s live mode ensures that every change is accurately reflected, making it easier to achieve optimal alignment.
5. Documentation and Reporting
   • Upon completing the alignment, the system prompts users to save the results and generate a PDF report. This report includes all relevant measurements, correction values, and a summary of the alignment status.
   • The ability to customize reports, including adding company logos and detailed notes, enhances the professional presentation of the data. This feature is particularly useful for maintenance audits and compliance with industry standards.

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Advantages of the AT-100 Shaft Alignment System

1. Ease of Use
   • The intuitive design of the AT-100 system, combined with its comprehensive software, makes it accessible to both novice and experienced users. The step-by-step guidance provided by the app reduces the learning curve and ensures consistent alignment quality.
2. Portability and Durability
   • The compact and lightweight design of the sensors, coupled with their IP54 environmental protection rating, makes the AT-100 system suitable for a wide range of applications. It is particularly advantageous in field settings where portability and robustness are essential.
3. Safety Features
   • The Class II laser and built-in safety measures, such as secure battery circuits and durable housing, ensure safe operation even in demanding environments. The system’s warning indicators and instructions help prevent common user errors that could compromise safety or measurement accuracy.

The AT-100 Shaft Alignment system is a versatile and efficient tool for achieving precise shaft alignment across various industrial applications. Its combination of advanced measurement technology, user-friendly software, and robust construction makes it an indispensable asset for maintenance teams looking to improve equipment reliability and operational efficiency.

By streamlining the alignment process and providing accurate, real-time feedback, the AT-100 system ensures optimal machine performance and contributes to the overall productivity of industrial operations.

Technical specifications for the AT-100 Shaft Alignment system

• Housing material: Anodized aluminum frame and ABS plastic.
• Operating temperature: 0 to 50°C (32 to 122°F).
• Storage temperature: -20 to 70°C (-4 to 158°F).
• Long-term storage temperature: Room temperature (18 to 28°C or 64 to 82°F).
• Battery charging temperature: 0 to 40°C (32 to 104°F).
• Relative humidity: 10 – 90%.
• Weight: 222 grams (7.8 oz).
• Dimensions: 94 mm x 87 mm x 37 mm (3.7 in x 3.4 in x 1.4 in).
• Environmental protection: IP54 rating.
• Laser: 650 nm Class II diode laser with power < 1 mW.
• Measurement distance: Up to 2 meters.
• Detector: Digital line sensor, 20 mm length with a resolution of 0.01 mm.
• Measurement accuracy: 1% ± 1 digit.
• Inclinometer resolution: 1°, with an accuracy of ±3°.
• Wireless communication: Class I Bluetooth transmitter with a communication range of 10 meters (33 feet).
• Connectors: 1 USB Mini port; 5V, 0.5A for charging.
• Power supply: High-performance Li-Ion battery or external power.
• Operating time: 12 hours of continuous use.
• Battery charging time: 8 hours (when the system is off and at room temperature).
• Battery capacity: 10.4 Wh.
• LED indicators: Indicate wireless communication, laser transmission, and battery status.

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