Problems with misalignment usually begin when coupled shafts are positioned so that their gaps or offsets are beyond acceptable limits. Shafts subsequently run off-centre, leading to higher loading, excessive heat generation and greater energy consumption.
Indications of misalignment include increased temperature, high vibration, loose coupling bolts and excessive lubricant leakage at bearing seals. Any machines or systems showing these signs will likely have a negative effect on profitability through higher power usage.
NSK offers advanced laser alignment tools for shafts (LAS-Set) and belts (LAB-Set) that help to ensure alignment. LAS-Set uses dual line lasers for set-up, even at larger distances, along with high-resolution digital sensors for precise results. LAB-Set houses two line laser transmitters.
According to NSK, adopting these tools not only contributes to energy efficiency, but also reduces wear on critical machine parts such as couplings and seals, subsequently minimising machine downtime and maximising productivity.
Plants using NSK laser alignment tools are said to have recorded energy savings of up to 17%, leading to a return on investment.
Elsewhere in the business, NSK manufactures energy-efficient bearings that are claimed to save money via low machine running costs while also cutting carbon dioxide emissions. The company’s NSK deep groove ball bearings are claimed to reduce energy by up to 80% when deployed in electric motors.
Another solution is NSK’s EA7 grease, which is expected to reduce internal friction and increase energy efficiency.