TUTORIAL FORMULAS FOR INDICATOR REVERSE ALIGNMENT AND GRAPHING SHIM CHANGES By Larry Alvarez There are four

ways to write down the same misalignment (depending on where you zero your dial indicators) and four sets of formulas to calculate shim changes so that a positive answer means to add shims and a negative answer means to remove shims. Notice these formulas are nearly exact except for the addition and subtraction elements. Only one of these indicator orientations will allow you to graph the shim changes in such a manner that a positive indicator reading always means to plot up and a negative indicator reading always means to plot down, that is example #2. Abbreviations: MtoF = Movable to Fixed, the total indicator reading at the indicator reading on the fixed machine. FtoM = Fixed to Movable, the total indicator reading at the indicator reading on the movable machine. 1. 0 0 .005 MtoF .005 -.005 FtoM -.005 .010 -.010

Front Shim Change = [(Front Foot to First Button /Button to Button) * ((MtoF+FtoM)/2)] + (FtoM/2) Rear Shim Change = [(Rear Foot to First Button /Button to Button) * ((MtoF+FtoM)/2)] + (FtoM/2) 2. 0 .005 MtoF .005 .010 .010 .005 FtoM .005 0

Front Shim Change = [(Front Foot to First Button /Button to Button) * ((MtoF-FtoM)/2)] (FtoM/2) Rear Shim Change = [(Rear Foot to First Button /Button to Button) * ((MtoF-FtoM)/2)] (FtoM/2) 3. -.010 0 -.005 MtoF -.005 -.005 FtoM -.005 0 -.010

Front Shim Change = [(Front Foot to First Button /Button to Button) * ((MtoF-FtoM)/2)] + (FtoM/2) Rear Shim Change = [(Rear Foot to First Button /Button to Button) * ((MtoF-FtoM)/2)] + (FtoM/2) 4. -.010 .010 -.005 MtoF -.005 .005 FtoM .005 0 0

Front Shim Change = [(Front Foot to First Button /Button to Button) * ((MtoF+FtoM)/2)] (FtoM/2) Rear Shim Change = [(Rear Foot to First Button /Button to Button) * ((MtoF+FtoM)/2)] (FtoM/2)

To calculate shim changes by graphing follow these instructions. Make sure your indicators are oriented as in example #2. (Or change the signs accordingly). MtoF 0 here Fixed Machine[ ]_____Movable Machine_______________________ [Button to Button]Front Foot to First Button ^ ^ ------------- Rear Foot to First Button-------------- FtoM 0 here 1. 2. 3. 4. 5. 6. 7. 8. 9. On a piece of graph paper select a horizontal line (each square in the horizontal direction will represent one inch). Place a mark on the far right of this line representing the rear foot of the movable machine. Measure the distance between the rear foot and the front foot. Count over this number of squares on the horizontal line and place another mark representing the front foot of the movable machine. From the front foot measure to the plane of the first indicator button. Count over this many squares on the horizontal line and place a mark there representing the coupling. (Actually it may not be the coupling; its the place where the indicator is reading). Measure the distance between the two planes that the indicators sweep. Count over this many squares on the horizontal line and place another mark representing the other coupling. From the mark representing the MtoF indicator plot up or down half of this value and place a dot there. (We all know that the centerlines are really just half the indicator reading apart). If positive plot up if negative plot down. Each square in the vertical direction will represent one thousandths of an inch. (.001) From the mark representing the FtoM indicator plot up or down half of this value and place a dot there. Using a straight edge connect the dots with a line continuing across the entire movable machine side of the graph paper (do not extend this line to the side where the fixed machine is located as this might cause some confusion as to which machine is to be moved). From this line, where it intersects with he vertical line that represents the front foot, count the number of squares to the original horizontal line, this is the front shim change (if counting down remove shims if counting up add shims). From the mark at the rear foot count up or down to the original horizontal line, this is the rear shim change.

10. 11. 12. 13. Hints: 1. 2.

Should an alignment other than zero be required, plot the target alignment as the original line and count to the target line rather than the horizontal line. Unless you have a programmable calculator or a computer aided alignment program I recommend calculating shim changes by using the graph method. In calculating shim changes using these formulas there is great risk of human error. The graph is more intuitive and allows you to picture the alignment in your mind.

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When you draw the line to calculate the shim changes it goes off the graph before it crosses the vertical line at the feet. You need to reposition the original line in a different area of the graph paper or use larger graph paper. Dial out the sag, measure the sag in your fixture, then on the top indicator, instead of zeroing the indicator set it at the positive amount of sag. Instead of zeroing the bottom indicator, set it at the negative amount of sag. Continue to write down this reading as zero. To make a sideways correction, zero both indicators on the side of the machine, roll the shafts 180 degrees, and turn the indicator dials half way back to zero, and then move the machine until the indicators go the rest of the way to zero. Watch both indicators and make sure they go the correct way back to the original zero. You make a shim change and it appears that you went twice as far as you should have. Make sure you plot only one half of the indicator readings. You remove shims from the machine but the next set of readings show that it did not go down. Remove the hold down bolts and look down into the hole (a mirror may be required). If the bottom of the bolt is hitting on the top of the grout or if dirt has fallen down into the hole the bolt could be acting as a jack bolt and jacking the base up to the machine rather than pulling the machine down to the base. You should use shorter bolts or clean out the hole. You tighten the hold down bolt as carefully as you can but the machine moves sideways. The bolt may be bent, replace the bolt or tighten the other bolts first. The bolts are not bent but the machine moves sideways when you try to tighten the bolts. The flat washer under the bolt head may be cupped and the washer is trying to center itself in the bolt hole, pushing the machine sideways in the process. Use a very thick washer that will not give way when the bolt is tightened on it. You have lots of angular misalignment and when you make a shim change it doesnt even get close to your target alignment. Inherent graphical error causes alignment changes involving lots of angular misalignment to loose accuracy, you may have to make more than one correction to correct this type of misalignment. You have completed the alignment to within specifications yet a vibration analyst shows an alignment problem. Varying thermal growth of the support points may be making the hot running alignment unacceptable, a hot alignment check may be required and a new target alignment specified. Many times other problems manifest themselves as alignment problems, such as improper coupling lubrication, damaged coupling components, broken grid members, cracked flexplates or broken elastometers. Thoroughly inspect the coupling.

* Please report any errors found here to the author, Larry Alvarez.