Galvanizing Line Pot Equipment Life

A steel mill galvanizing line in the mid west was experiencing severe bearing wear of the pot equipment in the zinc tank. Projected bearing life was 6 weeks, but the mill was stopping production every 2 weeks to replace badly worn bearings and was running very close to complete bearing failure on several occasions.

After attempts to align the pot equipment by a local company using a Laser Tracker failed, AIM was brought in to do a survey of the galvanizing line pot equipment. A one day AIM survey, and corrections based on the survey that day, produced an immediate and dramatic change to the process. Bearing life improved to 8 weeks and strip tracking throughout the pot and tower areas improved as well.

Score: AIM = 1, Laser Tracker = 0

Limited Access Rolls

A recent survey by an AIM crew revealed some interesting results regarding felt tracking in a coater. This appears to also be an issue in the paper machine as well.

The survey performed with AIM’s state of the art Laser Systems and Tooling showed that the rolls that were easily accessible with conventional optical tooling were within a tolerance window that is considered acceptable. However, rolls that were not easily acceptable with conventional optical instruments were considerably out of alignment. In addition, the customer stated that the AIM crew collected considerably more data than any supplier had been able to collect in a conventional 8 hour down turn.

The issue of rolls in the basement of a paper mill and on top of the machine is always a difficult and time consuming project. AIM's technology and methonds have limited the amount of time required and increased the accuracy level by a very significant factor. To learn more about the AIM Advantage visit our website at http://www.aimlaser.com/

Laser Alignment vs Optical Alignment - Part 2

This is part 2 of a discussion comparing laser alignment techniques to optical alignment techniques.

The AIM ADVANTAGE  

Single Base-line
The AIM method of using a single baseline eliminates the multiple setups required with conventional optics. The need to constantly move and re-setup the “Gun” is gone. The laser is aligned to the baseline and a 90 degree Penta Prism accurately creates a plane at 90 degrees to the single baseline. Using a single baseline, the data can be repeated at unrelated time intervals.

Fixtures, Methods
Many years of experience using optical instruments and applying those lessons to laser technology have produced a multitude of procedures and tooling that can be applied to almost any situation. The unique methods and tooling created by AIM are only available through AIM. The patented “sweep” method of measuring enclosed rolls is just one example of unique solutions AIM brings to the table.

Experience
The experts at AIM provide more than just measurement data. AIM is an industry leader in laser-based measurement and alignment services with the ability to solve complex process problems. Our achievements in process improvements are second to none. Our experienced engineers and technicians have in-depth process knowledge and are trained in the use of advanced laser-based measurement equipment and methods. AIM personnel hold several patents on laser equipment and processes.

Computer Generated Reports
AIM service reports are among the best in the industry. Customers receive more than just survey dimensions and measurements. Our reports include drawings and layouts as well as interpretations, analysis and recommendations. We provide the complete report at the end of the service day and can provide data during the day as well, especially if corrections are warranted. Customers will soon have the ability to access all of their service reports online at http://www.aimlaser.com/.

New Wireless System
At AIM “the best just got better”! We utilize the latest wireless technology between the laser detector and the control box. No more cables.

Speed
The AIM ADVANTAGE saves you time and money!

Laser Alignment vs Optical Alignment - Part 1

This is part 1 of a discussion comparing laser alignment techniques to optical alignment techniques.

How does Laser Alignment compare to Optical Alignment?
At AIM we are redefining the standards for precision alignment by using laser technology coupled with fundamental measurement principles. These methods allow us to deliver unprecedented speed and accuracy to our customers.

Laser Alignment
• Objective Data
• Repeatable
• Precision
• “Live” moves (real time data)
• Latest Technology

Optical Alignment
• Subjective Data
• Inconsistent
• Operator Dependent
• Move & recheck, repeat
• Introduced in World War II

Laser-based data collection is objective, repeatable and precise! Visual optical surveying techniques rely heavily on the experience of the operator and his/her ability to read the scale accurately (subjective opinion). External factors such as vibration, heat, air flow and unknown windage can all affect the accuracy of optically collected data. Operator error can also be introduced in a variety of areas such as the ability of the “Stick Man” to hold the scale perpendicular to the part and to hold it level in-line with the roll center. AIM has designed dedicated fixturing to eliminate these issues.

Contact AIM to learn more about our Laser Alignment Services or visit our website at http://www.aimlaser.com/

About American Industrial Metrology

Laser-Based Alignment Services
AIM, founded in 1996, is a leading provider of laser-based process alignment services and laser machine alignment in the Midwest. We service many different industrial fields, but specialize in Steel Processes. Our achievements in process improvements are second to none.

Measurement Systems
AIM Systems provide accurate, precise data to improve your process. Our non-contact measurement systems are safe and environmentally friendly. It is no longer necessary to use radioactive sources. Contact us to find out how to replace your radioactive x-ray gauge.

Custom Solutions
Put our creativity and experience to work for you. We are experts in the field of laser alignment services and the application of laser-based measurement instruments. Our custom solutions have provided many companies with new methods of collecting accurate measurement data. Ask about some of our recent projects.

AIM Experience
AIM has a quality work force with strong references featuring over 65 years of combined experience. Our engineers and technicians are trained in problem solving with the use of advanced laser-based measurement equipment. AIM personnel hold several patents on laser equipment and processes. Among these is the patented ability to measure enclosed rolls (i.e. furnace rolls, acid rolls).

Industries We Serve:
• Steel (Hot Mills, Cold Mills, Service Centers, and Processors)
• Aluminum
• Paper Manufacturing
• Plastics
• Automotive Parts and Assembly
• Volume Parts Manufacturing & Machining