Types Of Incorrect Roll Alignment

Incorrect Roll Alignment

Roller alignment is important in many manufacturing and agricultural practices. These elements help to operate wheels, belts and several other elements that form an essential part of the overall business process. When you can maintain these components and ensure all are operating as intended, you can extend the life of all elements and ensure fewer breakdowns or drops in production. We can measure two types of misalignment in these spaces, in-plane and out-of-plane. When referring to the plane, it pertains to the web or belt going into a particular downstream process.


The type of optical analysis performed to determine in-plane misalignment is the “square” measurement for a horizontal run going into a downstream roller. Both upstream and downstream components square measurements are taken, as both elements should be level and in the same orientation. After all, the difference between the upstream and downstream roller’s square measurements is more important than their relation to the machine lines. These misaligned parts will usually shift the system’s efficiency overall and cause potential ruffling in the belt or moving mechanism. This can be catastrophic to manufacturing or product management, leading to broken parts or halted process and downtime.  


Out-of-plane misalignment is not as important as in-plane elements, as differences will be seen as a small twist to the web. This condition does not affect the formation of wrinkles as much as in-plane but instead allows for slopes to form on the web or belt. This can cause rubbing and increased tension o any belts or even cause the dislodging of material during processing. With a twist in the system, you can have several issues form, frequently causing a mess and creating downtime across the process. Sometimes this can be a low enough impact to allow machines to operate, but you will still experience increased wear over time. 

Optical Misalignment

Optical alignment is the measure of choice for rollers. The optical equipment is set up in line with the machine’s main centre line for exact measurements. The angles and positions are noted in detail and reflected on opposite sides for reference. With all measurements taken, you can check that the system is square; if not, you can detail the degree to which each element is out. With the right tools and processes, you can correctly analyse your system components are realigned them with efficiency. When you use optical systems, you can see the differences and use precise tools to recentre all elements. 

Pi Tape Misalignment

A quick method to check roll-to roll-alignment is to use a Pi tape. This process involves checking the distance around rollers on both the tending and drive sides. This gives you a relative difference to compare, but it cannot show you which element has shifted and to what degree. More readings of upstream or downstream rollers may need to be taken to determine which element is the one causing the issue. Acceptable tolerances vary depending on many factors, but as a quick device and check, they can be used to see whether or not alignment has occurred before taking on more intensive checks and approaches. 

You can quickly and effectively manage your machines and business processes with the right tools and services for roll alignment. These maintenance services ensure you have checked all belt and conveyor systems, and each runs at optimum levels. With professional solutions, you can decrease your downtime and increase the efficiency of the process around your working space. These tools and resources allow you to manage your business more effectively and ensure that you are not at risk of downtime or increased repair costs to keep your business operational. In addition, you can protect the machine and keep all components running well with more management. Contact us today to find out more about these services.