How Does Laser Alignment Work? A Guide for Facility Managers and Engineers

Most rotating equipment failures are caused by shaft and pulley misalignment. For anyone responsible for maintaining industrial machinery, laser alignment is one of the most effective tools available for extending equipment life, reducing breakdowns, and cutting energy costs.

Marley Flow Control has been providing laser alignment services across Australia since 2002. This guide explains how laser alignment works, why it outperforms traditional methods, and how to incorporate it into your maintenance schedule.

What is Laser Shaft Alignment?

Laser shaft alignment ensures that the shafts in your machinery are correctly aligned, both horizontally and vertically. It uses a laser to take precise measurements between two connected shafts.

The process works as follows:

1. A sensor is placed on each shaft

2. Both sensors fire a laser beam while simultaneously receiving the beam from the other sensor

3. A comparison of the beams reveals whether the shafts are correctly aligned

4. Results appear on a display unit, enabling analysis and any correction needed

Laser Alignment vs Traditional Alignment Methods

Laser-based technology has several distinct advantages over traditional tools such as straight edges, optics, and dial indicators.

Fast, accurate, and reliable measurements

Standard rulers and dial gauges are often not accurate enough for modern machinery. Laser alignment can be completed up to ten times faster than dial gauge methods and can measure down to 0.001 mm, a level of accuracy traditional setups cannot match.

Lasers are also unaffected by gravity, which is a significant advantage when taking measurements. The technology allows measurements to be taken with a shaft rotation of just 40 degrees, making it possible to work around piping and equipment that would obstruct traditional methods.

Expanded range of measurements

Advanced laser alignment tools go beyond basic shaft alignment. They can assess base flatness, twist, and straightness, and identify structural weaknesses such as poor foundations that could cause equipment damage through vibration. Advanced systems can also rotate to compensate for coupling anomalies and measure multiple pieces of equipment simultaneously.

Reduced potential for errors

Traditional alignment methods are prone to issues including bar sag, incorrect clamp setup, and reading errors from sticking dial hands. Non-contact laser technology eliminates these error sources entirely, delivering consistent, high-resolution results.

Energy efficiency

Accurate alignment allows machinery to operate at peak efficiency, reducing energy consumption over time. For facilities running large equipment continuously, this translates to measurable reductions in electricity costs.

Greater range of applications

Laser alignment suits both complex and routine tasks. Marley Flow Control has successfully aligned shafts up to 4.5 metres in length. The same technology is also used for everyday tasks such as pump alignment and engine alignment.

How Often Should Laser Alignment Be Performed?

The right schedule depends on your equipment, operating conditions, and how critical uptime is to your facility. As a starting point, we recommend a regular preventative monitoring and maintenance program rather than waiting for problems to appear.

Our team can assess your setup and recommend a schedule suited to your circumstances.

Laser Alignment Services from Marley Flow Control

Marley Flow Control provides a comprehensive range of laser alignment services across Australia. After every alignment, our team delivers a detailed report showing the change in alignment achieved.

Our team has the skills and equipment to carry out long laser alignments of up to four metres, as well as fitting new motors, driveshafts, gearboxes, and fans in the field.

Contact us today for a free quote.