Patent Description:
Rotating machinery often includes a driver and driven components. The driver and the driven components may be connected by a shaft. Proper alignment of the shaft is an important factor in ensuring proper function of the rotating machinery.

<CIT> provides a prior art example of a tool for use with a belted sheave system and a method of use.

The invention shall be specified by the appended set of claims.

The figures are not to scale. Instead, the thickness of the layers or regions may be enlarged in the drawings. Although the figures show layers and regions with clean lines and boundaries, some or all of these lines and/or boundaries may be idealized. In reality, the boundaries and/or lines may be unobservable, blended, and/or irregular. In general, the same reference numbers will be used throughout the drawing(s) and accompanying written description to refer to the same or like parts. As used in this patent, stating that any part (e.g., a layer, film, area, region, or plate) is in any way on (e.g., positioned on, located on, disposed on, or formed on, etc.) another part, indicates that the referenced part is either in contact with the other part, or that the referenced part is above the other part with one or more intermediate part(s) located therebetween. As used herein, connection references (e.g., attached, coupled, connected, and joined) may include intermediate members between the elements referenced by the connection reference and/or relative movement between those elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and/or in fixed relation to each other. As used herein, stating that any part is in "contact" with another part is defined to mean that there is no intermediate part between the two parts.

Unless specifically stated otherwise, descriptors such as "first," "second," "third," etc., are used herein without imputing or otherwise indicating any meaning of priority, physical order, arrangement in a list, and/or ordering in any way, but are merely used as labels and/or arbitrary names to distinguish elements for ease of understanding the disclosed examples. " In such instances, it should be understood that such descriptors are used merely for identifying those elements distinctly that might, for example, otherwise share a same name.

In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific examples that may be practiced. Certain features from different aspects of the following description may be combined to form yet new aspects of the subject matter discussed below.

Rotating machinery such as pumps, turbines, compressors, gears, and fans all include rotating shafts. The rotating shafts operate at high revolutions per minute (RPM), connecting a driver and driven elements.

Some modem rotating machinery operates at an extremely high speed (e.g., <NUM>,<NUM> RPM). In such machinery, proper shaft alignment is necessary to ensure effective operation of the rotating machinery. Improper shaft alignment can be associated with increased temperatures, excessive lubricant leakage, premature wear, and failure of the shaft. Rotating equipment with a misaligned shaft can also be dangerous. Improperly aligned shafts may cause excessive vibrations that lead to coupling failures, which may expel machine components from the rotating machinery at high speeds.

Conventional alignment solutions are often based on alignment of male shafts extending from each of the driver and the driven elements. In conventional alignment solutions, a coarse alignment can be achieved by aligning protruding shafts by moving a machine base, shimming the machinery, etc. Then, a dial indicator can confirm the alignment and/or facilitate measurements and determine any desired adjustments. Once aligned, a flexible coupling may lock the shafts together.

Conventional solutions cannot align a driver (e.g., a motor) and driven element (e.g., a gearbox) that both include female internally splined shafts. Examples disclosed herein permit alignment of the centerlines of two high speed rotating components that lack protruding features for alignment.

Disclosed examples include an alignment tool for a motor-driven propeller (MDP) gearbox. The motor-driven propeller includes both a motor and a gearbox that each have female splined shafts, with an intermediate rotating shaft connecting the motor and the gearbox. As the motor-driven propeller drivetrain does not include shafts that protrude from the motor or the gearbox, conventional solutions fail to achieve accurate alignment of the motor-driven propeller.

Disclosed examples include a first alignment tool with a first shaft and an expandable elastomer plug that is inserted into the gearbox. The expandable elastomer plug can be formed of urethane, rubber, silicone, etc. Some examples include a second alignment tool with a second shaft and a second expandable elastomer plug that is inserted into the motor. Expansion of the expandable plugs secures each respective alignment tool in place. The expansion occurs due to the Poisson's ratio of the plug and axial compression of the plug.

After alignment with the first and second alignment tools, the example MDP motor and the MDP propeller are then pinned in location. Removing either the motor or the gearbox allows the rotating shaft to be inserted. The removed motor or gearbox is re-installed using the pinned location.

In some examples, a motor may have a female splined shaft for alignment with a male stub shaft extending from a gearbox. In such an example, a single alignment tool may be inserted into the gearbox and aligned with the male stub shaft. In some examples, a gearbox may have a female splined shaft for alignment with a male stub shaft extending from a motor. In such an example, a single alignment tool may be inserted into the motor and aligned with the male stub shaft.

Disclosed examples may be used on a hybrid electric aircraft. Hybrid aircraft drivetrains in the field may include a motor-driven shaft that has become misaligned due to removal of one or both components for maintenance. Motor-driven alignment tools may also be used to align newly installed and/or replacement motors in the hybrid electric aircraft. Therefore, disclosed examples may be provided to maintenance/repair teams as a part of an aircraft repair toolset. Furthermore, the alignment tools described herein are not limited to use with motor-driven propellers. The motor and/or gearbox alignment tools may be adapted to provide a removable shaft for any machinery with female splined shafts.

Thus, whenever a claim employs any form of "include" or "comprise" (e.g., comprises, includes, comprising, including, having, etc.) as a preamble or within a claim recitation of any kind, it is to be understood that additional elements, terms, etc., may be present without falling outside the scope of the corresponding claim or recitation. The term "and/or" when used, for example, in a form such as A, B, and/or C refers to any combination or subset of A, B, C such as (<NUM>) A alone, (<NUM>) B alone, (<NUM>) C alone, (<NUM>) A with B, (<NUM>) A with C, (<NUM>) B with C, or (<NUM>) A with B and with C. As used herein in the context of describing structures, components, items, objects and/or things, the phrase "at least one of A and B" is intended to refer to implementations including any of (<NUM>) at least one A, (<NUM>) at least one B, or (<NUM>) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects and/or things, the phrase "at least one of A or B" is intended to refer to implementations including any of (<NUM>) at least one A, (<NUM>) at least one B, or (<NUM>) at least one A and at least one B. As used herein in the context of describing the performance or execution of processes, instructions, actions, activities and/or steps, the phrase "at least one of A and B" is intended to refer to implementations including any of (<NUM>) at least one A, (<NUM>) at least one B, or (<NUM>) at least one A and at least one B. Similarly, as used herein in the context of describing the performance or execution of processes, instructions, actions, activities and/or steps, the phrase "at least one of A or B" is intended to refer to implementations including any of (<NUM>) at least one A, (<NUM>) at least one B, or (<NUM>) at least one A and at least one B.

The term "a" or "an" object, as used herein, refers to one or more of that object. The terms "a" (or "an"), "one or more", and "at least one" are used interchangeably herein. Furthermore, although individually listed, a plurality of means, elements or method actions may be implemented by, e.g., the same entity or object.

Turning to the figures, <FIG> is an illustration of an example motor <NUM> and a gearbox <NUM> that are misaligned. The motor <NUM> includes a motor armature shaft <NUM>. The motor armature shaft <NUM> is a separable motor armature shaft that further includes internal motor splines <NUM>. A first alignment axis <NUM> extends from a center point of the motor armature shaft <NUM> outwards, illustrating an axis for alignment of the motor <NUM> and the gearbox <NUM>. The example motor <NUM> includes internal motor splines <NUM> and there is no external protrusion of the motor armature shaft <NUM> for alignment with the gearbox <NUM>.

The gearbox <NUM> includes a gearbox shaft <NUM> and internal gearbox splines <NUM>. Similarly to the motor <NUM>, the gearbox <NUM> does not include an external protrusion to facilitate alignment.

The example first alignment axis <NUM> of the motor <NUM> and a second alignment axis <NUM> of the gearbox <NUM> are not parallel when initially installed due to machining tolerances, surrounding mount hardware, etc. Therefore, the motor <NUM> and the gearbox <NUM> are not in alignment. However, the gearbox <NUM> and the motor <NUM> should be aligned for effective operation. As will be described in association with <FIG>, disclosed examples provide alignment tools that can be used to align the motor <NUM> and the gearbox <NUM>.

<FIG> is an illustration of an example gearbox alignment tool <NUM> and a motor alignment tool <NUM>. The gearbox alignment tool <NUM> includes at least four components: a first tubular body <NUM> (e.g., a first cylindrical body), a first plug <NUM>, a first threaded nut <NUM>, and a first cap screw <NUM>.

A first component of the example gearbox alignment tool <NUM> is the first tubular body <NUM>. The first tubular body <NUM> is an elongated member that is generally tubular (e.g., cylindrical) in shape with a hole (as will be described in association with <FIG>) extending from a first end <NUM> of the first tubular body <NUM> to a second end <NUM> of the first tubular body <NUM>. The hole may be a counterbore hole (as will be described in association with <FIG>) to allow a screw (e.g., a socket head cap screw) to sit flush with an outer surface of the first tubular body <NUM>. The first tubular body <NUM> includes a first shaft <NUM>, a first shoulder <NUM>, and a first neck <NUM>.

The example first shaft <NUM> includes a first flat member <NUM> and a second flat member <NUM>. The first flat member <NUM> and the second flat member <NUM> provide flat surfaces that can be gripped by a wrench or any other tool. The first shaft <NUM> is coupled to the first shoulder <NUM> that extends radially outward such the first shoulder <NUM> bears against an edge of the motor armature shaft <NUM>, locking the first shaft <NUM> in place. Accordingly, the first shoulder <NUM> is of greater diameter than the first shaft <NUM> and the first neck <NUM>.

The example first shoulder <NUM> is coupled to the first neck <NUM>. The first tubular body <NUM>, and more particularly the first neck <NUM>, includes radial sharp ridges at the second end <NUM> of the first tubular body <NUM> that extend towards the first plug <NUM> and retain the first plug <NUM>. The ridges of the first neck <NUM> will be illustrated in further detail in <FIG>.

A second component of the example gearbox alignment tool <NUM> is the first plug <NUM>. The first plug <NUM> is coupled to the first shoulder <NUM> at a first plug edge and coupled to the first threaded nut <NUM> at a second plug edge. The first plug <NUM> is an elastomeric plug such as a urethane plug, a rubber plug, etc. The first plug <NUM> also includes a hole through the first plug <NUM>, a diameter of the hole based on a diameter of the first cap screw <NUM>.

A third example component of the gearbox alignment tool <NUM> is the first threaded nut <NUM>. The first threaded nut <NUM> may be any type of fastener. The fastener (e.g., the first threaded nut <NUM>) may couple to a second fastener (e.g., the first cap screw <NUM>) by any means for fastening. Thus, examples disclosed herein are not limited to a threading to couple the first and second fasteners. The first fastener may be welded to the second fastener, the first fastener to generate an axial force along an axis defined by the second fastener. In some examples, the first and second fasteners may be a single, unitary force-generating member.

The first threaded nut <NUM> includes second ridges (as will be described in association with <FIG>) extending radially towards the first end <NUM> and includes second protrusions to couple the first threaded nut <NUM> to the first plug <NUM>. The first threaded nut <NUM> is a fastener that includes a first threaded hole <NUM> with threads to couple the first threaded nut <NUM> to the first cap screw <NUM>.

A fourth component of the example gearbox alignment tool <NUM> is the first cap screw <NUM>. The first cap screw <NUM> may be any type of fastener that may couple (e.g., threadably couple) to another fastener. The first cap screw <NUM> extends through the first tubular body <NUM>, the first plug <NUM>, and the first threaded nut <NUM>. The first cap screw <NUM> may include threads at a first threaded end of the first cap screw <NUM>. The first cap screw <NUM> includes, for example, a socket head that can be adjusted by a hex key, an Allen wrench, and/or any other torquing device.

In certain examples, the first cap screw <NUM> has a socket head. However, any type of screw (e.g., square head, one-way head, slotted head, torx head, etc.) can be used instead of a socket head cap screw. Furthermore, examples disclosed herein are not limited to a cap screw, a socket head cap screw, or any screw in general: any type of device to generate an axial force on the plug can be used. This extends not only to mechanical fasteners such as bolts (e.g., a hex-head bolt, any threaded or unthreaded bolt), but to methods such as pressurized fluid cylinders that can generate an axial force. Thus, in some examples screw threads facilitate generation of an axial force by a first fastening member. In other examples, a fluid cylinder (e.g., air cylinder, oil cylinder) generates the axial force with axial motion.

The example gearbox alignment tool <NUM> may be assembled by inserting a threaded end of the first cap screw <NUM> through the first end <NUM> towards the second end <NUM> of the first tubular body <NUM>. The first cap screw <NUM> is of greater length than the first tubular body <NUM> (e.g., the first cylindrical body). Therefore, the first cap screw <NUM> protrudes from the second end <NUM> of the first tubular body <NUM> when the head of the first cap screw <NUM> is flush with the first end <NUM>.

The example first plug <NUM> may be fed onto the first cap screw <NUM> and coupled to the second end <NUM> of the first tubular body <NUM>. The first threaded nut <NUM> may then be screwed onto threads of the first cap screw <NUM>.

In operation, the example gearbox alignment tool <NUM> is assembled and inserted into internal gearbox splines <NUM> of the gearbox <NUM> of <FIG>. The gearbox alignment tool <NUM> is inserted with the first threaded nut <NUM> in a first position that does not compress the first plug <NUM>. The gearbox alignment tool <NUM> is advanced into the gearbox <NUM> until the first shoulder <NUM> contacts the gearbox shaft <NUM> of <FIG>. Next, the first cap screw <NUM> is tightened, using another open-ended wrench on the machined flat, and more particularly, on the first flat member <NUM> to prevent rotation. The tightening of the first cap screw <NUM> causes the first threaded nut <NUM> to move to a second position towards the first tubular body <NUM>, the second position nearer the first tubular body <NUM> than the first position.

Movement of the example first threaded nut <NUM> to the second position axially compresses the first plug <NUM> which causes the first plug <NUM> to radially expand and contact the gearbox shaft <NUM> (<FIG>). The tightening of the first threaded nut <NUM> and the effect on the first plug <NUM> will be described in further detail in association with <FIG>.

The example motor alignment tool <NUM> includes a second tubular body <NUM> (e.g., a second cylindrical body), a second plug <NUM>, a second threaded nut <NUM>, and a second cap screw <NUM>. The second cap screw <NUM> may, in some instances, be a socket head cap screw. However, any type of device to generate an axial force on the second plug <NUM> may be used instead of a socket head cap screw.

The second tubular body <NUM> (e.g., the second cylindrical body) is an elongated member that is generally tubular (e.g., cylindrical) in shape with a hole (as will be described in association with <FIG>) extending from a third end <NUM> of the second tubular body <NUM> to a fourth end <NUM> of the second tubular body <NUM>. In some instances, the hole may be a counterbore hole (as will be described in association with <FIG>) to allow a screw (e.g., a socket head cap screw) to sit flush with an outer surface of the second tubular body <NUM>. The second tubular body <NUM> may be a unitary, integral, and/or one-piece construction that includes a second shaft <NUM>, a second shoulder <NUM>, and a second neck <NUM>. The second shaft <NUM> includes a third flat member <NUM> and a fourth flat member <NUM>. The second tubular body <NUM> may be a unitary (e.g., one-piece) construction or may include multiple parts that are welded and/or otherwise coupled together. In some instances, the first tubular body <NUM> may be a one-piece member while the second tubular body <NUM> is a multi-piece member with at least one weld.

The example second shoulder <NUM> is a protrusion having greater diameter than the second shaft <NUM> and the second neck <NUM>. The second shoulder <NUM> is coupled to the second neck <NUM>. The second tubular body <NUM>, and, more particularly, the second neck <NUM>, includes radial sharp ridges (e.g., at a fourth end <NUM>) that extend towards the second plug <NUM> and retain the second plug <NUM>. The second shoulder <NUM> is of a different diameter than the first shoulder <NUM>, as the example motor armature shaft <NUM> and the gearbox shaft <NUM> are different sizes.

The second plug <NUM> is coupled to the second shoulder <NUM> at a third plug edge and coupled to the second threaded nut <NUM> at a fourth plug edge. The second plug <NUM> also includes a hole through the second plug <NUM> to accommodate the second cap screw <NUM>. The second cap screw <NUM> may be any type of fastener (e.g., a second socket head cap screw) that may couple (e.g., threadably couple) to a second fastener. In some instances, the motor armature shaft <NUM> of <FIG> may be made of a different material than the gearbox shaft <NUM> of <FIG>. Accordingly, the second plug <NUM> may be comprised of a different materials than the first plug <NUM> to prevent damage to its respective component.

The second threaded nut <NUM> includes fourth protrusions to couple the second threaded nut <NUM> to the second plug <NUM>. The second threaded nut <NUM> may be any type of fastener that may couple (e.g., threadably couple) to a second fastener. The second threaded nut <NUM> includes a second threaded hole <NUM> with threads to couple the second threaded nut <NUM> to the second cap screw <NUM>. The second cap screw <NUM> (e.g., or any fastener of appropriate length) extends through the second tubular body <NUM>, the second plug <NUM>, and the second threaded nut <NUM>. The second cap screw <NUM> may include threads at a first threaded end <NUM> of the second cap screw <NUM>. The second cap screw <NUM> includes a socket head that can be adjusted by any matching torquing device such as a standard wrench, screwdriver, socket wrench, Allen wrench, etc..

The example motor alignment tool <NUM> is assembled and inserted into internal motor splines of the example motor <NUM> of <FIG> until the second shoulder <NUM> contacts the end of the motor armature shaft <NUM> of <FIG> (e.g., in order to assure the second shaft <NUM> is colinear with the motor armature shaft <NUM>). Next, the second cap screw <NUM> is tightened, expanding the example second plug <NUM> and securing the example motor alignment tool <NUM> into position.

Thus, the example motor alignment tool <NUM> shares geometric characteristics with the gearbox alignment tool <NUM>. However, when compared to the gearbox alignment tool <NUM>, the motor alignment tool <NUM> includes resized and/or reshaped analogues of members of the gearbox alignment tool <NUM>. The differences in shape between the gearbox alignment tool <NUM> and the motor alignment tool <NUM> are based on respective geometric characteristics of the gearbox <NUM> of <FIG> and the motor <NUM> of <FIG>.

<FIG> is another illustration of the example motor alignment tool <NUM>. Although the structure and function of the second plug <NUM> is described in association with <FIG>, the gearbox alignment tool <NUM> of <FIG> and the first plug <NUM> of <FIG> share functionalities described in association with <FIG>.

<FIG> includes the example motor alignment tool <NUM>, first ridges <NUM>, a first beveled edge <NUM>, second ridges <NUM>, first protrusions <NUM>, a second beveled edge <NUM>, first threads <NUM>, and a third beveled edge <NUM>.

As shown in <FIG>, an example first arrow <NUM> and an example second arrow <NUM> indicate directions of expansion of the example second plug <NUM> in response to an axial compression. An axial compression load is illustrated by an example third arrow <NUM>.

Rotation of the example second cap screw <NUM> (e.g., that moves the second threaded nut <NUM> in the direction of the third arrow <NUM>) causes the plug to bulge outward (e.g., as illustrated by dotted line and in the direction of the first arrow <NUM> and the second arrow <NUM>) and grip the internal motor splines <NUM> of <FIG>. An amount of expansion of the example second plug <NUM> can be calculated based on the Poisson effect. The Poisson effect is associated with a materials tendency to expand in a direction perpendicular to an axis of compression. A Poisson ratio is a ratio of relative contraction to relative expansion. In some examples, a material for the first plug <NUM> and the second plug <NUM> is selected based on the materials modulus of elasticity and/or a desired Poisson ratio. Example materials with suitable Poisson's ratios include urethanes and polymers (fluoropolymer elastomers, ethylene propylene diene monomer, nitrile rubber, etc.). Using "soft" materials such as this also has the added benefit of reducing and/or preventing potential damage to the female shaft contours into which the tool is inserted.

Although examples disclosed herein are described in association with a motor-driven propeller, the apparatus and methods described herein may be extended for use in other scenarios than those described above (e.g., within the aerospace industry, within industrial robotics, etc.). Generally, one or more alignment tools as described herein may be used for alignment of a driver component (e.g., a prime mover) and a driven component. The driver component may be an electric motor, a fluidic motor (e.g., air, hydraulic, etc.), a diesel engine, a gasoline engine, a steam engine, a steam turbine, a gas turbine, a windmill, etc. The driven component may be a stationary component such as a pump, a compressor, a generator, a fan, a milling machine, a rolling mill, a lathe, etc. Alternatively or additionally, the driven component may be a mobile component such as an automobile (e.g., a car, a truck, etc.), an aviation propeller, a marine propeller, a locomotive, etc. The driver component and the driven component may be connected by a gearbox or a transmission, for example. The alignment tools described herein may be used for alignment of any combination of the driver component and the driven components listed above. For example, a diesel engine may be coupled to a generator, a steam engine may be coupled to a ship's propeller, a hydraulic fluidic motor may be coupled to a milling machine, etc. In each example, the driver component and the driven component can be aligned using the alignment tools described herein.

As another example, the elastomeric plug(s) described herein can be repurposed as robotic gripper(s) that grip an object in the center hole (e.g., based on the Poisson effect) when the elastomeric plug(s) is/are axially compressed.

Since the example second plug <NUM> is made of an elastomer, the second plug <NUM> does not damage the internal motor splines <NUM> upon expansion, as the second plug <NUM> makes a soft compressive contact with the internal motor splines <NUM> of <FIG>. As the second cap screw <NUM> is tightened, the second cap screw <NUM> applies pressure to the second plug <NUM>. As the second plug <NUM> is urethane or another elastomer, the second plug <NUM> does not cause a metal-to-metal load that could damage the motor armature shaft <NUM> of <FIG>. Thus, the second plug <NUM> causes a firm contact between the soft, rubbery second plug <NUM> and the motor armature shaft <NUM>.

<FIG> illustrates additional characteristics of the example motor alignment tool <NUM>. The motor alignment tool <NUM> includes the first ridges <NUM> of the second neck <NUM>. The first ridges <NUM> are sharp ridges and/or teeth that press into the second plug <NUM>, securing the second plug <NUM> to the second neck <NUM>.

The example second threaded nut <NUM> includes the second ridges <NUM>. The second ridges <NUM> are sharp ridges and/or teeth that press into the second plug <NUM>, securing the second plug <NUM> to the second nut <NUM> and reducing rotation.

When the example second cap screw <NUM> is tightened (e.g., by an Allen wrench), the first threads <NUM> rotate. The second shaft <NUM> and the second neck do not rotate, however. Furthermore, as the first ridges <NUM> protrude into the second plug <NUM>, the second plug <NUM> does not rotate with the second cap screw <NUM>. The second threaded nut <NUM> is coupled to the second plug <NUM> by the second ridges <NUM> and therefore does not rotate with the second cap screw <NUM>.

Accordingly, as the example second cap screw <NUM> is rotated, the second nut <NUM> is displaced in the direction of the third arrow <NUM>, causing the second plug <NUM> to expand and exhibit the Poisson effect.

The example second plug <NUM> includes the first beveled edge <NUM> and the second beveled edge <NUM>. The first and second beveled edges <NUM> and <NUM> facilitate insertion of the motor alignment tool <NUM> into the motor <NUM> of <FIG>. The second threaded nut <NUM> includes the third beveled edge <NUM> to facilitate insertion of the tool into the motor <NUM> of <FIG>. (e.g., by self-centering). First protrusions <NUM> mate with the female splines in the motor <NUM> of <FIG>, further securing the motor alignment tool <NUM> to the motor <NUM> of <FIG>.

is a cross-sectional view of the example gearbox alignment tool <NUM> inserted into the gearbox <NUM> and the motor alignment tool <NUM> inserted into the motor <NUM>.

The example gearbox alignment tool <NUM> further includes a first axial hole <NUM> and a first counterbore <NUM>. The first axial hole <NUM> extends through the first tubular body <NUM>. The first counterbore <NUM> is a cylindrical flat-bottomed hole extending partially within the first tubular body <NUM>, that is coaxial with, and of greater diameter than, the first axial hole <NUM>. The first cap screw <NUM> includes a first socket head <NUM> that is of greater diameter than the first axial hole <NUM> and of a lesser diameter than the first counterbore <NUM>. The first counterbore <NUM> allows the first cap screw <NUM> to sit flush with an outer face of the gearbox alignment tool <NUM>. The example first socket head <NUM> is rotated by a hex key and/or any other adjustment device to cause the first threaded nut <NUM> to compress the first plug <NUM> and cause the first plug <NUM> to expand, as previously described.

The example motor alignment tool <NUM> includes a second axial hole <NUM> and a second counterbore <NUM>. The second axial hole <NUM> extends through the second tubular body <NUM>. The second counterbore <NUM> is a cylindrical flat-bottomed hole extending partially within the second tubular body <NUM>, that is coaxial with, and of greater diameter than, the second axial hole <NUM>. The second counterbore <NUM> allows the second cap screw <NUM> to sit flush with an outer face of the motor alignment tool <NUM>. An example second socket head <NUM> is rotated to compress the second plug <NUM> and cause the second plug <NUM> to expand.

The counterbore feature and use of a socket-head cap screw, such as first cap screw <NUM> and second cap screw <NUM>, inside the shafts <NUM> and <NUM> of the first tubular body <NUM> and <NUM>, respectively, may be optional in some examples. Other methods for compressing the plugs <NUM> and <NUM> can be used. For example, an air or hydraulically operated cylinder and rod can also be used to compress the plugs <NUM>, <NUM>.

<FIG> is an example first illustration <NUM> that shows alignment of the example motor <NUM> with the gearbox <NUM>. A first illustration <NUM> includes the gearbox alignment tool <NUM> and the motor alignment tool <NUM> that are out of alignment.

<FIG> is an example second illustration <NUM> that includes a dial indicator <NUM> that can be used to facilitate alignment of the motor <NUM> and the gearbox <NUM> based on the example motor alignment tool <NUM> and the example gearbox alignment tool <NUM>.

The example dial indicator <NUM> determines whether the motor alignment tool <NUM> and the gearbox alignment tool <NUM> are properly aligned. Based on a reading of the dial indicator <NUM>, the motor <NUM> and/or the gearbox <NUM> can be moved and rotated to facilitate parallel and angular alignment.

<FIG> is a third illustration <NUM> in which the motor <NUM> and the gearbox <NUM> are in parallel and angular alignment, as illustrated by a shaft alignment axis <NUM>. In some examples, at least one of the example gearbox <NUM> or the motor <NUM> is pinned into position, allowing removal of the other of the motor <NUM> and/or the gearbox <NUM>.

<FIG> is a fourth illustration <NUM> that shows a shaft <NUM> installed and in proper alignment. After the motor <NUM> and/or the gearbox <NUM> are removed, the example shaft <NUM> is inserted. The motor <NUM> and/or the gearbox <NUM> is then re-positioned based on the prior pinning. The shaft <NUM> is installed in an aligned motor-driven propeller to connect the motor <NUM> and the gearbox <NUM>.

<FIG> illustrates example molds for casting the first plug <NUM> and second plug <NUM> as described herein. A first mold <NUM> is a mold that can cast the first plug <NUM>. A second mold <NUM> is a second mold that can cast the second plug <NUM>. The first mold <NUM> and the second mold <NUM> are three-dimensional molds that include contours of each respective plug. To accurately form the plugs <NUM>, <NUM>, the first mold <NUM> and the second mold <NUM> replicate the internal splines of the motor armature shaft <NUM> of <FIG> and the gearbox shaft <NUM> of <FIG>, respectively. The first mold <NUM> includes a first cylindrical member <NUM> to form a first hole <NUM> in the first plug <NUM>. The second mold <NUM> includes a second cylindrical member <NUM> to form a second hole <NUM> in the second plug <NUM>. The first hole <NUM> and/or the second hole <NUM> may accommodate a compression-generating component such as a cap screw, bolt, or hydraulic/air cylinder shaft. More particularly, the hole <NUM> in first plug <NUM> accommodates the first cap screw <NUM> (<FIG>) and the hole <NUM> in the second plug <NUM> accommodates the second cap screw <NUM> (<FIG>).

<FIG> is a flowchart illustrating an example method to align a motor-driven propeller. The example method begins at block <NUM> at which the gearbox alignment tool <NUM> of <FIG> is inserted into the gearbox <NUM> of <FIG>. At block <NUM>, the first cap screw <NUM> of <FIG> is tightened. For instance, tightening of the first cap screw <NUM> causes the first plug <NUM> of <FIG> to expand and secure the gearbox alignment tool <NUM> of <FIG>.

At block <NUM>, the example motor alignment tool <NUM> of <FIG> is inserted into the motor <NUM> of <FIG>. At block <NUM>, the second cap screw <NUM> of <FIG> is tightened. For instance, tightening the second cap screw <NUM> of <FIG> causes the second plug <NUM> to expand and secure the motor alignment tool <NUM> of <FIG> to the motor <NUM> of <FIG>.

At block <NUM>, the example motor alignment tool <NUM> of <FIG> and the gearbox alignment tool <NUM> of <FIG> are aligned. For instance, the gearbox alignment tool <NUM> and the example motor alignment tool <NUM> of <FIG> can be aligned using dial indicator <NUM> of <FIG>.

At block <NUM>, the example gearbox <NUM> of <FIG> and/or the motor <NUM> of <FIG> are pinned into location. For instance, the motor <NUM> of <FIG> can be pinned into location before removing the gearbox <NUM> of <FIG> at block <NUM>.

At block <NUM>, the example drive shaft <NUM> of <FIG> is placed in the motor <NUM> of <FIG> or the gearbox <NUM> of <FIG> bef76ore replacing the motor <NUM> of <FIG> or the example gearbox <NUM> of <FIG> at block <NUM>.

From the foregoing, it will be appreciated that example systems, apparatus, and articles of manufacture have been disclosed that enable alignment of a motor-driven propeller. Examples disclosed herein include an example gearbox alignment tool and an example motor alignment tool. Disclosed examples facilitate effective alignment of internally splined shafts. Proper alignment of the shafts reduces stress on the rotating machinery, improving part lifespan and machinery safety.

Example methods, apparatus, systems, and articles of manufacture to align motor-driven propellers are disclosed herein. Further examples and combinations thereof are provided by the subject matter of the following clauses:.

An apparatus comprising a tubular body including a shaft, a shoulder, and a neck, the shaft coupled to the shoulder, the shoulder coupled to the neck, the shoulder having a greater diameter than respective diameters of the shaft and the neck, a plug coupled to the shoulder at a first plug edge and coupled to a first fastener at a second plug edge, the first fastener including a hole, and a second fastener coupled to the first fastener, the second fastener extending through the tubular body, the plug, and the first fastener.

The apparatus of the preceding clause, wherein the first fastener is a threaded nut, the second fastener is a cap screw, and wherein the tubular body, the plug, the threaded nut, and the cap screw define a motor alignment tool, the motor alignment tool coupled to a motor, the shaft extending from the motor to facilitate alignment of the motor.

The apparatus of any preceding clause, wherein the tubular body is a first tubular body, the plug is a first plug, the threaded nut is a first threaded nut, the cap screw is a first cap screw, and further including a gearbox alignment tool to facilitate an alignment of a gearbox with the motor, the gearbox alignment tool including a second tubular body, a second plug, a second threaded nut, and a second cap screw.

The apparatus of any preceding clause, wherein tightening the second cap screw causes an axial displacement of the second threaded nut from a first position to a second position, wherein the second position is nearer the second tubular body than the first position, and wherein a diameter of the second plug increases to contact the gearbox in response to the axial displacement.

The apparatus of any preceding clause, wherein the tubular body includes first ridges protruding into the plug and toward the threaded nut, and wherein the threaded nut includes second ridges protruding into the plug and towards the tubular body, the threaded nut threadably coupled to the cap screw.

The apparatus of any preceding clause, wherein a first end of the tubular body includes a second hole with a counterbore, the second hole extending through the shaft, the shoulder, and the neck to a second end of the tubular body.

The apparatus of any preceding clause, wherein the second cap screw further includes threads at a first end of the second cap screw, and a socket head at a second end of the second cap screw.

The apparatus of any preceding clause, wherein the first plug edge and the second plug edge are beveled, and wherein the plug includes radially outward extending protrusions.

The apparatus of any preceding clause, wherein the first fastener includes threads to threadably couple the first fastener to the second fastener.

The apparatus of any preceding clause, the tubular body further including a first flat member and a second flat member to secure the shaft for tightening of the second fastener.

The apparatus of any preceding clause, wherein the tubular body is a unitary member.

An alignment apparatus for a motor-driven propeller comprising a motor tool coupled to a motor of the motor-driven propeller, the motor tool extending from the motor to facilitate an alignment of the motor-driven propeller, a gearbox tool coupled to a gearbox of the motor-driven propeller and extending from the gearbox to facilitate the alignment, and at least one of the gearbox tool or the motor tool including a tubular body including a shaft, a shoulder, and a neck, the shaft coupled to the shoulder, the shoulder coupled to the neck, a plug coupled to the shoulder at a first plug edge and coupled to a first fastener at a second plug edge, the first fastener including a hole, and a second fastener extending through the tubular body, the plug, and the first fastener.

The alignment apparatus of the preceding clause, wherein the first fastener is a threaded nut, the second fastener is a cap screw, wherein to tighten the cap screw causes a displacement of the threaded nut from a first position to a second position, wherein the second position is nearer the tubular body, and wherein the displacement of the threaded nut causes the plug to increase in diameter to contact at least one of the gearbox or the motor.

The alignment apparatus of any preceding clause, the tubular body including first ridges protruding into the plug and towards the first fastener, the first fastener including second ridges protruding into the plug and towards the tubular body.

The alignment apparatus of any preceding clause, wherein a first end of the tubular body includes a second hole that extend through the shaft, the shoulder, and the neck to a second end of the tubular body.

The alignment apparatus of any preceding clause, wherein the first fastener is a cap screw that further includes threads at a first end of the cap screw, and a socket head at a second end of the cap screw.

The alignment apparatus of any preceding clause, wherein the first plug edge and the second plug edge are beveled, and wherein the plug includes at least one protrusion that extends radially outward.

The alignment apparatus of any preceding clause, wherein the tubular body is a one-piece body.

A method comprising inserting a gearbox alignment tool into a gearbox, tightening a first fastener of the gearbox alignment tool, inserting a motor alignment tool into a motor, tightening a second fastener of the motor alignment tool, and aligning the motor and the gearbox based on the motor alignment tool and gearbox alignment tool.

The method of the preceding clause, further including pinning the gearbox and the motor into an aligned location, removing the motor or the gearbox from the aligned location, inserting a shaft, and replacing the motor or the gearbox to the aligned location.

An alignment apparatus comprising at least one of a first alignment tool or a second alignment tool, the first alignment tool coupled to a driver component, the first alignment tool extending from the driver to facilitate an alignment, the second alignment tool coupled to a driven component and extending from the driven component to facilitate the alignment, and at least one of the first alignment tool or the second alignment tool including a tubular body including a shaft, a shoulder, and a neck, the shaft coupled to the shoulder, the shoulder coupled to the neck, a plug coupled to the shoulder at a first plug edge and coupled to a first fastener at a second plug edge, the first fastener including a hole, and a second fastener extending through the tubular body, the plug, and the first fastener.

The alignment apparatus of the preceding clause, wherein the first fastener is a threaded nut, the second fastener is a cap screw, wherein to tighten the cap screw causes a displacement of the threaded nut from a first position to a second position, wherein the second position is nearer the tubular body, and wherein the displacement of the threaded nut causes the plug to increase in diameter to contact at least one of the driver component or the driven component.

The alignment apparatus of any preceding clause, wherein the driver component is a motor and the driven component is a pump, a compressor, a generator, a fan, a milling machine, a rolling mill, or a lathe.

The alignment apparatus of any preceding clause, wherein the driver component is a motor and the driven component is an automobile, a truck, a propeller, or a locomotive.

The alignment apparatus of any preceding clause, wherein the motor is an electric motor.

The alignment apparatus of any preceding clause, wherein the motor a fluidic motor.

The alignment apparatus of any preceding clause, wherein the driver component is an engine and the driven component is a pump, a compressor, a generator, a fan, a milling machine, a rolling mill, or a lathe.

The alignment apparatus of any preceding clause, wherein the driver component is an engine and the driven component is an automobile, a truck, a propeller, or a locomotive.

The alignment apparatus of any preceding clause, wherein the engine is a diesel engine.

The alignment apparatus of any preceding clause, wherein the engine is a gasoline engine.

The alignment apparatus of any preceding clause, wherein the engine is a steam engine.

The alignment apparatus of any preceding clause, wherein the driver component is a turbine and the driven component is a pump, a compressor, a generator, a fan, a milling machine, a rolling mill, or a lathe.

The alignment apparatus of any preceding clause, wherein the driver component is a turbine and the driven component is an automobile, a truck, a propeller, or a locomotive.

The alignment apparatus of any preceding clause, wherein the turbine is a steam turbine.

The alignment apparatus of any preceding clause, wherein the turbine is a gas turbine.

The alignment apparatus of any preceding clause, wherein the driver component is a windmill and the driven component is a pump, a compressor, a generator, a fan, a milling machine, a rolling mill, a lathe, an automobile, a truck, a propeller, or a locomotive.

The alignment apparatus of any preceding clause wherein the driver component and the driven component are coupled by a gearbox or a transmission.

Claim 1:
An apparatus (<NUM>, <NUM>) for alignment of a driver and a driven component, comprising:
a tubular body (<NUM>, <NUM>) including a shaft (<NUM>, <NUM>), a shoulder (<NUM>, <NUM>), and a neck (<NUM>, <NUM>), the shaft (<NUM>, <NUM>) coupled to the shoulder (<NUM>, <NUM>), the shoulder (<NUM>, <NUM>) coupled to the neck (<NUM>, <NUM>), the shoulder (<NUM>, <NUM>) having a greater diameter than respective diameters of the shaft (<NUM>, <NUM>) and the neck (<NUM>, <NUM>);
a plug (<NUM>, <NUM>) coupled to the neck (<NUM>, <NUM>) at a first plug edge (<NUM>) and coupled to a first fastener (<NUM>, <NUM>) at a second plug edge (<NUM>), the first fastener (<NUM>, <NUM>) including a hole (<NUM>, <NUM>); and
a second fastener (<NUM>, <NUM>) coupled to the first fastener (<NUM>, <NUM>), the second fastener (<NUM>, <NUM>) extending through the tubular body (<NUM>, <NUM>), the plug (<NUM>, <NUM>), and the first fastener (<NUM>, <NUM>).