Regal Rexnord updates torque monitoring system

Regal Rexnord announced the launch of Powerlign 2.0, an updated torque monitoring system for turbomachinery applications. (Image: Regal Rexnord)

Regal Rexnord has introduced Powerlign 2.0, an updated torque monitoring system designed to provide continuous performance data for industrial turbomachinery trains.

The system is intended to support applications including predictive maintenance, fuel optimization, compressor load balancing and verification of driver and driven-equipment performance.

Powerlign 2.0 uses phase displacement torque monitoring and does not require on-site calibration to provide full-scale torque data, according to Regal Rexnord. The updated version incorporates a dual-sensor configuration and is available as an add-on to the company’s Kop-Flex and Ameridrives couplings.

The system can also be retrofitted to existing installations, subject to mass elastic data requirements. Existing coupling guards can be modified to accommodate the sensors, the company said.

“Powerlign is a high-precision, phase displacement torque monitoring system designed for continuous trending in demanding industrial environments,” said Chuck Sakers, director of engineering, high performance couplings at Regal Rexnord.

“With Powerlign 2.0, we have delivered improvements that reflect nearly 30 years of customer feedback and field experience to provide a tool that supports smarter, data-driven decisions.”

The updated system provides torque information that can be used to monitor the long-term performance of turbomachinery trains. Regal Rexnord said potential applications include establishing cleaning schedules, balancing loads across compressor bodies and validating performance improvements following upgrades to driving or driven equipment.

For new installations, the system can also be used to confirm that equipment is operating at specified throughput following commissioning.

Powerlign 2.0 incorporates an updated user interface that displays outputs graphically to support trend analysis. Diagnostic capabilities include sensor-channel diagnostics, signal-quality validation, noise correction and waveform-integrity checks.

Communication options have also been expanded. In addition to Modbus RS-485, the system supports Modbus Ethernet and 4–20 mA communications, allowing data to be integrated with industrial control and monitoring systems.

The Powerlign architecture does not place electronics or electrical power within the coupling. The system can integrate with distributed control systems as well as PCs and laptops for analysis of operating data.

Powerlign 2.0 can also be incorporated into closed-loop control applications. Operators can establish thresholds that trigger alerts or alarms based on measured conditions. Regal Rexnord said the system can also provide inputs used to shut down equipment or adjust gas or fuel flow to maintain load and operating efficiency.

The company said the combination of continuous torque measurement and trending is intended to give operations and maintenance personnel additional information for evaluating machinery condition and planning maintenance before equipment problems result in unplanned downtime.