Regal Rexnord Corporation is launching Powerlign 2.0, an updated torque monitoring system for turbomachinery applications, designed to simplify installation and enable more robust performance, better train efficiency and smarter maintenance planning
Its design makes Powerlign 2.0 easy to deploy into industrial turbomachinery applications and requires no on-site calibration to deliver full-scale torque data.
Turbomachinery equipment end-users will benefit from:
- Fuel optimisation
- Predictive maintenance
- Perfected cleaning schedules
- Real-time tuning and load balancing across compressor bodies
- Compliance with environmental regulations and emissions controls
- Validating driving and driven equipment performance upgrades
Chuck Sakers, director of Engineering, High Performance Couplings, said, “Powerlign is a high-precision, phase displacement torque monitoring system designed for continuous trending in demanding industrial environments. 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.”
Powerlign 2.0 is an add-on feature to industry-standard Kop-Flex and Ameridrives couplings and provides simplified installation with dual-sensor setup. It can be retrofitted into existing systems subject to mass elastic data compliance. Existing guards can be modified for sensor installation, making it cost-effective.
Powerlign 2.0 can also help ensure equipment is operating at peak efficiency, driving further cost savings. For new installations, Powerlign 2.0 establishes and confirms that the new equipment is achieving the specified throughput.
New features of the Powerlign 2.0 solution include:
- Enhanced user interface and improved software: The Powerlign 2.0 system now displays all outputs graphically, enabling more effective trend analysis. Comprehensive health and troubleshooting features include sensor channel diagnostics, signal quality validation (coil, RTD, analogue output), noise correction, and waveform integrity checks to support reliable operation.
- Enhanced communication modes: In addition to standard Modbus RS-485, the new system now supports Modbus Ethernet and 4–20 mA communication modes for broader industrial integration.
- Increased safety certification and reliability: Unlike other torque measuring devices, no electronics or electrical power are present in the coupling, and its new modular platform further enhances long term reliability.
- Smooth integration: Powerlign 2.0 features a unique patented architecture that enables more advanced system control, with full integration support for distributed control systems (DCS) or PCs and laptops for analysing system data.
- Alert and fail-safe capabilities: Powerlign can be an important part of a closed-loop system by establishing thresholds that can be configured to trigger an alert or alarm. It can also be used as a control system to shut down equipment or direct the flow of gas or fuel to maintain load and efficiency.
