Advanced torque monitoring from Regal Rexnord delivers superior coupling value for turbomachinery asset management
26th August 2026
Powerlign™ 2.0, an add-on feature to Kop-Flex™ and Ameridrives™ couplings, offers improved torque trend monitoring for better predictability and increased uptime.
Regal Rexnord Corporation, a global leader in engineering and manufacturing solutions that power, transmit and control motion, has announced the launch of Powerlign 2.0, an updated torque monitoring system for turbomachinery applications. The updated system is designed to make installation and use simpler, while enabling more robust performance, better train efficiency and smarter maintenance planning.
This 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 find value in the long-term performance insights that Powerlign 2.0 enables, including:
- Fuel optimization
- 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
“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. “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 offers a more condensed installation, with dual sensor setup. It can also be retrofitted into existing systems subject to mass elastic data compliance. Existing guards can be modified for sensor installation, making it a cost-effective upgrade.
In addition to its benefits for predictive maintenance, Powerlign 2.0 can help operations and maintenance managers ensure that equipment is operating at peak efficiency, driving further cost savings. For new installations, Powerlign 2.0 quickly 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: Powerlign 2.0 system now displays all outputs in graphical form enabling more effective trend analysis for the user. As well, comprehensive health and troubleshooting features include sensor channel diagnostics, signal quality validation (coil, RTD, analog output), noise correction, and waveform integrity checks to support reliable operation.
- Enhanced communication modes: In addition to the standard Modbus RS-485 mode, the new system now provides 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 allows for more advanced system control with full integration support for distributed control systems (DCS) or PCs and laptops for analyzing system data.
- Alert and fail-safe capabilities: Powerlign can act as an important part of a closed-loop system by establishing certain 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.
Learn more about how Powerlign 2.0 can support your high-performance coupling applications.
Image 1: Powerlign™ 2.0 offers improved torque trend monitoring for better predictability and increased uptime.
About Regal Rexnord
Regal Rexnord’s 30,000 associates around the world help create a better tomorrow by providing sustainable solutions that power, transmit and control motion. The Company’s electric motors and air moving subsystems provide the power to create motion. A portfolio of highly engineered power transmission components and subsystems efficiently transmits motion to power industrial applications. The Company’s automation offering, comprised of controllers, drives, precision motors, and actuators, controls motion in applications ranging from factory automation to precision tools used in surgical applications.
The Company’s end markets benefit from meaningful secular demand tailwinds, and include discrete automation, food & beverage, aerospace, medical, data center, energy, residential and commercial buildings, general industrial, and metals and mining.
Regal Rexnord is comprised of three operating segments: Industrial Powertrain Solutions, Power Efficiency Solutions, and Automation & Motion Control. Regal Rexnord is headquartered in Milwaukee, Wisconsin and has manufacturing, sales and service facilities worldwide. For more information, including a copy of our Sustainability Report, visit RegalRexnord.com.
The Company’s end markets benefit from meaningful secular demand tailwinds, and include discrete automation, food & beverage, aerospace, medical, data center, energy, residential and commercial buildings, general industrial, and metals and mining.
Regal Rexnord is comprised of three operating segments: Industrial Powertrain Solutions, Power Efficiency Solutions, and Automation & Motion Control. Regal Rexnord is headquartered in Milwaukee, Wisconsin and has manufacturing, sales and service facilities worldwide. For more information, including a copy of our Sustainability Report, visit RegalRexnord.com.
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