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Dynamic balancing machines and vibration analysis equipment for the production and repair of any rotating component. Used machines, training seminars, technical publications...
Welcome to Schenck-usa.com
History of balancing
Schenck in the USA
http://www.schenck-usa.com/
Welcome to Schenck-usa.com
History of Balancing
History of Balancing...
The first patent for balancing technology was filed by Henry Martinson of Canada in 1870, four years after the
development of the dynamo by Siemens. Near the turn of the century, Akimoff (USA) and Stodola (Switzerland)
attempted to develop Martinson's technology and apply it for industrial use.
However, it was in 1907 when a modified version of the technology was patented
by Dr. Franz Lawaczek, and offered to Carl Schenck, Darmstadt, Germany, for
development. Schenck built the first industrial two-plane balancer, and
subsequently bought exclusive world rights to the dynamic balancing machine in
1915.
Through the years, craftsmanship and quality have
been the hallmarks of Schenck products.
Technology advancements gave way to improved sensitivity, frequency selectivity and
plane separation capability. The development of electronics and mechanical/electrical
transducers, greatly reduced balancing time and paved the way for modern balancing
technology.
Today Schenck balancing equipment is used with
confidence for a wide range of applications - from the smallest rotors for dental drill
instruments to the largest steam turbines in the world. Our precision balancing
machines assure accurate, dependable rotor operation and are available in nearly
any configuration for rotors weighing as much as 600,000 lbs.
http://www.schenck-usa.com/
What is Unbalance?
According to DIN/ISO 1925 Unbalance is that condition which exists in a rotor when vibratory force or motion
is imparted to its bearings as a result of centrifugal forces.
Why Balance?
An unbalanced rotor will cause vibration and stress in the rotor itself and in its supporting structure. Balancing
of the rotor is, therefore, necessary to accomplish one or more of the following:
a.
b.
c.
d.
e.
f.
g.
Unbalance in just one rotating component of an assembly may cause the entire assembly to vibrate. This
induced vibration in turn may cause excessive wear in bearings, bushings, shafts, spindles, gears, etc.,
substantially reducing their service life. Vibrations set up highly undesirable alternating stresses in structural
supports and housings, which may eventually lead to their complete failure. Performance is decreased because
of the absorption of energy by the supporting structure. Vibrations may be transmitted through the floor to
adjacent machinery and seriously impair its accuracy or proper functioning.
Unbalance vs. Centrifugal forces
Centrifugal force acts upon the entire mass of a rotating component, impelling each particle outward and away
from the axis of rotation in a radial direction. If the mass of a rotating component is evenly distributed about its
shaft axis, the part is "balanced" and rotates without vibration. However, if an excess of mass exists on one side
of a rotor, the centrifugal force acting upon this heavy side exceeds the centrifugal force exerted by the light side
and pulls the entire rotor in the direction of the heavy side.
This figure shows the side view of a rotor having an excess mass m on one side. Due to centrifugal force exerted
by m during rotation, the entire rotor is being pulled in the direction of the arrow F.
Figure 1
Centrifugal force increases with the square of the speed
A rotating element having an uneven mass distribution, i.e., unbalance, will vibrate due to the excess centrifugal
force exerted during rotation by the heavier side of the rotor. When at rest, the excess mass exerts no centrifugal
force and, therefore, causes no vibration. Yet the actual unbalance is still present. Unbalance, therefore, is
independent of rotational speed and remains the same, whether the part is at rest or is rotating (provided the part
does not deform during rotation). Centrifugal force, however, varies with speed. The higher the speed, the
greater the centrifugal force exerted by the unbalance and the more violent the vibration. Centrifugal force
increases proportionately to the square of the increase in speed. If the speed is doubled, the centrifugal force
quadruples; if the speed is tripled, the centrifugal force is multiplied by nine.
Causes of Unbalance
The excess of mass on one side of the rotor in figure - 1, is called unbalance. In the example illustrated, it is the
"heavy spot". Unbalance may also occur due to lack of mass (such as a drill hole, porous spot, etc.) in which
case it is called the "light spot. Either one may be caused by a variety of reasons, including the following:
a.
b.
c.
d.
Symmetrical design and careful setting of tolerances and fits can often minimize balancing problems. Large
amounts of unbalance require large corrections. If such corrections are made by removal of material, additional
machining cost is involved and part strength may be affected. If corrections are made by addition of material,
cost is again a factor and space requirements for the added material may be a problem.
Manufacturing processes are the major source of unbalance. Unmachined portions of castings or forgings, which
cannot be made concentric and symmetrical with respect to the shaft axis, introduce substantial unbalance.
Manufacturing tolerances and processes, which permit any eccentricity or lack of squareness with respect to the
shaft axis, are sources of unbalance. The tolerances, necessary for economical manufacturing and assembly of
several elements of a rotor, permit radial displacement of parts of the assembly and thereby introduce unbalance.
Limitations imposed by rotor design often introduce unbalance effects that cannot be corrected adequately by
refinement of the design itself. For example, electrical design considerations impose a requirement that one coil
be at a greater radius than the others in a certain type of universal motor armature. It is impractical to design a
compensating unbalance into the armature.
Fabricated parts, such as fans, often distort nonsymmetrically under service conditions. Design and economic
considerations prevent the adaptation of methods that might eliminate this distortion and thereby reduce the
resulting unbalance.
Ideally, rotating parts should always be designed for inherent balance, whether a balancing operation is to be
performed or not. Where low service speeds are involved and the effects of a reasonable amount of unbalance
can be tolerated, this practice may eliminate the need for balancing. In parts that require unbalanced masses for
functional reasons, these masses can often be counterbalanced by designing for symmetry about the shaft axis.
Correction Methods
Corrections for rotor unbalance are made either by the addition of mass to the rotor, by the removal of material,
or in some cases, by relocating the shaft axis (mass centering"). The selected correction method should ensure
that there is sufficient space or material to allow correction of the maximum unbalance, which may occur. The
ideal correction method permits a reduction of the maximum initial unbalance to less than balance tolerance in a
single correction step. However, this is often difficult to achieve. The more common methods described below,
e.g., drilling, usually permit a single step reduction of 10:1 in unbalance if carried out carefully. Milling and
grinding are less accurate, unless carried out in automatic or semi-automatic balancing machines, which have
integrated mass correction devices.
The addition of mass may achieve a reduction ratio as large as 20:1 or higher, provided the mass and its position
are closely controlled. If the method selected for reduction of maximum initial unbalance cannot be expected to
bring the rotor within the permissible residual unbalance in a single correction step, a preliminary correction is
made. Then a second correction follows to reduce the remaining unbalance to its permissible value.
Addition of Mass
1.
2.
Addition of two-component Epoxy: It is difficult to apply the material so that its center-of-gravity is
precisely at the desired correction location. Variations in location introduce errors in correction. This
method is often used in balancing of wound armatures.
Addition of Bolted or Riveted Standard washers: This method is quick, but somewhat limited in
accuracy because the washers come in incremental sizes, i.e., the mass of one washer may vary
considerably from the mass of the next washer of the same type and size. This method is often used in
balancing of AC motor rotors.
3.
4.
Addition of Premanufactured weights: The same limitations as in (2) apply. A typical application is
addition of spring clips to the blades of automotive A/C blower wheels.
Addition of cut-to-size weights: This is practiced on drive shafts, for instance, by resistance welding
the weights to the outside rotor surface. Welding provides a means of attaching a wide variety of
correction masses at any desired angular locations. Care must be taken that welding heat does not
distort the rotor.
Removal of Mass
1.
2.
3.
Drilling: Material is removed from the rotor by a drill, which penetrates the rotor to a measured depth,
thereby removing the intended amount of material with a high degree of accuracy. A depth gage or
limit switch can be provided on the drill spindle to ensure that the hole is drilled to the desired depth.
This is probably the most effective method of unbalance correction.
Milling, Shaping, or Fly Cutting: This method permits accurate removal of mass when the rotor
surfaces, from which the depth of cut is measured, are machined surfaces, and when means are
provided for accurate measurement of cut with respect to those surfaces; used where relatively large
corrections are required.
Grinding: In general, grinding must be considered a trial-and-error method of correction. It is difficult
to evaluate the actual mass of the material, which is removed. This method is usually used only where
the rotor design or material does not permit a more economical type of correction.
Mass Centering
Such a procedure is used, for instance, to reduce initial unbalance in crankshaft castings or forgings. The shaft is
mounted in a balanced cage or cradle, which in turn, is rotated in a balancing machine. The shaft is adjusted
radially with respect to the cage until the unbalance indication for the combined shaft and cradle assembly is
within a given tolerance. At this point the principal inertia axis of the shaft essentially coincides with the shaft
axis of the balanced cage. Center drills, guided along the axis of the cage, then drill the shaft centers and thereby
provide an axis in the crankshaft about which it is in balance. The subsequent machining of the crankshaft is
carried out between these centers.
Because material removal is uneven at different parts of the shaft, the machining operation will introduce some
new unbalance. A final balancing operation is, therefore, still required. It is generally accomplished by drilling
into the crankshaft counterweights. However, final unbalance corrections are small and balancing time is
significantly shortened. Furthermore, final correction (usually by drilling) does not exceed the material available
for it, nor does it reduce the mass of the counterweights to a level where they no longer perform their proper
function, namely to compensate for the opposed throws and crankpins of the crankshaft.
Units of Unbalance
Unbalance is measured in ounce-inches, gram-inches, or gram-millimeters, all having a similar meaning, namely
a mass multiplied by its distance from the shaft axis, i.e., its "radius". An unbalance of 100 g-in, for example,
indicates that one side of the rotor has an excess mass equivalent to 10 grams at a 10 inch radius, or 20 grams at
a 5 inch radius.
Since a given excess mass at a given radius represents the same unbalance, regardless of rotational speed
(provided the rotor does not change its shape over speed), the speed at which the unbalance is measured is
determined primarily by the type of balancing machine, its drive system, the required balancing accuracy, and
safety concerns (i.e. the slower the rotational speed, the less energy is stored in the rotor).
Once the unbalance has been corrected there will no longer be any significant disturbing centrifugal force and,
therefore, no more excessive vibration. A small residual unbalance will usually remain in the part, just as there
is a tolerance in any machining operation. Generally, the higher the service speed, the smaller should be the
residual unbalance.
While most countries use the metric system, and subsequently use metric units of unbalance, e.g., grammillimeters (abbreviated g-mm), in the U.S.A. many branches of the industry use a combination of metric and
English units, gram-inch (abbreviated g-in), because it has proven to be the most practical. A true English unit,
e.g., ounce-inch (abbreviated oz-in) is too large for many balancing applications, necessitating fractions or a
subdivision into hundredths, neither of which has become very popular.
Types of Unbalance
The following paragraphs explain the four different types of unbalance as defined by the internationally
accepted ISO Standard No. 1925 on balancing terminology. For each of the four mutually exclusive cases an
example is shown, illustrating displacement of the principal axis of inertia from the shaft axis caused by the
addition of certain unbalance masses in certain distributions to a perfectly balanced rotor.
1. Static Unbalance:
2. Couple Unbalance:
4. Dynamic unbalance:
Since the force that a given amount of unbalance exerts at a given speed is always the same, no matter whether
the unbalance occurs in a small or large, light or heavy rotor, the output from the sensing elements attached to
the balancing machine bearing supports remains proportional to the centrifugal force resulting from unbalance
in the rotor. The output is not influenced by bearing mass, rotor mass, or inertia, so that a permanent relation
between unbalance and sensing element output can be established.
Centrifugal force from a given unbalance rises with the square of the balancing speed. Output from the pickups
rises proportionately with the second or third power of the speed depending on the type of pickup used. Suitable
integrator circuitry then reduces the pickup signal inversely proportional to the square respectively cube of the
balancing speed increase, resulting in a constant unbalance readout. Unlike soft-bearing balancing machines, the
use of calibration masses or shakers is not required to calibrate the machine for a given rotor.
Search
ISO 2954:1975 Mechanical vibration of rotating and reciprocating machinery -- Requirements for instruments for
measuring vibration severity
Why Balance?
ISO 3719:1994 Mechanical vibration -- Symbols for balancing machines and associated instrumentation
Unbalance vs.
Centrifugal Force
ISO 4866:1990 Mechanical vibration and shock -- Vibration of buildings -- Guidelines for the measurement of
vibrations and evaluation of their effects on buildings
Causes of Unbalance
Correction Methods
Units of Unbalance
ISO 5344:1980 Electrodynamic test equipment for generating vibration -- Methods of describing
equipment characteristics
Types of Unbalance
Types of Balancing
Machines
Balancing Standards
ISO 7475:2002 Mechanical vibration -- Balancing machines -- Enclosures and other protective measures for the
measuring station (available in English only)
ISO 7626-1:1986 Vibration and shock -- Experimental determination of mechanical mobility -- Part 1: Basic
definitions and transducers
ISO 7626-2:1990 Vibration and shock -- Experimental determination of mechanical mobility -- Part 2:
Measurements using single-point translation excitation with an attached vibration exciter
ISO 7626-5:1994 Vibration and shock -- Experimental determination of mechanical mobility -- Part 5:
Measurements using impact excitation with an exciter which is not attached to the structure
ISO 7919-1:1996 Mechanical vibration of non-reciprocating machines -- Measurements on rotating shafts and
evaluation criteria -- Part 1: General guidelines
ISO 7919-2:2001 Mechanical vibration -- Evaluation of machine vibration by measurements on rotating shafts -Part 2: Land-based steam turbines and generators in excess of 50 MW with normal operating speeds of
1500 r/min, 1800 r/min, 3000 r/min and 3600 r/min
ISO 7919-3:1996 Mechanical vibration of non-reciprocating machines -- Measurements on rotating shafts and
evaluation criteria -- Part 3: Coupled industrial machines
ISO 7919-4:1996 Mechanical vibration of non-reciprocating machines -- Measurements on rotating shafts and
evaluation criteria -- Part 4: Gas turbine sets
ISO 7919-5:1997 Mechanical vibration of non-reciprocating machines -- Measurements on rotating shafts and
evaluation criteria -- Part 5: Machine sets in hydraulic power generating and pumping plants
ISO 8042:1988 Shock and vibration measurements -- Characteristics to be specified for seismic pick-ups
ISO 8569:1996 Mechanical vibration and shock -- Measurement and evaluation of shock and vibration effects on
sensitive equipment in buildings
ISO 8821:1989 Mechanical vibration -- Balancing -- Shaft and fitment key convention
ISO 9688:1990 Mechanical vibration and shock -- Analytical methods of assessing shock resistance of
mechanical systems -- Information exchange between suppliers and users of analyses
ISO 10055:1996 Mechanical vibration -- Vibration testing requirements for shipboard equipment and machinery
components
ISO 10137:1992 Bases for design of structures -- Serviceability of buildings against vibration (available in English
only)
ISO/TS 10811-1:2000 Mechanical vibration and shock -- Vibration and shock in buildings with sensitive
equipment -- Part 1: Measurement and evaluation
ISO/TS 10811-2:2000 Mechanical vibration and shock -- Vibration and shock in buildings with sensitive
equipment -- Part 2: Classification
ISO 10814:1996 Mechanical vibration -- Susceptibility and sensitivity of machines to unbalance
ISO 10816-1:1995 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 1: General guidelines
ISO 10816-2:2001 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 2: Land-based steam turbines and generators in excess of 50 MW with normal operating speeds of
1500 r/min, 1800 r/min, 3000 r/min and 3600 r/min
ISO 10816-3:1998 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and
15 000 r/min when measured in situ
ISO 10816-4:1998 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 4: Gas turbine driven sets excluding aircraft derivatives
ISO 10816-5:2000 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 5: Machine sets in hydraulic power generating and pumping plants (available in English only)
ISO 10816-6:1995 Mechanical vibration -- Evaluation of machine vibration by measurements on non-rotating
parts -- Part 6: Reciprocating machines with power ratings above 100 kW
ISO 10817-1:1998 Rotating shaft vibration measuring systems -- Part 1: Relative and absolute sensing of radial
vibration
ISO 10819:1996 Mechanical vibration and shock -- Hand-arm vibration -- Method for the measurement and
evaluation of the vibration transmissibility of gloves at the palm of the hand
ISO 11342:1998 Mechanical vibration -- Methods and criteria for the mechanical balancing of flexible rotors
(available in English only)
ISO 11342/Cor1:2000 Mechanical vibration -- Methods and criteria for the mechanical balancing of flexible rotors
(Technical Corrigendum 1)
ISO 13373-1:2002 Condition monitoring and diagnostics of machines -- Vibration condition monitoring -- Part 1:
General procedures
ISO 14694:2003 Industrial fans -- Specifications for balance quality and vibration levels
ISO 14695:2003 Industrial fans -- Method of measurement of fan vibration
ISO 14839-1:2002 Mechanical vibration -- Vibration of rotating machinery equipped with active magnetic bearings
-- Part 1: Vocabulary
ISO 16063-1:1998 Methods for the calibration of vibration and shock transducers -- Part 1: Basic concepts
ISO 16063-11:1999 Methods for the calibration of vibration and shock transducers -- Part 11: Primary vibration
calibration by laser interferometry (available in English only)
ISO 16063-12:2002 Methods for the calibration of vibration and shock transducers -- Part 12: Primary vibration
calibration by the reciprocity method (available in English only)
ISO 16063-13:2001 Methods for the calibration of vibration and shock transducers -- Part 13: Primary shock
calibration using laser interferometry
NATIONAL STANDARDS
ANSI S2.7-1982 (R1997)
SAE Documents
ARP587B : Balancing Machines - Description and Evaluation Horizontal, Two-Plane, Soft-Bearing Type for Gas
Turbine Rotors
ARP588B : Balancing Machines - Description and Evaluation Vertical, Single-Plane, Soft-Bearing Type for Gas
Turbine Rotors
ARP1134 : Adapter Interface - Turbine Engine Blade Moment Weighing Scale
ARP1202 : Balancing Machines, Dynamic, Ball Type Slave Bearings for Rotor Support
ARP1382 : Design Criteria for Balancing Machine Tooling
ARP4048 : Balancing Machines - Description and Evaluation Horizontal, Two-Plane, Hard-Bearing Type for Gas
Turbine Rotors
ARP4050 : Balancing Machines - Description and Evaluation Vertical, Two-Plane, Hard-Bearing Type for Gas
Turbine Rotors
ARP4162A : Balancing Machine Proving Rotors
ARP4163 : Balancing Machines, Tooling Design Criteria (as of 7-2003 being worked on, will supersede ARP
1382)
ARP5323 : Balancing Machines - Description and Evaluation Vertical, Single-Plane, Hard-Bearing Type for Gas
Turbine Rotors
ARP510A : Moment Weight of Turbine and Compressor Rotor Blades
AIR1839 : A Guide to Aircraft Turbine Engine Vibration Monitoring Systems
ANSI and ISO Documents may be ordered through http://www.ansi.org/
API Standards may be ordered through a distributor, Global Engineering Documents at http://global.ihs.com/
SAE Standards may be ordered through http://www.sae.org/
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