Balancing Theory

Single and Two Plane Balancing: Theory
Machine Dynamics & Component Integrity

January 2007

Whenever a mass unbalance occurs in a machine and the vibration levels are not acceptable, balancing is required to reduce the vibration levels to run the machine for long time without any operating restriction.
January 2007

Mass unbalance occurs in a rotating machine when the center of the mass does not coincide with the geometric center as shown in the Figure below and it results in a heavy spot:
January 2007

Geometric Center
Heavy Spot
Mass Center
Unbalance = Me = We/g
where: e - eccentricity, in. W- weight of the rotor, lb. g - gravity, 386.4 in. /sec2
January 2007

The forces generated by the mass unbalance is dependent on the location of the center of the mass (the distance between the mass center and geometric center - sometimes called eccentricity), the total mass of the rotor and the square of the speed.
January 2007
F = me2
where: F = force due to mass unbalance, pounds m = W/g, mass of rotor or component e = eccentricity, inches = machine speed, radians/second = 2N/60 N = machine speed, RPM
January 2007

The forces on the bearings, structure, shaft and couplings resulting from mass unbalance are sometimes unacceptable because they will lead to vibrations that cause premature failures, unacceptable noise and general discomfort to those around the machine.
January 2007
To minimize the detrimental effect of unbalance, machinery rotors are balanced with a variety of methods. Most rotors are successfully balanced in slow speed balancing machines. This approach provides good accessibility to all correction planes and the option of multiple runs to achieve a satisfactory balance.
January 2007

January 2007

However, it should be understood that balancing at slow speeds with the rotor supported by simple bearings or rollers does not duplicate the rotating dynamics of the real field installation and in-situ balancing is often required.
January 2007

To reduce the mass unbalance forces, a small balance weight is positioned opposite the heavy spot as shown in the Figure below:
January 2007

Geometric Center

Heavy Spot
Mass Center
M WB eb
Balance Weight
Unbalance = Me = (WB /g) r

where: e - eccentricity, in. WB - the balance weight, lb. eb - radius of the balance weight, in. g - gravity, 386.4 in. /sec2 M - rotor mass
January 2007

The most common causes of unbalance include: Mass eccentricity due to unsymmetrical design; Machining errors and existence of applicable machining and assembling tolerances;
January 2007

Corrosion and wear; Deposit buildup; Thermal distortion; Non-uniform material properties; Components shift; Mass loss (blades, bolt, rivets, etc.).
January 2007

Types of unbalance: Static Couple Dynamic
January 2007

Static unbalance: the rotor center of mass is offset from the axis of rotation and the principal axis of inertia is parallel to the axis of rotation.
January 2007
Center of Mass Principal Axis of Inertia Axis of Rotation
Static Unbalance

This type of unbalance is commonly found (but not limited to) in narrow discs and impellers comprising the majority of the rotor weight. Vibration measured on the supporting bearings in the same direction is in-phase (0 20).
January 2007
Couple unbalance: the rotor center of mass lies on the axis of rotation and the principal axis of inertia intersects the axis of rotation at the center of mass at some angle.
January 2007

Center of Mass Axis of Rotation
Principal Axis of Inertia
Couple Unbalance

This type of unbalance occurs when two equal unbalance masses are positioned at opposite ends of the rotor 180 from each other circumferentially. When rotor spins, these masses are causing a rocking, or wobbling motion of the rotor.
January 2007

Vibration measured on the supporting bearings in the same direction is out-of-phase (180 20).
January 2007
Single and Two Plane Balancing: Theory Dynamic unbalance: a random combination of static and couple unbalance. The center of mass does not lie on the axis of rotation and the principal axis of inertia is angularly misaligned with respect to the axis of rotation.
January 2007 Machine Dynamics & Component Integrity
Center of Mass Axis of Rotation
Principal Axis of Inertia
Dynamic Unbalance

The amount and position of the unbalance in any machine are in general unknown, and the proper correction in the selected correction planes must be established by tests.
January 2007

For balancing, a vibration measuring device (Digital Vector Filter, analyzer, portable data collector, etc.) is usually used to obtain the operating speed (or synchronous) component of vibration associated with the mass unbalance.
January 2007

The amplitude of vibration, as well as the phase angle between a reference point (e.g. a key way) on the rotor and the vibration peak are acquired. To provide accurate phase readings, either a photoelectric sensor or a proximity probe is most commonly used today.
January 2007

To measure vibration amplitude, proximity probes, velocity pickups or accelerometers can be used. Proximity probes provide the most direct measurements; however, runout which causes phase and amplitude errors, must be subtracted.
January 2007

January 2007

The influence coefficient method is most commonly used technique for calculation of correction weights. Applying this technique, the mechanical system is calibrated with a known weight placed at a known angle.
January 2007

The response from the calibration or trial weights is used to calculate the influence coefficients and a balance correction that minimizes the measured initial vibration amplitudes at the balancing speed.
January 2007

The influence coefficient is a vector: its magnitude defines the system response per a unit of the trial weight (for displacement, usually m/kg or m/g). The influence coefficient phase is the phase lag between the heavy spot and the high spot.
January 2007

The proper selection of the trial weight is very important. The approach of installing the trial weight of any size at any angular location is extremely dangerous practice that can result in serious mechanical damage.
January 2007

In field balancing situations where historical data is unavailable, it is customary to install calibration weight that produces centrifugal forces in the vicinity of 10% of the rotor weight. The trial weight can be calculated using the following formula:
January 2007

where: WT trial weight, oz. eb radius of balancing plane, in. W static weight of the rotor, lb. N speed of the machine, RPM.
January 2007
The mass unbalance generates the force that leads the vibration peak (high spot) by 0 to 180, depending on location of the operating speed with respect to the critical speed. This phenomenon is termed as a mechanical phase lag, that is, vibration lags the force that causes it.
January 2007
Machine Dynamics & (heavyComponent spot) Integrity
When a machine operates substantially below its first critical speed (50% and more), the rotor can be classified as a rigid rotor. For this condition, the heavy spot is close to the measured high spot. In practice, however, there is always some phase lag of 20- 30.
January 2007

For the rigid rotors, when the location of the trial weight on the shaft is selected, it is related to the measured phase of the vibration peak (measured high spot) minus mechanical phase lag plus 180: T = + 180
January 2007

The selected trial weight is placed on the shaft in the available balancing plane at the angle T from the shaft reference mark (key way, notch, piece of a reflective tape, etc.) against direction of rotation.
January 2007

Machine Dynamics & Component Integrity Vibration Probe
Heavy Spot
Key Phasor
High Spot
Trial Weight
January 2007

Machine Dynamics & Component Integrity 0 initial vibration vector; 1 vibration vector with the trial weight installed; T vibration response from the trial weight; trial weight adjustment angle; __
__ AT __ A1 __ A0
__ WT
__ WB
wT the trial weight;

__ WB the balancing weight. January 2007

Balancing Plane 1 Center of Mass Principal Axis of Inertia
Brg 1
Brg 2
Axis of Rotation Unbalance Trial Weights
Static Unbalance: Single Plane Balancing January 2007

The influence coefficients are calculated using the following formula: __ __ __ S11 = AT11 / WT1 __ where S11 influence coefficient calculated for the Brg 1 from the trial weight WT1 installed in the balancing plane 1.
January 2007

Balance solution (trial weight removed) is calculated using the following formula: __ __ __ WB1 = A01( + 180) / S11 __ where WB1 balancing weight in the balancing __ plane 1. A01 initial vibration vector measured on the Brg 1.

Balance solution (the trial weight remains in the plane 1) is calculated using the following formula: __ __ __ WB1 = A11( + 180) / S11 __ where WB1 balancing weight in the balancing __ plane 1. A11 vibration vector measured on the Brg 1 with the WT1 installed.

When single plane balancing technique can not reduce vibration amplitudes down to the satisfactory levels (which is not uncommon even for static unbalance), two plane balancing method should be used. Calibration weights are placed in sequence in the balancing planes at both ends of the rotor and the influence coefficients are calculated.
January 2007

Almost all modern data collectors are able to perform this function. Balance calculation is almost automated and it produces satisfactory balancing solution in majority of cases. Manual calculation is more complicated; it consumes a lot of time and requires systematic meticulous approach and accuracy.
January 2007

Balancing is considered completed when satisfactory vibration levels have been achieved. Usually these levels are compared to different vibration Standards and Severity Charts available for different groups of the machines. An example of ISO Standards used for large turbine generator sets is presented below:
January 2007

January 2007

January 2007

If balancing has not resulted in improvement of vibration condition of the machine, the following should be considered: This is not unbalance; Measurements are not accurate; Error in balance weights installation;
January 2007
Single and Two Plane Balancing: Theory Operating condition before and after balancing are not consistent; Balancing weight is too small; Balancing weight is too large; Improperly selected system of balancing weights;
Improperly selected balancing planes.

January 2007

The first and most important step in any balancing project is to properly diagnose the root cause of mechanical behaviour of the machine. The machinery diagnostician must be reasonably confident that the problem is mass unbalance before proceeding.
January 2007

If this step is ignored, then the balancing work will yield only a marginal (if any at all) improvement in the vibration levels. Attempts to correct the problem the unbalance is not responsible for will only result in time and production losses.
January 2007

A variety of other mechanisms can produce vibration at synchronous (1X) rotational speed. No balancing should be attempted to reduce vibration levels caused by the following mechanisms : Excessive bearing clearance; Cracked shaft;
January 2007

Gear/pulley runout;
Locked coupling; Compliant support or foundation; Thermal distortion of structure; Misalignment (static, thermally induced, hydraulically induced);
January 2007

Structural looseness;
Component looseness; Resonance; Heavy rub.
January 2007
Single and Two Plane Balancing: Theory Heavy rub

January 2007
Resonance
Horizontal Dir. 1X = 30.6 mm/sec
January 2007
Resonance
Vertical Dir. 1X = 1.2 mm/sec
January 2007
Resonance
January 2007

Even though the balancing is sometimes considered as relatively simple and straightforward task, it represents one of most exciting and interesting field in vibration business.
Good Luck!!!
January 2007

Balancing Theory

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Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Unbalance = Me = (WB /g) r

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Types of unbalance: Static Couple Dynamic

Single and Two Plane Balancing: Theory

Center of Mass Principal Axis of Inertia Axis of Rotation

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Principal Axis of Inertia

Single and Two Plane Balancing: Theory

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Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

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Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

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Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Machine Dynamics & (heavyComponent spot) Integrity

Single and Two Plane Balancing: Theory

Machine Dynamics & Component Integrity

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

wT the trial weight;

Single and Two Plane Balancing: Theory

Axis of Rotation Unbalance Trial Weights

Static Unbalance: Single Plane Balancing January 2007

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Single and Two Plane Balancing: Theory

Improperly selected balancing planes.