OU "Vibromera" http://goodbal.com/ ru Wed, 15 Apr 2015 00:00:00 +0300 English guide step-by-step English guide step-by-step

 OU "Vibromera" 


Balancing set "BalCom-1"


User manual 
rev 1.0



Jun  2012



1. Introduction

 BalCom-1 is portable balancer  used to balance rigid rotors in their own bearings (in-situ) or as embedded measuring system in the portable balancing machines. It provide on-situ (field) single- and two-plane dynamic balancing services for fans, grinding wheels, spindles, crushers, pumps and other rotating machinery.  Balancing  software  provides the correct balancing solution for single-plane and two-plane balancing automatically. 
 BalCom-1 is simple to use for non-vibration experts.


 

BalCom-1 includes:

1 - Interface unit
2 - two vibration sensors 
3 - 1 optical sensor (laser tachometer)
4- scale
5 - Software ( notebook not included - supplied by additional order)
 

Specifications:

2x vibration sensors based on Analog Devices ADXL series.
1 x optical sensor (laser)
1 x interface module with software for PC connection
Software provides measuring vibration, phase angle, calculation of value and angle of correcting mass.

Details:

Amplitude vibration range 0.005-100 mm/sec
Vibration frequency range 5  - 300 Hz
Accuracy - 5% of full scale
Correction planes 1 or 2
Rotation speed measuring 30-90000​  rpm
Phase angle measurement error +-1 degree
Power  -  140- 220VAC 50Hz
Weigh - 1.4 KG

2. Prepare to work. Software and hardware setup for two-plane balancing.

Install drivers and BalCom-1 software from installation CD.
Insert USB cable to computer USB port. Interface module supplied from USB port.

Use  shortcut to run the program.

2.2  Sensor installation

Install sensors as shown  on the fig. 1 below

Connect cables 
- vibration sensors to connectors X1 and X2
- phase laser sensor to connector X3




fig.1 Main window for two-plane balancing



 Install reflector mark on the rotor and check led light on the phase sensor when rotor rotate. 

 

fig.1.1  phase sensor settings

3. Balancing procedure

After sensors install click on "F7 - Balancing" button and set balancing parameters. Then click "F9-Next"


 Make step-by-step operations  as shown in the Table 1.

  Table 1
Run 0 - Start-up without test weight.
  2. Run  the  machine  at  its operating  speed (but lower than resonance frequency) 
  3. Click on F9-Start and measure  the vibration  level and  phase angle  in turn without test weight.
Duration of the measuring process  may amounts  2-10 sec.

Two plane balancing window







Correction weight mount

Run 1 - Test weight in plane 1
4. Stop the  machine  and mount a test weight  of suitable  size  arbitrarily  in plane 1.
5. Start up the  machine, click on F9-Run and  measure   the new vibration  level   and  phase angle.  Duration of the measuring process  may amounts  2-10 sec.
6. Stop  the machine and  remove the  test  weight 
Run 2 - Test weight in plane 2
7. Mount a trial weight of  suitable size in plane 2 . 
8. Start  the  machine again, click on F9-Run   and measure  the vibration  level  and phase  angle  once  more.  
9. Stop  the machine and remove  the  test  weight . 
Step 4 - Calculation
10. The values of the correction weights  and angles required will be calculated automatically and shown in popup form.  
RunC
 11. Mount the correction (balance) weights  at the  positions  indicated  in popup form  at the same radius   as the  test (trial) weights (as shown in the figure in right column).  
 12. Start up  the  machine  again and   measure the  amount of residual  unbalance in  the rotor , to see how  successful  the  balancing  job has been .  



After balancing you can save influence coefficient balancing (F8- coefficients) and other information (F9- Add to archive) and use it later. (see 4.3, 4.4)

4. Other features

4.1 Vibrometer mode.

To select Vibrometer mode click "F5- Vibrometer" button in the main window for two-(one-) plane balancing  
To start the measuring process click "F9-Run" 



V1s (V2s) - summary vibration in plane 1(2) (mean-square)
V1o (V2o) -  vibration in plane 1(2) (first "revolution" harmonic value)
In the right side you can see spectrum window.
Measuring data files can be saved in archive.




4.3 INFLUENCE COEFFICIENT BALANCING 

If you save the results of previous balance runs, you can eliminate the test weight run and balance the machine using its saved coefficients.  Select "Secondary" in the "Type of balancing" window and click "F2 Select" button to choose previous machine type from list.




To save coefficients after balancing click "F8-coefficients" in the balancing result pop-up window (see Tab.1) and then click "F9-Save" button. Input machine type ("Name") and other information in the table.


4.4 Archives and reports.

To save  balancing information click "F9- Add to archive" in the balancing result pop-up window (see Tab.1). Input machine type ("Name") and other information in the table. 
To open previous saved archives  click "F6-Report" in the main window.


To print report click "F9-Report"



 

4.6 Charts 

To view charts of vibration click on "F8-Diagrams"
Two kind of charts available "Total vibration" and  "Vibration on rotor revolution frequency" (for example, for 3000 revmin frequency is equal 50Hz)
To zoom chart - select chart region by mouse from top left to right bottom direction, to redo changes - select region  from top right to left bottom direction


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Wed, 15 Apr 2015 00:00:00 +0300
How to balance П.1.1. Rotor balancing in one and two planes of correction.
The quantity of balancing planes is defined with design features of a rotor of the balanced mechanism.

Balancing in one plane ("static") is usually carried out for the narrow disk-shaped rotors with no essential axial beats.
Typical examples of rotors of this class are:

  • narrow grinding wheels;
  • pulleys of belt drives;
  • disk flywheels;
  • cogwheels;
  • couplings;
  • tightening cartridges of lathes;
  • narrow fans, etc.

Balancing in two planes ("dynamic") is carried out for long (arched) double-bearing rotors.
Typical examples of rotors of this class are:

  • rotors of electric motors and generators;
  • rotors for compressors and pumps;
  • turbine wheel and fans;
  • wide wheels;
  • spindles;
  • shafts of flour machines with whips, etc.

П.1.2. Features of the balanced machine installation.
As a rule, balancing of the machine is carried out directly on a place of its installation.
The exception takes place when the speed of a rotor gets to one of car resonance ranges. A sign of it is the difference (more than for 10-20%) of results of amplitude and/or a phase measurements from start to start. In case of a resonance identification it is necessary to change the speed of a rotor rotation and in case it is impossible - to change conditions of car installation on the base (for example, having it temporarily established on elastic support).

П.1.3. Choice of speed rotation of a rotor.
Balancing is usually set at operation speed of a rotor rotation. Balancing is usually carried out at the operating speed of the rotor. In the case when applies an actuator with speed change ability, it is advisable to select the highest operation speed.

Attention!
At a choice of rotation speed of a rotor when balancing it is necessary to avoid hit in ranges of resonances of the car (see Ann. Par. 1.2.)

П.1.4. Choice of measuring points and planes of correction.
Bearing supports or pole planes are preferably selected as vibration measurement points.
When balancing in a single plane it is sufficient to have one measuring point (see Fig. Ann. 1.1.).

Схема балком-1

Схема Балком-1

Схема Балком-1

When balancing in two planes there should be two points of measurement (see. Fig. Ann. 1.2 and Ann. 1.3).
Correction planes, in which occurs the removal (setting) of correction loads on the rotor, should be selected as close as possible to the point of measurement. In case of balancing in two planes distance between the planes should be chosen as large as possible.

Par.1.5. Choice of test load weight.
Weight of the test load may be approximately determined from the empirical formula:
http://goodbal.ru/images/upload/help4.png

where: Мп - test load weight, g
Мр – balanced rotor weight, g
Rп –test load installation radius, sm
N – rotor speed, rpm
К= from 1 to 5 – coefficient considering conditions of installation of the balanced rotor.

When the weight of test load is correct its installation on the rotor should lead to noticeable changes in the level of vibration. Otherwise, the weight of the test load should be increased.

Par.1.6. Features of sensors installation.
1) The vibration sensor may be installed at the measurement point using:

  • Threaded rod (rigid attachment);
  • Magnetic sucker;
  • transitional probe (clip with a hand);
  • direct contact of the sensor with a support (clip with a hand).

2) Phase-angle sensor can be installed on the machine with special devices (e.g., magnetic rack or clamp) and must be oriented on normal to the cylindrical or end surface of the rotor. Mark is applied with a chalk, light-reflecting tape or likewise on the surface of the rotor to reference the phase angle. As a mark also be used the keyways, holes, protruding bolt heads, etc which are available on specific rotors.
For production of the reflecting mark the adhesive mirror reflecting tape or the adhesive light-reflecting tape are included in a dekivery set.
Light-reflecting tape is recommended to be used for severe conditions of the sensor operation (the raised gap, a flare external sources of light radiation).
The gap between the sensor and the rotating surface of the rotor for phase angle sensor of DT 2234C + type must be installed within 10 - 500 mm.
For phase angle sensors of other models, which can optionally be equipped with the device, the allowable range of the operating clearance is set to meet the requirements of technical documentation for the sensor.
It must be understood that the choice of width of "L" mark depends on the rotation frequency of a rotor and radius of mark installation. Approximately it can be calculated on a formula:

Формула
where: L – mark width (min), sm
N – rotor speed, rpm
R – mark installation radius, sm

Based on the experience of practical application the recommended width of mark must be min 1 - 1.5 cm.
For midget rotors with the mark installation radius of 10 mm it is recommended to use a narrower label. It is desirable to conduct an experimental verification of correctness of the label width choice.

Attention!

When using the photoelectric phase angle sensor in order to avoid interference, it is desirable to avoid direct sunlight or strong artificial light reflecting on the mark and / or sensor (photodiode).

Par.1.7. Criteria of balance according to the state standard ISO 10816-1-97 ( ISO
2372).
Limit values for vibration level established for the four classes of machines are listed in Table A.1.

                              *)

      The class mechanism 

**Acceptable levels of vibration, mm / sec RMS**

Good

acceptably

Еще допустимо

unacceptable

1

< 0.7

0.7-1.8          

1.8-4.5    

> 4.5

2

<1.1

1.1-2.8          

2.8-7.1

>7.1

3

<1.8

1.8-4.5   

4.5-11

>11

4

<2.8

2.8-7.1

7.1-18

>18

*)Note:
- class 1 corresponds to small machines, installed on rigid foundations (analogue - motors up to 15 kW);
- Class 2 corresponds to average machines, installed without separate foundations (analogue - electric power of 15-75kvt), as well as actuators on detached foundations with individual power up to 300 kW;
- Class 3 corresponds to large machines installed on rigid foundations (analogue - the electrical equipment of more than 300 kW);
- Class 4 corresponds to large machines installed on foundations of facilitated type (analog - electrical equipment more than 300 kW).

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Sat, 17 Jan 2015 00:00:00 +0300
Video of fan balancing. ]]> Wed, 19 Nov 2014 00:00:00 +0300 9 tons weighing balancing With the help of the device Balkom-1 was the shaft is balanced weighing 9 tons.
He jumped to resonate at 900 RPM.

balanced weighing 9 tons

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Thu, 13 Feb 2014 00:00:00 +0400
balancing fluid coupling The cold weather ... Outside warm car minus two and fluid coupling that must be balanced.
balancing fluid coupling

This time we were lucky. Fitting the test load and its weight was enough that would reduce vibration to a very good standard. Vibration decreased 10 times from 3.4 mm / sec to 0.3-0.4 mm / s.
Balancing the cold unpleasant, but possible.

balancing fluid coupling
balancing fluid coupling
balancing fluid coupling
balancing fluid coupling
balancing fluid coupling
balancing fluid coupling

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Tue, 26 Nov 2013 00:00:00 +0400
The process of balancing the impeller Balancing the impeller 240mm.

Before balancing:
1 plane 11,8 mm/sec
2 plane 54,5 mm/sec

after balancing
1 plane 1 1.62 mm / sec
2 plane 0,408 mm / sec

The process of balancing the impeller

The process of balancing the impeller

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Sat, 26 Oct 2013 00:00:00 +0400
Balancing machine for grinding skis Today, over balancing drum sander for skis.

Balancing was successful, but unfortunately apart from the drum has a strong vibration motor.
.

Vibration before balancing:
21.2 in the first plane
4.83 in the second plane

After balancing:
first plane: 0.586
the second plane: 0,618

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Thu, 05 Sep 2013 00:00:00 +0400