OU "Vibromera"

Balancing Mulchers, Combines and Harvesters

Thu, 07 Sep 2023 00:00:00 +0300

Professional Mulcher, Combine & Harvester Balancing Services | Agricultural Equipment Specialists

Why Agricultural Equipment Balancing is Critical for Your Operations

Modern agricultural equipment like mulchers, combines, and harvesters operate under demanding conditions with high-speed rotating components. Proper dynamic balancing is essential for maintaining peak performance, reducing operational costs, and ensuring equipment longevity.

Unbalanced rotors in agricultural machinery can result from normal wear, component replacement, repairs, or impact damage from field debris. Without proper balancing, these issues escalate into costly repairs and significant downtime during critical harvest seasons.

The Hidden Costs of Unbalanced Agricultural Equipment

⚠️ Warning Signs Your Equipment Needs Balancing:

Excessive vibration during operation
Premature bearing failures
Increased fuel consumption
Operator fatigue and discomfort
Uneven crop processing or cutting
Accelerated wear on drivetrain components

Financial Impact of Poor Balancing

Increased Maintenance Costs: Unbalanced equipment can reduce bearing life by up to 50%
Higher Fuel Consumption: Vibrations increase energy requirements by 10-15%
Reduced Productivity: Equipment downtime during peak seasons
Safety Risks: Excessive vibrations can lead to component failures and accidents

Comprehensive Agricultural Equipment Balancing Services

Our specialized agricultural equipment balancing services cover a wide range of rotating machinery used in farming and agricultural processing:

???? Mulchers & Shredders

Self-propelled mulchers
Rotary mulchers
Forestry mulchers
Straw mulchers
Roadside maintenance equipment

???? Combines & Harvesters

Threshing drums
Cleaning fans
Chopper assemblies
Rotor assemblies
Concave systems

⚙️ Rotating Components

Transport augers
Discharge augers
Grain elevators
Fan assemblies
Beater elements

???? Support Equipment

Grinder shafts
Chopper knives
Centrifugal separators
Blower assemblies
Hammer mills

Advanced On-Site Balancing Technology

Balanset-1A: Professional Field Balancing Solution

We utilize the industry-leading Balanset-1A portable balancing analyzer for all agricultural equipment balancing services. This advanced system enables:

✅ Key Advantages of Our Balancing Technology:

On-Site Service: No need to remove equipment from the field
Single & Two-Plane Balancing: Comprehensive solutions for all rotor types
Real-Time Analysis: Immediate vibration measurement and correction calculations
ISO 1940 Compliance: Meets international balancing standards
Minimal Downtime: Typical balancing completed in 1-3 hours
Permanent Records: Digital documentation for maintenance tracking

Our Professional Balancing Process

Pre-Balancing Inspection: Complete mechanical assessment and repairs
Initial Measurement: Baseline vibration analysis using precision sensors
Trial Weight Testing: Systematic testing to determine correction requirements
Calculation & Correction: Precise weight and placement calculations
Verification: Final measurement to confirm balancing success
Documentation: Comprehensive report with before/after measurements

Pre-Balancing Requirements for Optimal Results

???? Essential Pre-Balancing Checklist:

To ensure successful balancing, complete these tasks before our service visit:

Replace worn or damaged bearings
Repair or replace damaged blades/hammers
Complete all welding and structural repairs
Ensure proper mounting and alignment
Clean debris from rotating components
Verify all bolts and fasteners are tight

Any mechanical work performed after balancing will require re-balancing to maintain optimal performance.

Industry-Leading Balancing Standards

ISO 1940-1-2007 Compliance

All our agricultural equipment balancing services strictly adhere to ISO 1940-1-2007 international standards. We achieve the minimum possible residual unbalance appropriate for each specific equipment class:

G 6.3: Agricultural machinery rotors with special requirements
G 16: Standard agricultural equipment rotors
G 40: Rough service agricultural applications

Quality Assurance

Certified technicians with agricultural equipment expertise
Calibrated precision instruments
Comprehensive testing and verification
Detailed documentation and reporting
Follow-up support and recommendations

Benefits of Professional Agricultural Equipment Balancing

???? Immediate Benefits:

Reduced Vibration: Up to 90% reduction in harmful vibrations
Extended Equipment Life: 50-100% increase in component lifespan
Improved Performance: Better crop processing and cutting quality
Fuel Savings: 10-15% reduction in fuel consumption
Operator Comfort: Significant reduction in cab vibration
Reduced Maintenance: Fewer bearing and component replacements

Long-Term Economic Impact

ROI Typically 300-500%: Balancing costs recovered within one season
Predictable Maintenance: Scheduled rather than emergency repairs
Higher Resale Value: Well-maintained equipment retains value
Increased Productivity: Less downtime during critical periods

Seasonal Balancing Programs for Agricultural Operations

Pre-Season Preparation

Schedule mulcher balancing, combine balancing, and harvester balancing before peak season to ensure optimal performance when you need it most.

Recommended Balancing Schedule:

Spring: Pre-planting equipment preparation
Early Summer: Mulcher and mowing equipment
Late Summer: Harvest equipment preparation
Winter: Post-season maintenance and repairs

Emergency Balancing Services

We understand that equipment issues don't wait for convenient times. Our emergency balancing services ensure minimal disruption to your critical agricultural operations.

Ready to Optimize Your Agricultural Equipment Performance?

Don't let unbalanced equipment cost you time, money, and productivity. Our expert team is ready to provide professional balancing services for your mulchers, combines, harvesters, and other agricultural equipment.

Contact us today for a consultation and quote!

Frequently Asked Questions About Agricultural Equipment Balancing

How often should agricultural equipment be balanced?

Typically annually before peak season, or after any significant repairs, component replacements, or impact damage.

Can balancing be performed in the field?

Yes, our portable Balanset-1A system enables complete on-site balancing without equipment removal.

How long does the balancing process take?

Most single-rotor balancing is completed in 1-3 hours, depending on equipment complexity and access.

What's included in the balancing service?

Complete vibration analysis, precision balancing, verification testing, and detailed documentation with recommendations.

Do you provide balancing for custom or modified equipment?

Yes, our experienced technicians can balance virtually any rotating agricultural equipment, including custom modifications.

English guide step-by-step

Wed, 15 Apr 2015 00:00:00 +0300

Balanset-1A User Manual

1. Introduction
2. Technical Specifications
3. Package Contents
4. System Setup
5. Software Interface
6. Balancing Procedures
7. Vibrometer Mode
8. Charts & Analysis
9. Reports & Archive
10. Influence Coefficients
11. Safety Precautions
12. Technical Support

1. Introduction

Balanset-1A is a portable two-channel balancing and vibration analysis system designed for on-site dynamic balancing of rotors and comprehensive vibration diagnostics. The system provides single-plane and two-plane balancing services for fans, grinding wheels, spindles, crushers, pumps, and other rotating machinery.

Fig. 1.1 - Balanset-1A Complete Set

The Balanset-1A includes a USB interface module, two accelerometers, a laser tachometer, comprehensive balancing software, and all accessories needed for field work. The system is designed to be simple to use even for non-vibration experts while providing professional-level results.

Key Features

Easy single and two-plane balancing with automatic calculations
FFT spectrum analysis and harmonic diagnostics
Unlimited storage of balancing data and reports
Phase measurement accuracy ±1°
Vibration velocity measurement (RMS): 0.02–80 mm/s
Frequency range: 5–550 Hz
Rotational speed measurement: 100–100,000 rpm
USB-powered, works with any modern Windows notebook
Storage of unlimited balancing data
User selectable trial mass
Split weight calculation, drill calculation
Trial mass validity automatically popup message
Measuring RPM, amplitude and phase of vibration velocity overall and 1x vibration
Dual-channel simultaneous data collection
Waveform and spectrum display
Balancing using saved influence coefficients
Trim balancing
Balancing mandrel eccentricity calculations (Index balancing)
Balancing tolerance calculation (ISO 1940 G-classes)
Polar graph
Manual data input

2. Technical Specifications

Parameter	Value	Units
Vibration velocity measurement (RMS)	0.02 – 80	mm/s
Frequency range for RMS measurement	5 – 200	Hz
FFT spectrum frequency range	5 – 550	Hz
Rotational speed measurement	100 – 100,000	rpm
Vibration phase measurement range	0 – 360	degrees
Phase measurement accuracy	±1	degrees
Number of correction planes	1 or 2	-
Operating temperature	5 – 50	°C
Relative humidity	< 85%	unsaturated
Total weight	< 5	kg
Case dimensions	39×33×13	cm
Accelerometer dimensions (max)	25×25×20	mm
Accelerometer weight (max)	0.04	kg

3. Package Contents

USB Interface Module (2 channels)

2× Vibration Sensors (Accelerometers)

Laser Tachometer (Phase Sensor)

Reflective Tape

Magnetic Stand for Tachometer

Digital Scales

Balanset-1A Software (USB Flash Drive)

Hard Carrying Case

User Manual (PDF and Online)

The delivery set includes all necessary components for immediate field balancing operations. No additional equipment is required except for a Windows-compatible laptop or PC.

4. System Setup

4.1 Software Installation

Install drivers and Balanset-1A software from installation USB flash drive. Insert USB cable to computer USB port. Interface module is supplied from USB port.

Fig. 4.1 - Use shortcut to run the program

4.2 Sensor Installation

Install sensors as shown on the figure below. Connect cables:

Vibration sensors to connectors X1 and X2
Phase laser sensor to connector X3

Fig. 4.2 - Main window for two-plane balancing

Install reflector mark on the rotor and check LED light on the phase sensor when rotor rotates.

Fig. 4.3 - Phase sensor settings

Ensure all sensors are securely attached and cables do not interfere with rotating parts. The tachometer must have a clear line of sight to the reflective tape for proper phase measurement.

5. Software Interface

The Balanset-1A software features a comprehensive interface with function buttons accessible via mouse clicks or keyboard function keys:

F1 - About

Displays program information and access to the user manual

F2 - Single Plane

Activates single-plane (static) balancing mode using the first vibration channel

F3 - Two Plane

Activates two-plane (dynamic) balancing mode using both vibration channels simultaneously

F4 - Settings

Access sensor calibration coefficients and system configuration options

F5 - Vibrometer

Real-time vibration measurement mode for diagnostics and monitoring

F6 - Reports

Access balancing archive and generate printable reports

F7 - Balancing

Primary balancing function for measurement runs and calculations

F8 - Charts

Access to vibration charts, spectrum analysis, and waveform displays

F10 - Exit

Close the application safely

6. Balancing Procedures

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

Fig. 6.1 - Balancing parameters setup

6.1 Two-Plane Balancing Procedure

Make step-by-step operations as shown in the table below:

Procedure Step	Two Plane Balancing Window
Run 0 - Start-up without test weight 1. Run the machine at its operating speed (but lower than resonance frequency) 2. Click on F9-Start and measure the vibration level and phase angle in turn without test weight Duration of the measuring process may amount 2-10 sec.	Two plane balancing window Correction weight mount
Run 1 - Test weight in plane 1 3. Stop the machine and mount a test weight of suitable size arbitrarily in plane 1 4. Start up the machine, click on F9-Run and measure the new vibration level and phase angle. Duration of the measuring process may amount 2-10 sec. 5. Stop the machine and remove the test weight
Run 2 - Test weight in plane 2 6. Mount a trial weight of suitable size in plane 2 7. Start the machine again, click on F9-Run and measure the vibration level and phase angle once more 8. Stop the machine and remove the test weight
Step 4 - Calculation 9. The values of the correction weights and angles required will be calculated automatically and shown in popup form
RunC - Final Check 10. Mount the correction (balance) weights at the positions indicated in popup form at the same radius as the test (trial) weights 11. 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.

6.2 Important Balancing Notes

Measurements should be carried out with constant speed of rotation of the mechanism
Correction weights must be installed on the same radius as the trial weights
Mass of the trial weight is selected so that after its installation phase (> 20-30°) and (20-30%) the amplitude of vibration change significantly
If changes are too small, the error increases greatly in subsequent calculations
Conveniently set trial mass at the same place (the same angle) as the phase mark
After each test run trial mass are removed
Correction weights set at an angle calculated from the place of trial weight installation in the direction of rotation of the rotor

7. 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"

Fig. 7.1 - Vibrometer mode interface

7.1 Measurement Parameters

V1s (V2s) - summary vibration in plane 1(2) (mean-square)
V1o (V2o) - vibration in plane 1(2) (first "revolution" harmonic value)
Phase angle - Phase relationship between vibration and rotation reference
RPM - Real-time rotational speed measurement

In the right side you can see spectrum window. Measuring data files can be saved in archive.

7.2 Diagnostic Applications

Unbalance Detection: High 1× vibration indicates mass unbalance requiring correction
Mechanical Looseness: Broadband vibration with multiple harmonics suggests loose components
Bearing Defects: High-frequency vibration at bearing characteristic frequencies
Misalignment: High 2× vibration often indicates shaft misalignment

8. Charts & Analysis

To view charts of vibration click on "F8-Diagrams". Two kinds of charts are available: "Total vibration" and "Vibration on rotor revolution frequency" (for example, for 3000 rev/min frequency is equal 50Hz)

Fig. 8.1 - Total vibration chart

Fig. 8.2 - Spectrum analysis chart

8.1 Chart Navigation

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

8.2 Analysis Features

Dual Channel Display: Simultaneous analysis of both measurement channels
FFT Spectrum Analysis: Frequency domain analysis for fault diagnosis
Time Waveform: Time domain analysis of vibration patterns
Harmonic Analysis: Analysis of vibration harmonics
Overall Vibration: Total vibration energy measurement
1× Vibration: Synchronous vibration at rotation frequency

9. Reports & Archive

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

Fig. 9.1 - Archive and reports window

To print report click "F9-Report"

Fig. 9.2 - Balancing report example

9.1 Data Management

Unlimited Storage: Archive capacity limited only by computer disk space
Session Indexing: Each balancing job automatically indexed with date, time, and rotor identification
Data Retrieval: Quick search and retrieval of historical balancing data
Report Generation: Professional reports for documentation and compliance

9.2 Report Contents

Machine identification and location
Balancing type and date
Before/after vibration measurements
Correction weight calculations
Tolerance compliance verification
Vibration waveforms and spectra

10. 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.

Fig. 10.1 - Influence coefficient balancing selection

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

Fig. 10.2 - Saving influence coefficients

10.1 Benefits of Influence Coefficients

Eliminates need for trial weight runs on identical rotors
Significantly reduces balancing time
Improves repeatability and accuracy
Suitable for production environments
Database storage for multiple machine types

10.2 When to Use Influence Coefficients

Identical rotor geometries
Same mounting configurations
Similar operating conditions
Regular maintenance balancing
Production line balancing

11. Safety Precautions

When operating on 220V AC power, observe all electrical safety regulations. Never attempt repairs while connected to mains power.

Always use appropriate safety glasses and follow site safety procedures during balancing operations.

11.1 Operating Environment

EMI Protection: Avoid operation near strong electromagnetic fields
Power Quality: Use battery power for improved measurement quality in environments with poor AC power
Sensor Mounting: Ensure all sensors are securely attached and cables routed away from rotating parts
Temperature Limits: Operate within 5-50°C temperature range
Humidity: Keep relative humidity below 85%, unsaturated

11.2 Pre-Operation Checklist

Step 1: Verify all cable connections are secure

Step 2: Check that reflective tape is properly adhered

Step 3: Confirm tachometer has clear line of sight

Step 4: Ensure work area is clear of personnel during rotation

Step 5: Verify emergency stop procedures are understood

12. Technical Support

12.1 Software Updates

Regular software updates provide enhanced features and improved functionality:

Download latest version from vibromera.eu
Automatic update notifications available
Backward compatibility with existing data files
Enhanced user interface and analysis capabilities

12.2 Contact Information

Technical Support:
Website: https://vibromera.eu
Email: info@vibromera.eu
WhatsApp: +372 5836 4849

Support Hours: Monday-Friday, 9:00-17:00 CET
Response Time: Typically within 24 hours

12.3 Warranty and Service

Warranty Period: 24 months from date of purchase
Calibration Service: Annual calibration recommended for optimal accuracy
Repair Service: Factory repair service available with quick turnaround
Sensor Replacement: Individual sensors can be recalibrated or replaced

9 tons weighing balancing

Thu, 13 Feb 2014 00:00:00 +0400

With the help of the device Balkom-1 was the shaft is balanced weighing 9 tons.
He jumped to resonate at 900 RPM.