Balancing Theory
Balancing Theory
Balancing Theory
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.
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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:
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Mass Center
Unbalance = Me = We/g
where: e - eccentricity, in. W- weight of the rotor, lb. g - gravity, 386.4 in. /sec2
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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.
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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
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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.
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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.
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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.
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To reduce the mass unbalance forces, a small balance weight is positioned opposite the heavy spot as shown in the Figure below:
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Mass Center
M WB eb
Balance Weight
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The most common causes of unbalance include: Mass eccentricity due to unsymmetrical design; Machining errors and existence of applicable machining and assembling tolerances;
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Corrosion and wear; Deposit buildup; Thermal distortion; Non-uniform material properties; Components shift; Mass loss (blades, bolt, rivets, etc.).
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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.
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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).
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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.
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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.
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Vibration measured on the supporting bearings in the same direction is out-of-phase (180 20).
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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
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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:
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where: WT trial weight, oz. eb radius of balancing plane, in. W static weight of the rotor, lb. N speed of the machine, RPM.
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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.
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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.
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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
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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.
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Key Phasor
High Spot
Trial Weight
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__ AT __ A1 __ A0
__ WT
__ WB
Brg 1
Brg 2
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.
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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.
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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.
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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:
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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;
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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;
Machine Dynamics & Component Integrity
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.
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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.
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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;
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Gear/pulley runout;
Locked coupling; Compliant support or foundation; Thermal distortion of structure; Misalignment (static, thermally induced, hydraulically induced);
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Structural looseness;
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Resonance
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Resonance
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Resonance
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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!!!
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