TRAINING PROGRAM

ON
BALANCING OF ROTORS

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INTRODUCTION
Unbalance is the non uniform distribution of mass from centre of gravity of the rotating body. When the mass distribution is not uniform; the extra mass on the rotating body will produce a centrifugal force. This centrifugal will be acting away from the rotor and will try to pull the rotating body from the centerline.

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ISO- Definition
That condition which exists in a rotor when vibratory force or motion is imparted to its bearings as a result of centrifugal forces.

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TYPES OF UNBALANCE

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MASS UNBALANCE/FORCE UNBALANCE

Unbalance occurs when the mass centerline does not coincides with the shaft centerline.

Static Unbalance

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COUPLE UNBALANCE
Couple unbalance is the condition where the mass centerline axis intersect the shaft centerline axis at the rotors center of gravity

Couple Unbalance
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DYNAMIC UNBALANCE
condition in which the mass of the centerline is neither parallel to nor

intersects the shaft centerline axis.

Dynamic Unbalance

In essence it is the combination of both the unbalance

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Balancing of Rotors
What is rotor? Any link or machine member that is in pure rotation is called rotor. TYPES OF ROTOR

Rigid rotors If the rotating frequency of a rotor is less than (0.6~0.75)nC1 ( the rotors first resonant frequency)the rotor is supposed to have no deformation during rotation, it is called rigid rotor. The types of rotors which we normally consider to be rigid are electric motor rotors, single stage pumps, fans, coupling spool pieces, etc.
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Balancing of Rotors
Flexible rotors If the working rotating frequency of the rotor is higher than (0.6~0.75)nc1,then the rotor will have large elastic deformation due to the imbalance during rotation. The elastic deformation makes the eccentricity larger than the original one. So that a new imbalance factor is added and the balancing problem become more serious and complicated. Such rotor is called flexible rotor. Flexible rotors would include multistage pumps, steam turbines, compressors, paper rolls, etc.

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SINGLE PLANE BALANCING

If the rotor under consideration is very thin body, the residual centrifugal force acting from non uniform distribution of mass can be considered as a single force acting only in one plane.

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MULTI PLANE BALANCING

When the width of rotor is considerable, there can be forces acting on different planes due to non uniform distribution of mass. Such rotors can be considered as many thin disc rotors joined together and each of this plane can have unbalance forces.

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Guideline for choosing planes

If, L=width of rotor D=Diameter of Rotor If the ratio L/D is less than 0.5, single plane balancing is sufficient up to operating speed above 500RPM. If the ratio L/D is less than 0.5, Two plane balancing is required for above speed of 750RPM. If the ratio L/D is more than 0.5, Two plane balancing is required.

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FORCE UNBALANCE

O/B Hz/Vt phase will equal to I/B Hz/Vt phase 1X RPM always present and normally dominates Amplitude varies with square of increasing speed Can cause high radial amplitudes (Hz > Vt) Balancing requires Correction in single plane The difference in Hz and Vt phase should be equal
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PHASE AT 1XRPM FOR A MACHINE WITH DOMINANT FORCE UNBALANCE

1 MOTOR 2 3 4 PUMP

DIR
A H V

1
60 30 120

2
70 25 110
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3
60 30 120

4
80 40 135

COUPLE UNBALANCE

1800 out of phase on the same shaft 1X RPM always present and normally dominates Amplitude varies with square of increasing speed Can cause high axial as well as radial amplitudes Balancing requires Correction in two planes at 180o

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PHASE AT 1XRPM FOR A MACHINE WITH DOMINANT COUPLE UNBALANCE

1 MOTOR

PUMP

DIR A H V

1 60 30 120

2 70 210 295
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3 60 200 280

4 80 180 300

DYNAMIC UNBALANCE

O/B Hz/Vt phase difference may 0-180 to I/B Hz/Vt phase 1X RPM always present and normally dominates may high on one bearing Amplitude varies with square of increasing speed Can cause high radial amplitudes Balancing requires Correction in at least two plane The difference in Hz and Vt phase should be equal

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PHASE AT 1XRPM FOR A MACHINE WITH DOMINANT DYNAMIC UNBALANCE 1 MOTOR 2

4 PUMP

DIR A H V

1 60 30 120

2 70 90 180
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3 60 80 170

4 80 70 165

CAUSES AND EFFECTS

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Unbalance can occur on all rotating parts like: Fan Impeller Couplings Pulleys Large gear running at high speed Electric motors Crusher rotors Pumps

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CAUSES OF UNBALANCE
Eccentricity due to improper mounting Minor breakages in coupling, pulleys. Addition of key and keyways Distortion of Rotating parts Erosion and Wear Corrosion of rotating parts Welding repairs and non uniform size of fasteners

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CAUSES OF UNBALANCE

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Weight of Fan Impeller =8000 Weight of Fan Shaft = 6000 Eccentric in the mounting = 0.02 The unbalance moment is=(8000+6000)X0.02/10 X 1000 =28000 If this fan is running at a speed of 1500rpm, the centrifugal force generated, F= 0.01 X (1500/1000)2X28000 = 630 kgs

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CAUSES OF UNBALANCE

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CAUSES OF UNBALANCE

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BALANCE QUALITY REQUIRED

The G number is the product of specific unbalance and the angular velocity of the rotor at Maximum operating speed and is constant for rotors of the same type. G=exw DETERMINING PERMISSIBLE RESUDUAL UNBALANCE U(per) = e (per) X m (rotor mass)

Balancing Chart1 Balancing Chart2

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BALANCING MACHINES

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HARD BEARING BALANCING MACHINE

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HARD BEARING BALANCING MACHINE

By nature of their design, are best suited to being permanently installed for production and high speed balancing. Because the machines are designed to measure unbalance forces, which are proportional to the square of the rotational speed, the sensitivity to a given unbalance level is speed dependent; the higher the rotational speed of the rotors, the higher the sensitivity. Hence, Hard Bearing machines are not the most suitable for low speed balancing

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SOFT BEARING BALANCING MACHINE

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SOFT BEARING BALANCING MACHINE

The balancing speed range of this type of machine is above the natural frequency of the suspension system, and the rotor is essentially isolated by the pendulum action of the suspensions Its performance is therefore not influenced by the mass and/or stiffness of the supporting structure and foundations. Hence, the machine can be mounted very easily and quickly at any location that is capable of supporting its static weight and that of the rotor

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CENTRAL PRINCIPAL AXIS

SHAFT AXIS

STATIC UNBALANCE

BACK
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CENTRAL PRINCIPAL AXIS SHAFT AXIS

COUPLE UNBALANCE
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CENTRAL PRINCIPAL AXIS

SHAFT AXIS

DYNAMIC UNBALANCE
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