PORTABLE BALANCER "BALANSET-1A"
Dvokanalnog PC-baziranog sistema za dinamičko balansiranje
UPUTSTVO ZA UPOTREBU
rev. 1.56 maj 2023
2023 | Estonija, Narva
SAFETY NOTICE: Ovaj uređaj je u skladu sa EU normama sigurnosti. Laserski proizvod klase 2. Pratite procedure sigurnosti rotacijske opreme. Pogledajte sve informacije o sigurnosti ispod →
1. PREGLED SISTEMA ZA BALANSIRANJE
Balanset-1A balanser omogućava usluge jednoravnog i dvostrukoravnog dinamičkog uravnoteživanja za ventilatore, brusne ploče, vretena, drobilice, pumpe i druge rotirajuće mašine.
Balanset-1A uravnotežavač uključuje dva vibrosenzora (akserometara), laserski senzor faze (tahometar), 2-kanalni USB interfejs sa predojačivačima, integratorima i ADC modulom za prikupljanje podataka i Windows softvera za uravnoteživanje. Balanset-1A zahteva prijenosno računalo ili drugi Windows (WinXP...Win11, 32 ili 64bit) kompatibilan računar.
Softver za balansiranje pruža ispravno rješenje za balansiranje u jednoj i dvije ravni automatski. Balanset-1A jednostavan je za upotrebu za stručnjake koji ne koriste vibracije.
Svi rezultati balansiranja se čuvaju u arhivi i mogu se koristiti za kreiranje izvještaja.
Key Features
Easy to Use
- • Pokusna masa - izbor korisnika
- • Popup validnosti pokusne mase
- • Ručni unos podataka
Mogućnosti mjerenja
- • Broj okretaja, amplituda i faza
- • FFT spektralna analiza
- • Prikaz talasa i spektra
- • Istovremeni podaci dvaju kanala
Napredne funkcije
- • Sačuvani koeficijenti uticaja
- • Finije uravnoteživanje
- • Proračun ekscentričnosti mandre
- • Proračun tolerancije ISO 1940
Upravljanje podacima
- • Neograničena pohrana podataka o balansiranju
- • Pohrana talasnog oblika vibracija
- • Arhiva i izvještaji
Alati za proračun
- • Proračun podijeljene težine
- • Proračun bušenja
- • Promjena ravnina korekcije
- • Vizuelizacija polarnog grafa
Opcije analize
- • Uklanjanje ili zadržavanje pokusnih težina
- • Grafikoni RunDown (eksperimentalno)
2. SPECIFIKACIJA
| Parameter | Specification |
|---|---|
| Mjerni opseg srednje kvadratne vrijednosti (RMS) brzine vibracije, mm/sec (za 1x vibraciju) | from 0.2 to 80 |
| Frekvencijski opseg RMS mjerenja brzine vibracije, Hz | from 5 to 1000 (amplitude error ≤10% above 550 Hz) |
| Broj ravni korekcije | 1 ili 2 |
| Opseg mjerenja frekvencije rotacije, o/min | 250 – 90000 |
| Opseg mjerenja faze vibracije, ugaoni stepeni | od 0 do 360 |
| Greška mjerenja faze vibracije, ugaoni stepeni | ± 1 |
| Tačnost mjerenja RMS brzine vibracija | ±(0.1 + 0.1×Vmeasured) mm/sec |
| Tačnost mjerenja frekvencije rotacije | ±(1 + 0.005×Nmeasured) rpm |
| Srednje vrijeme između kvarova (MTBF), sati, min | 1000 |
| Prosječni vijek trajanja, godine, min | 6 |
| Dimenzije (u tvrdom koferu), cm | 39*33*13 |
| Mass, kg | <5 |
| Ukupne dimenzije senzora vibratora, mm, maks | 25*25*20 |
| Masa senzora vibratora, kg, maks | 0.04 |
|
Uslovi rada: - Temperature range: from 5°C to 50°C - Relativna vlažnost: < 85%, nezasićena - Bez jakog elektromagnetskog polja i jakih udara |
|
3. PAKET
Balanset-1A uključuje dva jednoosnovna akcelerometra, laserski marker za referencu faze (digitalni tahometar), 2-kanalni USB interfejsni modul sa predpojačivačima, integratorima i ADC modulom za prikupljanje podataka te Windows software za balansiranje.
Delivery Set
| Opis | Broj | Bilješka |
|---|---|---|
| USB interfejs jedinica | 1 | |
| Referentni marker laserske faze (tahometar) | 1 | |
| Jednoosnovna akcelerometra | 2 | |
| Magnetno postolje | 1 | |
| Digitalne vage | 1 | |
| Tvrdi kofer za transport | 1 | |
| "Balanset-1A". Korisničko uputstvo. | 1 | |
| Flash disk sa softverom za balansiranje | 1 |
4. BALANCE PRINCIPLES
4.1. "Balanset-1A" uključuje (sl. 4.1) USB interfejsni modul (1), dva akcelerometra (2) and (3), marker za referencu faze (4) i prijenosno računalo (nije uključeno) (5).
Komplet isporuke također uključuje magnetni stalak (6) ) used for mounting the phase reference marker and digital scales 7.
X1 and X2 connectors intended for connection of the vibration sensors respectively to 1 and 2 measuring channels, and the X3 connector used for connection of the phase reference marker.
The USB cable provides power supply and connection of the USB interface unit to the computer.
Sl. 4.1. Komplet isporuke "Balanset-1A"
Mechanical vibrations cause an electrical signal proportional to the vibration acceleration on the output of the vibration sensor. Digitized signals from ADC module transferred via USB to the portable PC ( (5). Marker za referencu faze generiše signal impulsa koji se koristi za izračunavanje frekvencije rotacije i ugla faze vibracije. Windows software nudi rješenja za balansiranje u jednoj i dvije ravnine, analizu spektra, dijagrame, izvještaje i pohranu koeficijenata utjecaja.
5. SAFETY PRECAUTIONS
⚡ OPASNOST - Električna sigurnost
5.1. When operating on 220V electrical safety regulations must be observed. It is not allowed to repair the device when connected to 220 V.
5.2. Ako koristite uređaj u okruženju slabe kvalitete napajanja AC strujom ili u prisustvu smetnji na mreži, preporučuje se korištenje baterije prijenosnog računala.
⚠️ Dodatni zahtjevi sigurnosti za rotirajuću opremu
- !Blokiranje машине: Uvijek primijenite odgovarajuće procedure zaključavanja/označavanja prije instalacije senzora
- !Lična zaštitna oprema: Nositi zaštitne naočale, zaštitu za sluh i izbjegavati labavu odjeću blizu rotirajućih dijelova
- !Sigurna instalacija: Osigurati da su svi senzori i kablovi čvrsto učvršćeni i da ne mogu biti zahvaćeni rotirajućim dijelovima
- !Nužne mjere: Poznavati lokaciju zaustavnog gumba za hitne slučajeve i proceduru gašenja
- !Training: Samo obučeni osoblje smije raditi sa opremom za balansiranje na rotirajućim dijelovima
6. SOFTVERSKE I HARDVERSKE POSTAVKE
6.1. USB drivers and balancing software installation
Before working install drivers and balancing software.
Spisak foldera i datoteka
Installation disk (flash drive) contains the following files and folders:
- Bs1Av###Setup – folder sa softverom za balansiranje "Balanset-1A" (### – broj verzije)
- ArdDrv – USB drivers
- EBalancer_manual.pdf – this manual
- Bal1Av###Setup.exe – datoteka instalacije. Ova datoteka sadrži sve arhivirane datoteke i foldere navedene gore. ### – verzija softvera "Balanset-1A".
- Ebalanc.cfg – vrijednost osjetljivosti
- Bal.ini – neki podaci inicijalizacije
Procedura instalacije softvera
For installing drivers and specialized software run file Bal1Av###Setup.exe and follow setup instructions by pressing buttons «Next», «ОК» etc.
Choose setup folder. Usually the given folder should not be changed.
Then the program requires specifying Program group and desktop folders. Press button Next.
Završetak instalacije
- ✓Install sensors on the inspected or balanced mechanism (Detailed information about how to install the sensors is given in Annex 1)
- ✓Connect vibration sensors 2 and 3 to the inputs X1 and X2, and phase angle sensor to the input X3 of USB interface unit.
- ✓Connect USB interface unit to the USB-port of the computer.
- ✓Prilikom korištenja napajanja iz AC izvora, priključiti računar na mrežu. Priključiti napajanje na 220 V, 50 Hz.
- ✓Kliknuti na prečicu "Balanset-1A" na radnoj površini.
7. SOFTVER ZA BALANSIRANJE
7.1. General
Initial window
Prilikom pokretanja programa "Balanset-1A" pojavljuje se početni prozor, prikazan na Sl. 7.1.
Sl. 7.1. Početni prozor "Balanset-1A"
U početnom prozoru nalaze se 4 dugmeta sa nazivima funkcija koje se realizuju klikom na njih.
F1-«About»
Sl. 7.2. Prozor F1–«O programu»
F2-«Single plane», F3-«Two plane»
Pressing "F2- Single-plane" (or F2 function key on the computer keyboard) selects the measurement vibration on the X1.
After clicking this button, the computer display diagram shown in Fig. 7.1 illustrating a process of measuring the vibration only on the first measuring channel (or the balancing process in a single plane).
Pressing the "F3-Two-plane" (or F3 function key on the computer keyboard) selects the mode of vibration measurements on two channels X1 and X2 simultaneously. (Fig. 7.3.)
Sl. 7.3. Početni prozor "Balanset-1A". Balansiranje u dvije ravni.
F4 – "Postavke"
Sl. 7.4. Prozor "Postavke"
In this window you can change some Balanset-1A settings.
- Sensitivity. The nominal value is 13 mV / mm/s.
Changing the sensitivity coefficients of sensors is required only when replacing sensors!
Pažnja!
Kada unesete koeficijent osjetljivosti, njegov decimalni dio je odvojen od cijeloga dijela sa decimalnom točkom (znakom ",").
- Averaging – number of averaging (number of revolutions of the rotor over which data is averaged to more accuracy)
- Tacho channel# - kanal na koji je priključen tahometar. Podrazumevanom - 3. kanal.
- Unevenness - razlika u trajanju između susjednih impulsa tahometра koja iznad daje upozorenje "Failure of the tachometer"
- Imperial/Metric - Odaberite sistem jedinica.
Com port number is assigned automatically.
F5 – "Mjerač vibracija"
Pressing this button (or a function key of F5 on the computer keyboard) activates the mode of vibration measurement on one or two measuring channels of virtual Vibration meter depending on the buttons condition “F2-jedna ravnina", "F3-two-plane".
F6 – «Reports»
Pressing this button (or F6 function key on the computer keyboard) switches on the balancing Archive, from which you can print the report with the results of balancing for a specific mechanism (rotor).
F7 – «Balansiranje»
Pressing this button (or function key F7 on your keyboard) activates balancing mode in one or two correction planes depending on which measurement mode is selected by pressing the buttons “F2-jedna ravnina", "F3-two-plane".
F8 – «Grafikoni»
Pressing this button (or F8 function key on the computer’s keyboard) enables graphic Vibration meter, the implementation of which displays on a display simultaneously with the digital values of the amplitude and phase of the vibration graphics of its time function.
F10 – «Exit»
Pressing this button (or F10 tipka funkcije na računarskoj tipkovnici) završava program "Balanset-1A".
7.2. "Mjerač vibracija"
Prije rada u modu "Merač vibracija" način rada, instalirajte senzore vibracija na stroj i povežite ih redom na konektore X1 i X2 USB jedinice sučelja. Senzor tahometра treba biti priključen na ulaz X3 USB jedinice sučelja.
Fig. 7.5 USB interface unit
Postavite reflektivnu traku na površinu rotora radi rada tahometра.
Sl. 7.6. Reflektivna traka.
Recommendations for the installation and configuration of sensors are given in Annex 1.
Za početak mjerenja u modu Mjerač vibracija kliknite na dugme "F5 – Vibration Meter" u početnom prozoru programa (vidjeti sl. 7.1).
Vibration Meter window appears (see. Fig.7.7)
Fig. 7.7. Vibration meter mode. Wave and Spectrum.
Za početak mjerenja vibracija kliknite dugme "F9 – Run" (ili pritisnite tipku funkcije F9 on the keyboard).
If Način pokretanja Automatski is checked – the results of vibration measurements will be periodically displayed on the screen.
In case of simultaneous measurement of vibration on the first and second channels, the windows located beneath the words “Plane 1" and "Plane 2" će biti popunjeno."
Vibration measuring in the “Vibration” mode also may be carried out with disconnected phase angle sensor. In the Initial window of the program the value of the total RMS vibration (V1s, V2s) will only be displayed.
U modu "Vibrometar" dostupna su sljedeća podešavanja
- RMS Low, Hz – najniža frekvencija za izračunavanje RMS-a ukupne vibracije
- Bandwidth – propusni opseg frekvencije vibracije na grafikonu
- Averages – broj usrednjavanja za veću tačnost mjerenja
Za završetak rada u modu "Vibrometar" kliknite gumb "F10 – Exit" i vratite se na početni prozor.
Fig. 7.8. Vibration meter mode. Rotation speed Unevenness, 1x vibration wave form.
Fig. 7.9. Vibration meter mode. Rundown (beta version, no warranty!).
7.3 Postupak balansiranja
Balancing is performed for mechanisms in good technical condition and correctly mounted. Otherwise, before the balancing the mechanism must be repaired, installed in proper bearings and fixed. Rotor should be cleaned of contaminants that can hinder from balancing procedure.
Before balancing measure vibration in Vibration meter mode (F5 button) to be sure that mainly vibration is 1x vibration.
Fig. 7.10. Vibration meter mode. Checking overall (V1s,V2s) and 1x (V1o,V2o) vibration.
Ako je vrijednost ukupne vibracije V1s (V2s) približno jednaka amplitudi vibracije na frekvenciji rotacije (vibracija 1x) V1o (V2o), može se zaključiti da je nebalansiranost rotora glavni uzrok mehanizma vibracije. Ako je vrijednost ukupne vibracije V1s (V2s) značajno veća od komponente 1x vibracije V1o (V2o), preporučuje se provjeriti stanje mehanizma – stanje ležajeva, njegovo pričvršćivanje na osnovu, osigurati da nema kontakta između fiksnih dijelova i rotora tijekom rotacije, itd.
You should also pay attention to the stability of the measured values in Vibration meter mode – the amplitude and phase of the vibration should not vary by more than 10-15% in the measurement process. Otherwise, it can be assumed that the mechanism is running close-to-resonance domain. In this case, change the speed of rotation of the rotor, and if this is not possible – change the conditions of installation of the machine on the foundation (for example, temporarily setting on spring supports).
Za balansiranje rotora metoda koeficijenata utjecaja balansiranja (metoda 3 pokušaja) trebalo bi se koristiti.
Trial runs are done to determine the effect of trial mass on vibration change, mass and place (angle) of installation of correction weights.
First determine the original vibration of a mechanism (first start without weight), and then set the trial weight to the first plane and made the second start. Then, remove the trial weight from the first plane, set in a second plane and made the second start.
The program then calculates and indicates on the screen the weight and location (angle) of installation of correction weights.
When balancing in a single plane (static), the second start is not required.
Trial weight is set to an arbitrary location on the rotor where it is convenient, and then the actual radius is entered in the setup program.
(Position Radius is used only for calculating the unbalance amount in grams * mm)
Important!
- Measurements should be carried out with the 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.
Formula za izračunavanje mase probne težine
Mt = Mr × Ksupport × Kvibration / (Rt × (N/100)²)
Where:
- Mt — masa ispitne težine, g
- Mr – masa rotora, g
- Ksupport — koeficijent krutosti oslonca (1-5)
- Kvibration – koeficijent nivoa vibracije (0,5–2,5)
- Rt – radijus instalacije probne težine, cm
- N – brzina rotora, RPM
Koeficijent krutosti oslonca (Ksupport):
- 1.0 - Vrlo meki oslonci (gumeni prigušivači)
- 2.0-3.0 - Srednja krutost (standardni ležajevi)
- 4.0-5.0 - Kruti oslonci (masivna temeljna konstrukcija)
Koeficijent nivoa vibracije (Kvibration):
- 0.5 – Niska vibracija (do 5 mm/s)
- 1.0 – Normalna vibracija (5–10 mm/s)
- 1.5 – Povišena vibracija (10–20 mm/s)
- 2.0 - Visoka vibracija (20-40 mm/sec)
- 2.5 - Vrlo visoka vibracija (>40 mm/sec)
🔗 Koristite naš online kalkulator:
Kalkulator za ispitnu masu →⚠️ Important!
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!
Objašnjenje izračunavanja ugla:
Ugao instalacije korekcijske mase je ALWAYS brojano od točke instalacije ispitne mase u smjeru rotacije rotora.
- Nulta točka (0°): Točno mjesto gdje ste instalirali ispitnu masu postaje vaša referentna točka (0 stepeni).
- Direction: Izmjerite ugao u istom smjeru u kojem se rotor vrti.
Primjer: Ako se rotor vrti u smjeru kazaljke na satu, izmjerite ugao u smjeru kazaljke na satu od položaja ispitne mase. - Interpretation: Ako program prikazuje ugao od 120°, morate instalirati korekcijsku masu 120 stepeni unaprijed od položaja ispitne mase u smjeru rotacije.
Fig. 7.11. Correction weight mounting.
Recommended!
Before performing dynamic balancing, it is recommended to make sure that static imbalance is not too high. For rotors with horizontal axis, the rotor can be manually rotated by an angle of 90 degrees from the current position. If the rotor is statically unbalanced, it will be rotated to a position of equilibrium. Once the rotor will assume the position of equilibrium, it is necessary to set the weight balancing in the top point approximately in the middle part of the rotor length. Weight of the weight should be chosen in such a way that the rotor is not moving in any position.
Such pre-balancing will reduce the amount of vibration at the first start of strongly unbalanced rotor.
Instalacija i montaža senzora
Vibration sensor must be installed on the machine in the selected measuring point and connected to the input X1 of the USB interface unit.
Postoje dvije konfiguracije montaže:
- Magnets
- Threaded studs M4
Optical tacho sensor should be connected to the input X3 of the USB interface unit. Furthermore, for use of this sensor a special reflecting mark should be applied on surface of a rotor.
📏 Zahtjevi za instalaciju optičkog senzora
- ✓Udaljenost do površine rotora: 50-500 mm (ovisno o modelu senzora)
- ✓Širina refleksivne trake: Minimalno 1-1,5 cm (zavisi od brzine i radijusa)
- ✓Orientation: Okomito na površinu rotora
- ✓Mounting: Koristite magnetni stalak ili stezač za stabilno pozicioniranje
- ✓Izbjegavajte direktnu sunčevu svjetlost ili jaku vještačku rasvjetu na senzoru/traci
💡 Izračunavanje širine trake: Za optimalnu performansu, izračunajte širinu trake koristeći:
L ≥ (N × R)/30000 ≥ 1.0-1.5 cm
Gdje: L - širina trake (cm), N - brzina rotora (rpm), R - radijus trake (cm)
Detailed requirements on site selection of the sensors and their attachment to the object when balancing are set out in Annex 1.
7.4 Balansiranje u jednoj ravnini
Sl. 7.12. "Balansiranje u jednoj ravnini"
Arhiv balansiranja
Da biste počeli rad na programu u modusu "Single-Plane balancing" modu, kliknite na dugme "F2-Single-plane" (ili pritisnite F2 na tipkovnici računara).
Zatim kliknite na dugme "F7 – Balancing" dugme, nakon čega će Single Plane balancing archive window will appear, in which the balancing data will be saved (see Fig. 7.13).
Fig. 7.13 The window for selecting the balancing archive in single plane.
In this window, you need to enter data on the name of the rotor (Rotor name), place of rotor installation (Place), tolerances for vibration and residual imbalance (Tolerance), date of measurement. This data is stored in a database. Also, a folder Arc### is created in, where ### is the number of the archive in which the charts, a report file, etc. will be saved. After the balancing is completed, a report file will be generated that can be edited and printed in the built-in editor.
After entering the necessary data, you need to click the “F10-OK" dugme, nakon čega će "Single-Plane balancing" prozor biti otvoren (vidjeti Sl. 7.13)
Balancing settings (1-plane)
Fig. 7.14. Single plane. Balancing settings
Na lijevoj strani ovog prozora prikazani su podaci mjerenja vibracija i dugmadi za kontrolu mjerenja "Run # 0", "Run # 1", "RunTrim".
In the right side of this window there are three tabs
- Balancing settings
- Charts
- Result
The "Balancing settings" kartica se koristi za unos postavki balansiranja:
- "Koeficijent uticaja" -
- "New Rotor” – selection of the balancing of the new rotor, for which there are no stored balancing coefficients and two runs are required to determine the mass and installation angle of the correction weight.
- "Saved coeff.” – selection of the rotor re-balancing, for which there are saved balancing coefficients and only one run is required for determining the weight and installation angle of the corrective weight.
- "Masa pokusne težine" -
- "Percent" - korekcijska težina se izračunava kao procenat pokusne težine.
- "Gram" - poznata masa pokusne težine se unosi i masa korekcijske težine se izračunava u grams or in oz for Imperial system.
⚠️ Attention! Ako je potrebno koristiti "Saved coeff.” Mode for further work during initial balancing, the trial weight mass must be entered in grams or oz, not in %. Scales are included in the delivery package.
- "Metodu prikačivanja težine"
- "Free position" - težine se mogu instalirati na proizvoljna uglovna pozicija na obodu rotora.
- "Fixed position” – weight can be installed in fixed angular positions on the rotor, for example, on blades or holes (for example 12 holes – 30 degrees), etc. The number of fixed positions must be entered in the appropriate field. After balancing, the program will automatically split the weight into two parts and indicate the number of positions on which it is necessary to establish the masses obtained.
- "Circular groove" – koristi se za uravnoteživanje brusnog toka U ovom slučaju koriste se 3 protuteže za eliminaciju neuravnoteženosti
Fig. 7.17 Grinding wheel balancing with 3 counterweights
Fig. 7.18 Grinding wheel balancing. Polar graph.
Fig. 7.15. Result tab. Fixed position of correction weight mounting.
Z1 i Z2 – pozicije instaliranih korekcijskih težina, izračunate od Z1 pozicije prema smjeru rotacije. Z1 je pozicija gdje je instalirana pokusna težina.
Fig. 7.16 Fixed positions. Polar diagram.
- "Mass mount radius, mm" - "Ravnina1" - Radijus pokusne težine u 1. ravnini. Potreban je za izračunavanje veličine početne i rezidualne neuravnoteženosti kako bi se odredilo poštivanje dozvoljene vrijednosti rezidualne neuravnoteženosti nakon uravnoteživanja.
- "Leave trial weight in Plane1.” Usually the trial weight is removed during the balancing process. But in some cases it is impossible to remove it, then you need to set a check mark in this to account for the trial weight mass in the calculations.
- "Ručni unos podataka” – used to manually enter the vibration value and phase into the appropriate fields on the left side of the window and calculate the mass and installation angle of the correction weight when switching to the “Results" tab
- Button "Restore session data“. During balancing, the measured data is saved in the session1.ini file. If the measurement process was interrupted due to computer freezing or for other reasons, then by clicking this button you can restore the measurement data and continue balancing from the moment of interruption.
- Mandrel eccentricity elimination (Index balancing) Balancing with additional start to eliminate the influence of the eccentricity of the mandrel (balancing arbor). Mount the rotor alternately at 0° and 180° relative to the. Measure the unbalances in both positions.
- Balancing tolerance Entering or calculating residual imbalance tolerances in g x mm (G-classes)
- Use Polar Graph Use polar graph to display balancing results
1-plane Balancing. New rotor
Kao što je navedeno gore, "New Rotor" uravnoteživanje zahtijeva dva pokusna prolaza i najmanje jedan prilagođavajući prolaz mašine za uravnoteživanje.
Run#0 (Initial run)
After installing the sensors on the balancing rotor and entering the settings parameters, it is necessary to turn on the rotor rotation and, when it reaches working speed, press the “Run#0" dugme za početak mjerenja. Kartica "Charts" će se otvoriti u desnom panelu, gdje će biti prikazani oblik vala i spektar vibracija. U donjoj části kartice vodi se istorijska datoteka u kojoj se čuvaju rezultati svih pokretanja sa vremenskom referencom. Na disku se ova datoteka čuva u arhivskoj mapi pod imenom memo.txt
Pažnja!
Before starting the measurement, it is necessary to turn on the rotation of the rotor of the balancing machine (Run#0) and make sure that the rotor speed is stable.
Fig. 7.19. Balancing in one plane. Initial run (Run#0). Charts Tab
After measurement process finished, in the Run#0 dio u lijevoj paneli pojavljuju se rezultati mjerenja - brzina rotora (RPM), RMS (Vo1) i faza (F1) vibracija 1x.
The "F5-Back to Run#0” button (or the F5 function key) is used to return to the Run#0 section and, if necessary, to repeat measure the vibration parameters.
Run#1 (Trial mass Plane 1)
Prije početka mjerenja parametara vibracija u dijelu "Run#1 (Trial mass Plane 1), pokusna težina bi trebala biti instalirana prema "Trial weight mass" field.
The goal of installing a trial weight is to evaluate how the vibration of the rotor changes when a known weight is installed at a known place (angle). Trial weight must changes the vibration amplitude by either 30% lower or higher of initial amplitude or change phase by 30 degrees or more of initial phase.
Ako je potrebno koristiti "Saved coeff.” balancing for further work, the place (angle) of installation of the trial weight must be the same as the place (angle) of the reflective mark.
Turn on the rotation of the rotor of the balancing machine again and make sure that it rotation frequency is stable. Then click on the “F7-Run#1" dugme (ili pritisnite F7 na tastaturi računara).
Nakon mjerenja u odgovarajućim poljima dijela "Run#1 (Trial mass Plane 1)" dio, pojavljuju se rezultati mjerenja brzine rotora (RPM), kao i vrijednost RMS komponente (Vо1) i faze (F1) vibracija 1x.
U isto vrijeme, kartica "Result" se otvara na desnoj strani prozora.
This tab displays the results of calculating the mass and angle of corrective weight, which must be installed on the rotor to compensate imbalance.
Moreover, in the case of using the polar coordinate system, the display shows the value of the mass (M1) and the installation angle (f1) of the correction weight.
U slučaju da je "Fixed positions” the numbers of the positions (Zi, Zj) and trial weight splitted mass will be shown.
Fig. 7.20. Balancing in one plane. Run#1 and balancing result.
If Polarni graf is checked polar diagram will be shown.
Fig. 7.21. The result of balancing. Polar graph.
Fig. 7.22. The result of balancing. Weight splitted (fixed positions)
Also if "Polarni graf" bilo označeno, prikazat će se polarni grafikon.
Fig. 7.23. Weight splitted on fixed positions. Polar graph
⚠️ Attention!
- 1. After completing the measurement process at the second run (“Run#1 (Trial mass Plane 1)”) of the balancing machine, it is necessary to stop the rotation and remove installed trial weight. Then install (or remove) the corrective weight on the rotor according result tab data.
If the trial weight was not removed, you need to switch to the “Balancing settings" kartice i uključite polje za potvrdu u "Leave trial weight in Plane1". Zatim se vratite na karticu "Result” tab. The weight and installation angle of the correction weight are recalculated automatically.
- Kutni položaj korigovane težine vrši se od mjesta postavljanja ispitne težine. Smjer referencije kuta poklapa se sa smjerom rotacije rotora.
- U slučaju da je "Fixed position" - the 1st position (Z1), coincides with the place of installation of the trial weight. The counting direction of the position number is in the direction of rotation of the rotor.
- Po defaultu će se korigovana težina dodati na rotor. To je navedeno oznakom postavljenom u polju "Add". Ako trebate ukloniti težinu (npr. bušenjem), morate postaviti oznaku u "Delete” field, after which the angular position of the correction weight will automatically change by 180º.
After installing the correction weight on the balancing rotor in the operating window (see Fig. 7.15), it is necessary to carry out a RunC (trim) and evaluate the effectiveness of the performed balancing.
RunC (Check balance quality)
⚠️ Attention! Before starting the measurement on the RunC, it is necessary to turn on the rotation of the rotor of the machine and make sure that it has entered the operating mode (stable rotation frequency).
Da biste izvršili mjerenje vibracija u "RunC (Check balance quality)" odjeljenju, kliknite na dugme "F7 – RunTrim" (ili pritisnite tipku F7 na tastaturi).
Nakon uspješnog završetka procesa mjerenja, u "RunC (Check balance quality)" odjeljenju u lijevoj ploči pojavljuju se rezultati mjerenja brzine rotora (RPM), kao i vrijednost RMS komponente (Vo1) i faza (F1) vibracije 1x.
In the "Result” tab, the results of calculating the mass and installation angle of the additional corrective weight are displayed.
Fig. 7.24. Balancing in one plane. Performing a RunTrim. Result Tab
This weight can be added to the correction weight that is already mounted on the rotor to compensate for the residual imbalance. In addition, the residual rotor unbalance achieved after balancing is displayed in the lower part of this window.
In the case when the amount of residual vibration and / or residual unbalance of the balanced rotor meets the tolerance requirements established in the technical documentation, the balancing process can be completed.
Otherwise, the balancing process may continue. This allows the method of successive approximations to correct possible errors that may occur during the installation (removal) of the corrective weight on a balanced rotor.
When continuing the balancing process on the balancing rotor, it is necessary to install (remove) additional corrective mass, the parameters of which are indicated in the section “Correction masses and angles".
Influence coefficients (1-plane)
The "F4-Inf.Coeff" dugme u "Result" kartica se koristi za pregled i pohranu u memoriju računala koeficijenata balansiranja rotora (Koeficijenti uticaja) izračunati iz rezultata kalibracionih pokusa.
Kada se pritisne, prozor "Influence coefficients (single plane)" se pojavljuje na ekranu računala, u kojem se prikazuju koeficijenti balansiranja izračunati iz rezultata kalibracije (testnih) pokusa. Ako se tokom naknadnog balansiranja ove mašine pretpostavlja korištenje "Saved coeff.” Mode, these coefficients must be stored in the computer memory.
Da biste to učinili, kliknite na dugme "F9 - Save" i idite na drugu stranicu od "Arhiva koeficijenta uticaja. Jednoplanski."
Fig. 7.25. Balancing coefficients in the 1st plane
Then you need to enter the name of this machine in the “Rotor" kolona i kliknite na "F2-Save” button to save the specified data on the computer.
Then you can return to the previous window by pressing the “F10-Exit" dugme (ili F10 tipka na računarskoj tastaturi).
Sl. 7.26. "Arhiva koeficijenta uticaja. Jednoplanski."
Balancing report
After balancing all data saved and Balancing report created. You can view and edit report in built-in editor. In the "Arhiva balansiranja u jednoj ravni" (Sl. 7.9) pritisnite dugme "F9 -Report" da biste pristupili editoru izveštaja o balansiranju.
Sl. 7.27. Izveštaj o balansiranju.
Saved coeff. balancing procedure with saved influence coefficients in 1 plane.
Setting up the measuring system (input of initial data).
Saved coeff. balancing can be performed on a machine for which balancing coefficients have already been determined and entered into the computer memory.
⚠️ Attention! When balancing with saved coefficients, the vibration sensor and the phase angle sensor must be installed in the same way as during the initial balancing.
Input of the initial data for Saved coeff. balancing (kao u slučaju primarnog("New rotor") balansiranja) počinje u "Single plane balancing. Balancing settings.".
U ovom slučaju, u "Influence coefficients" sekciji, izaberite "Saved coeff" stavku. U ovom slučaju, druga stranica "Influence coeff. archive. Single plane.", koja čuva arhivu sačuvanih koeficijenata balansiranja.
Fig. 7.28. Balancing with saved influence coefficients in 1 plane
Krećući se kroz tabelu ove arhive pomoću "►" ili "◄" kontrolnih dugmadi, možete izabrati željeni zapis sa koeficijentima balansiranja mašine od interesa. Zatim, da biste koristili ove podatke u trenutnim merenjima, pritisnite "F2 – Select" button.
After that, the contents of all other windows of the “Single plane balancing. Balancing settings." se popunjavaju automatski.
After completing the input of the initial data, you can begin to measure.
Merenja tokom balansiranja sa sačuvanim koeficijentima uticaja
Balancing with saved influence coefficients requires only one initial run and at least one test run of the balancing machine.
⚠️ Attention! Before starting the measurement, it is necessary to turn on the rotation of the rotor and make sure that rotating frequency is stable.
Da biste izvršili merenje parametara vibracija u "Run#0 (Initial, no trial mass)" sekciji, pritisnite "F7 – Run#0" (ili pritisnite F7 tipku na računarskoj tastaturi).
Fig. 7.29. Balancing with saved influence coefficients in one plane. Results after one run.
U odgovarajućim poljima "Run#0" odjeljka pojavljuju se rezultati mjerenja brzine rotora (RPM), vrijednost RMS komponente (Vо1) i faze (F1) vibracije 1x.
U isto vrijeme, kartica "ResultThis tab displays the results of calculating the mass and angle of corrective weight, which must be installed on the rotor to compensate imbalance.
Štoviše, u slučaju korištenja polarnog koordinatnog sustava, prikaz pokazuje vrijednosti mase i uglove instalacije korekcijskih utega.
In the case of splitting of the corrective weight on the fixed positions, the numbers of the positions of the balancing rotor and the mass of weight that need to be installed on them are displayed.
Further, the balancing process is carried out in accordance with the recommendations set out in section 7.4.2. for primary balancing.
Mandrel eccentricity elimination (Index balancing)
If during balancing the rotor is installed in a cylindrical mandrel, then the eccentricity of the mandrel may introduce an additional error. To eliminate this error, the rotor should be deployed in the mandrel 180 degrees and carry out an additional start. This is called index balancing.
To carry out index balancing, a special option is provided in the Balanset-1A program. When checked Mandrel eccentricity elimination an additional RunEcc section appears in the balancing window.
Fig. 7.30. The working window for Index balancing.
After running Run # 1 (Trial mass Plane 1), a window will appear
Fig. 7.31 Index balancing attention window.
After installing the rotor with an 180 turn, Run Ecc must be completed. The program will automatically calculate the true rotor imbalance without affecting the mandrel eccentricity.
7.5 Balansiranje u dvije ravnine
Before starting work in the Two plane balancing mode, it is necessary to install vibration sensors on the machine body at the selected measurement points and connect them to the inputs X1 and X2 of the measuring unit, respectively.
An optical phase angle sensor must be connected to input X3 of the measuring unit. In addition, to use this sensor, a reflective tape must be glued onto the accessible rotor surface of the balancing machine.
Detailed requirements for choosing the installation location of sensors and their mounting at the facility during balancing are set out in Appendix 1.
Rad na programu u "Two plane balancing" režimu počinje iz Glavnog prozora programa.
Click on the "F3-Two plane" tipka (ili pritisnite F3 na računalnoj tipkovnici).
Further, click on the “F7 – Balancing” button, after which a working window will appear on the computer display (see Fig. 7.13), selection of the archive for saving data when balancing in two p
Fig. 7.32 Two plane balancing archive window.
In this window you need to enter the data of the balanced rotor. After pressing the “F10-OK" tipka, pojavit će se prozor balansiranja.
Balancing settings (2-plane)
Fig. 7.33. Balancing in two planes window.
Na desnoj strani prozora nalazi se "Balancing settings" kartica za unos postavki prije balansiranja.
- Influence coefficients Balancing a new rotor or balancing using stored influence coefficients (balancing coefficients)
- Mandrel eccentricity elimination - Balansiranje s dodatnim pokretanjem za eliminaciju utjecaja ekscentričnosti mandrelja
- Weight Attachment Method Installation of corrective weights in an arbitrary place on the circumference of the rotor or in a fixed position. Calculations for drilling when removing the mass.
- "Free position" - težine se mogu instalirati na proizvoljna uglovna pozicija na obodu rotora.
- "Fixed position” – weight can be installed in fixed angular positions on the rotor, for example, on blades or holes (for example 12 holes – 30 degrees), etc. The number of fixed positions must be entered in the appropriate field. After balancing, the program will automatically split the weight into two parts and indicate the number of positions on which it is necessary to establish the masses obtained.
- Trial weight mass - Trial weight
- Leave trial weight in Plane1 / Plane2 - Uklonite ili ostavite pokusni uteg pri balansiranju.
- Mass mount radius, mm - Radijus montaže pokusnih i korekcijskih utega
- Balancing tolerance - Entering or calculating residual imbalance tolerances in g-mm
- Use Polar Graph - Koristi polarni graf za prikaz rezultata balansiranja
- Ručni unos podataka - Ručni unos podataka za izračunavanje utega balansiranja
- Restore last session data - Oporavak podataka mjerenja iz zadnje sesije u slučaju neuspjeha nastavka balansiranja.
2 planes balancing. New rotor
Setting up the measuring system (input of initial data).
Input of the initial data for the New rotor balancing in the "Balansiranje u dvije ravnine. Postavke".
U ovom slučaju, u "Influence coefficients" sekciji, izaberite "New rotor" item.
Dalje, u odjeljku "Trial weight mass", morate odabrati mjernu jedinicu mase pokusnog utega - "Gram" or "Percent".
Pri odabiru mjerne jedinice "Percent”, all further calculations of the mass of the corrective weight will be performed as a percentage in relation to the mass of the trial weight.
Prilikom izbora "Gram” unit of measurement, all further calculations of the mass of the corrective weight will be performed in grams. Then enter in the windows located to the right of the inscription “Gram" masa pokusnih težina koje će biti postavljene na rotor.
⚠️ Attention! Ako je potrebno koristiti "Saved coeff.” Mode for further work during initial balancing, the mass of trial weights must be entered in grams.
Then select "Weight Attachment Method" - "Circum" or "Fixed position".
Ako odaberete "Fixed position", morate uneti broj pozicija.
Calculation of tolerance for residual imbalance (Balancing tolerance)
Dozvoljeno odstupanje za preostalu nebalansu (Tolerancija balansiranja) može se izračunati u skladu sa postupkom opisanim u ISO 1940 Vibrations. Zahtevi za kvalitet balansa rotora u stalnom (krutom) stanju. Deo 1. Specifikacija i provera tolerancija balansa.
Fig. 7.34. Balancing tolerance calculation window
Initial run (Run#0)
Pri balansiranju u dvije ravni u "New rotor” mode, balancing requires three calibration runs and at least one test run of the balancing machine.
Merenje vibracija pri prvom pokretanju mašine vrši se u "Two plane balance" radnoj prozoru u "Run#0" section.
Sl. 7.35. Rezultati merenja pri balansiranju u dvije ravni nakon početnog pokretanja.
⚠️ Attention! Before starting the measurement, it is necessary to turn on the rotation of the rotor of the balancing machine and make sure that it has entered the operating mode with a stable speed.
To measure vibration parameters in the Run#0 sekcija, kliknite na "F7 – Run#0" dugme (ili pritisnite taster F7 na računarskoj tastaturi)
The results of measuring the rotor speed (RPM), the value RMS (VО1, VО2) and phases (F1, F2) of 1x vibration appearing appear in the corresponding windows of the Run#0 section.
Run#1.Trial mass in Plane1
Pre nego što počnete sa merenjem parametara vibracija u "Run#1.Trial mass in Plane1” section, you should stop the rotation of the rotor of the balancing machine and install a trial weight on it, the mass selected in the “Trial weight mass" section.
⚠️ Attention!
- 1. The question of choosing the mass of trial weights and their installation places on the rotor of a balancing machine is discussed in detail in Appendix 1.
- Ako je potrebno koristiti Saved coeff. Mode in future work, the place for installing the trial weight must necessarily coincide with the place for installing the mark used to read the phase angle.
After this, it is necessary to turn on the rotation of the rotor of the balancing machine again and make sure that it has entered the operating mode.
Za merenje parametara vibracija u "Run # 1.Trial mass in Plane1" odjeljenju, kliknite na dugme "F7 – Run#1" dugme (ili pritisnite F7 na tastaturi računara).
Uspešnom završetku procesa merenja, vraćeni ste na kartici sa rezultatima merenja.
U ovom slučaju, u odgovarajućim prozorima "Run#1. Trial mass in Plane1” section, the results of measuring the rotor speed (RPM), as well as the value of the components of the RMS (Vо1, Vо2) and phases (F1, F2) of 1x vibration.
"Pokus br. 2.Pokusna masa u Ravni 2"
Pre nego što počnete sa merenjem parametara vibracija u sekciji "Run # 2.Trial mass in Plane2", morate izvršiti sledeće korake:
- zaustaviti rotaciju rotora mašine za balansiranje;
- ukloniti pokušajnu masu instaliranu u ravnini 1;
- instalirati pokušajnu masu u ravnini 2, masa odabrana u odjeljku "Trial weight mass".
After this, turn on the rotation of the rotor of the balancing machine and make sure that it has entered the operating speed.
Za početak mjerenja vibracija u "Run # 2.Trial mass in Plane2" odjeljenju, kliknite na dugme "F7 – Run # 2" dugme (ili pritisnite tipku F7 na tipkovnici računara). Tada će se "Result" tab opens.
In the case of using the Weight Attachment Method" - "Free positions, displej prikazuje vrijednosti masa (M1, M2) i kutove instalacije (f1, f2) korekcijskih utega.
Fig. 7.36. Results of calculation of corrective weights – free position
Sl. 7.37. Rezultati proračuna korekcijskih težina – slobodna pozicija. Polarni dijagram
In the case of using the Weight Attachment Method" – "Fixed positions
Sl. 7.38. Rezultati proračuna korekcijskih utega – fiksna pozicija.
Slika 7.39. Rezultati proračuna korektivnih težina – fiksna pozicija. Polarni dijagram.
U slučaju korištenja metode pričvršćivanja utega" – "Circular groove"
Sl. 7.40. Rezultati proračuna korekcijskih utega – Kružni žlijeb.
⚠️ Attention!
- Nakon dovršetka procesa mjerenja na RUN#2 of the balancing machine, stop the rotation of the rotor and remove the trial weight previously installed. Then you can to install (or remove) corrective weights.
- Kutna pozicija korekcijskih utega u polarnom koordinatnom sustavu računa se od mjesta instalacije pokušajne mase u smjeru vrtnje rotora.
- U slučaju da je "Fixed position" - the 1st position (Z1), coincides with the place of installation of the trial weight. The counting direction of the position number is in the direction of rotation of the rotor.
- Po defaultu će se korigovana težina dodati na rotor. To je navedeno oznakom postavljenom u polju "Add". Ako trebate ukloniti težinu (npr. bušenjem), morate postaviti oznaku u "Delete” field, after which the angular position of the correction weight will automatically change by 180º.
RunC (Trim run)
After installing the correction weight on the balancing rotor it is necessary to carry out a RunC (trim) and evaluate the effectiveness of the performed balancing.
⚠️ Attention! Before starting the measurement at the test run, it is necessary to turn on the rotation of the rotor of the machine and make sure that it has entered the operating
Za mjerenje parametara vibracija u odjeljku RunTrim (Provjera kvalitete uravnoteženja), kliknite na "F7 – RunTrim" dugme (ili pritisnite F7 na tastaturi računara).
The results of measuring the rotor rotation frequency (RPM), as well as the value of the RMS component (Vо1) and phase (F1) of 1x vibration will be shown.
The "Result" kartica se pojavljuje na desnoj strani radnog prozora s tablicom rezultata mjerenja, koja prikazuje rezultate proračuna parametara dodatnih korekcijskih utega.
These weights can be added to corrective weights that are already installed on the rotor to compensate for residual imbalance.
In addition, the residual rotor unbalance achieved after balancing is displayed in the lower part of this window.
U slučaju kada vrijednosti rezidualne vibracije i/ili rezidualnog neuravnoteženja uravnoteženog rotora zadovoljavaju tolerancijske zahtjeve uspostavljene u tehničkoj dokumentaciji, proces uravnoteženja može biti završen.
Otherwise, the balancing process may continue. This allows the method of successive approximations to correct possible errors that may occur during the installation (removal) of the corrective weight on a balanced rotor.
When continuing the balancing process on the balancing rotor, it is necessary to install (remove) additional corrective mass, the parameters of which are indicated in the “Result” window.
In the "Result" prozor postoje dva kontrolna dugmeta koja se mogu koristiti - "F4-Inf.Coeff", "F5 – Change correction planes".
Influence coefficients (2 planes)
The "F4-Inf.Coeff" dugme (ili tipka funkcije F4 na tipkovnici računara) koristi se za pregled i spremanje koeficijenata uravnoteženja rotora u memoriji računara, izračunatih iz rezultata dva kalibracijska pokretanja.
Kada se pritisne, prozor "Influence coefficients (two planes)" radni prozor se pojavljuje na zaslonu računala, u kojem se prikazuju koeficijenti uravnoteženja izračunati na osnovu rezultata prva tri kalibracijiskog pokretanja.
Fig. 7.41. Working window with balancing coefficients in 2 planes.
In the future, when balancing of such type of the machine it is supposed, require to use the “Saved coeff." način rada i koeficijenti uravnoteženja pohranjeni u memoriji računara.
Za spremanje koeficijenata, kliknite na "F9 – Save" dugme i idite na "Influence coefficients archive (2planes)" prozore (vidi sl. 7.42)
Fig. 7.42. The second page of the working window with balancing coefficients in 2 planes.
Change correction planes
The "F5 – Change correction planes" gumb se koristi kada trebate promijeniti poziciju ravnina korekcije, kada je potrebno ponovno izračunati mase i kutove instalacije korekcijskih utega.
This mode is primarily useful when balancing rotors of complex shape (for example, crankshafts).
Kada se pritisne ovaj gumb, radni prozor "Recalculation of correction weights mass and angle to other correction planes" je prikazan na prikazu računala.
In this working window, you should select one of the 4 possible options by clicking corresponding picture.
The original correction planes (Н1 and Н2) in Fig. 7.29 are marked in green, and new (K1 and K2), for which it recounts, in red.
Then, in the "Calculation data" odjeljak, unesite tražene podatke, uključujući:
- udaljenost između odgovarajućih ravnina korekcije (a, b, c);
- nove vrijednosti polumjera instalacije korekcijskih utega na rotoru (R1', R2').
Nakon unosa podataka, morate pritisnuti gumb "F9-calculate"
The calculation results (masses M1, M2 and installation angles of corrective weights f1, f2) are displayed in the corresponding section of this working window (see Fig. 7.42).
Slika 7.43 Promjena ravnina korekcije. Ponovno izračunavanje korekcijske mase i kuta za druge ravnine korekcije.
Sačuvani koef. balansiranja u 2 ravnine
Saved coeff. balancing can be performed on a machine for which balancing coefficients have already been determined and saved in the computer memory.
⚠️ Attention! When re-balancing, the vibration sensors and the phase angle sensor must be installed in the same way as during the initial balancing.
Unos početnih podataka za ponovno balansiranje počinje u "Balansiranje u 2 ravnine. Postavke balansiranja".
U ovom slučaju, u "Influence coefficients" sekciji, izaberite "Saved coeff." stavka. U tom slučaju, prozor "Influence coefficients archive (2planes)" će se pojaviti, u kojem se pohranjuje arhiva prethodno određenih koeficijenata balansiranja.
Krećući se kroz tabelu ove arhive pomoću "►" ili "◄" kontrolnih dugmadi, možete izabrati željeni zapis sa koeficijentima balansiranja mašine od interesa. Zatim, da biste koristili ove podatke u trenutnim merenjima, pritisnite "F2 – OK” button and return to the previous working window.
Fig. 7.44. The second page of the working window with balancing coefficients in 2 planes.
After that, the contents of all other windows of the “Balansiranje u 2 rav. Početni podaci" se popunjava automatski.
Saved coeff. Balancing
"Saved coeff.” balancing requires only one tuning start and at least one test start of the balancing machine.
Vibration measurement at the tuning start (Run # 0") stroja se provodi u "Balancing in 2 planes" radnom prozoru s tablicom rezultata balansiranja u Run # 0 section.
⚠️ Attention! Before starting the measurement, it is necessary to turn on the rotation of the rotor of the balancing machine and make sure that it has entered the operating mode with a stable speed.
To measure vibration parameters in the Run # 0 odjeljak, kliknite na "F7 – Run#0" dugme (ili pritisnite F7 na tastaturi računara).
The results of measuring the rotor speed (RPM), as well as the value of the components of the RMS (VО1, VО2) and phases (F1, F2) of the 1x vibration appear in the corresponding fields of the Run # 0 section.
U isto vrijeme, kartica "Result" kartica se otvara, koja prikazuje rezultate izračunavanja parametara korekcijskih utega koji moraju biti instalirani na rotoru kako bi se kompenzirala njegova neuravnoteženost.
Štoviše, u slučaju korištenja polarnog koordinatnog sustava, prikaz pokazuje vrijednosti mase i kutove instalacije korekcijskih utega.
In the case of decomposition of corrective weights on the blades, the numbers of the blades of the balancing rotor and the mass of weight that need to be installed on them are displayed.
Further, the balancing process is carried out in accordance with the recommendations set out in section 7.6.1.2. for primary balancing.
⚠️ Attention!
- After completion of the measurement process after the second start of the balanced machine stop the rotation of its rotor and remove the previously set trial weight. Only then you can begin to install (or remove) correction weight on the rotor.
- Counting the angular position of the place of adding (or removing) of the correction weight from the rotor is carried out on the installation site of trial weight in the polar coordinate system. Counting direction coincides with the direction of the angle of rotor rotation.
- U slučaju balansiranja na lopaticama – lopatica uravnoteženog rotora, označena kao pozicija 1, poklapa se sa mjestom instalacije pokusne težine. Smjer referentnog broja lopatice prikazane na ekranu računara izvršava se u smjeru rotacije rotora.
- U ovoj verziji programa pretpostavlja se po zadanoj vrijednosti da će se korekcijska težina dodati na rotor. Oznaka postavljena u polju "Dodavanje" to potvrđuje. U slučaju korekcije neuravnoteženosti uklanjanjem težine (na primjer bušenjem) potrebno je postaviti oznaku u polju "Uklanjanje" tada će se kutna pozicija korekcijske težine automatski promijeniti za 180º.
Eliminacija ekscentričnosti vretena (Indeksno balansiranje) - Dvije ravnine
If during balancing the rotor is installed in a cylindrical mandrel, then the eccentricity of the mandrel may introduce an additional error. To eliminate this error, the rotor should be deployed in the mandrel 180 degrees and carry out an additional start. This is called index balancing.
To carry out index balancing, a special option is provided in the Balanset-1A program. When checked Mandrel eccentricity elimination an additional RunEcc section appears in the balancing window.
Fig. 7.45. The working window for Index balancing.
After running Run # 2 (Trial mass Plane 2), a window will appear
Fig. 7.46. Attention windows
After installing the rotor with an 180 turn, Run Ecc must be completed. The program will automatically calculate the true rotor imbalance without affecting the mandrel eccentricity.
7.6 Režim grafika
Rad u režimu "Grafika" počinje iz početnog prozora (vidi sl. 7.1) pritiskom na "F8 – Grafika". Tada se otvara prozor "Mjerenje vibracija na dva kanala. Grafika" (vidi sl. 7.19).
Sl. 7.47. Radni prozor "Mjerenje vibracija na dva kanala. Grafika".
Tokom rada u ovom režimu moguće je iscrtati četiri verzije grafikona vibracija.
Prva verzija omogućava dobijanje vremenske funkcije ukupne vibracije (brzine vibracije) na prvom i drugom mjernom kanalu.
Druga verzija vam omogućava da dobijete grafike vibracija (brzine vibracije), koje se javljaju na frekvenciji rotacije i njenim višim harmonijskim komponentama.
Ovi grafikoni su dobijeni kao rezultat sinhronog filtriranja ukupne funkcije vremena vibracije.
Treća verzija daje grafikone vibracija sa rezultatima harmonijske analize.
Četvrta verzija omogućava dobijanje grafikona vibracija sa rezultatima analize spektra.
Grafici ukupne vibracije
Za crtanje grafa ukupne vibracije u radnom prozoru "Merenje vibracija na dva kanala. Charts" potrebno je odabrati režim rada "ukupne vibracije” klikom na odgovarajuće dugme. Zatim podesite mjerenje vibracije u okviru „Trajanje, u sekundama“, klikom na dugme «▼» i sa padajuće liste izaberite željeno trajanje procesa merenja, koje može biti jednako 1, 5, 10 , 15 ili 20 sekundi;
Kada je spreman pritisnite (kliknite) dugme "F9-Mjerenje" tada počinje proces mjerenja vibracija istovremeno na dva kanala.
Nakon završetka procesa mjerenja u radnom prozoru se pojavljuju grafikoni vremenske funkcije ukupne vibracije prvog (crvenog) i drugog (zeleno) kanala (vidi. Sl. 7.47).
Na ovim grafikonima vrijeme je iscrtano na X-osi, a amplituda brzine vibracije (mm/sec) je iscrtana na Y-osi.
Sl. 7.48. Radni prozor za prikaz vremenske funkcije grafika ukupne vibracije
Na ovim grafikonima postoje i oznake (plave boje) koje povezuju grafikone ukupne vibracije sa frekvencijom rotacije rotora. Osim toga, svaka oznaka označava početak (kraj) sljedećeg okretaja rotora.
Za promjenu skale grafikona na X-osi klizač, usmjeren strelicom na sl. 7.20, može se koristiti.
Grafici 1x vibracije
Za crtanje grafa 1x vibracije u radnom prozoru "Merenje vibracija na dva kanala. Charts" potrebno je odabrati režim rada "1x vibracija" klikom na odgovarajuće dugme.
Tada se pojavljuje radni prozor "1x vibracija".
Pritisnite (kliknite) "F9-Mjerenje" tada počinje proces mjerenja vibracija istovremeno na dva kanala.
Sl. 7.49. Radni prozor za prikaz grafika 1x vibracije.
Nakon završetka procesa mjerenja i matematičkog izračunavanja rezultata (sinhrono filtriranje vremenske funkcije ukupne vibracije) na displeju u glavnom prozoru u periodu jednakom jedan okret rotora pojavljuju se grafikoni 1x vibracija na dva kanala.
U ovom slučaju, grafikon za prvi kanal je prikazan crvenom, a za drugi kanal zelenom bojom. Na ovim dijagramima ugao obrtaja rotora je iscrtan (od oznake do oznake) na X-osi, a amplituda brzine vibracije (mm/sec) na Y-osi.
Osim toga, u gornjem dijelu radnog prozora (desno od dugmeta “F9 – Measure") numeričke vrijednosti mjerenja vibracija oba kanala, slične onima koje dobijamo u "Merač vibracija" režim, se prikazuju.
Posebno: RMS vrijednost ukupne vibracije (V1s, V2s), veličina RMS (V1o, V2o) i faza (Fi, Fj) od 1x vibracije i brzine rotora (Nrev).
Dijagrami vibracija s rezultatima harmonijske analize
Da biste nacrtali dijagram s rezultatima harmonijske analize u radnom prozoru "Merenje vibracija na dva kanala. Charts" potrebno je odabrati režim rada "Harmonijska analiza" klikom na odgovarajuće dugme.
Zatim se pojavljuje operativni prozor za simultani izlaz dijagrama privremene funkcije i spektra aspekata harmoničnih vibracija čiji je period jednak ili višestruki frekvenciji rotacije rotora (vidi sliku 7.49)
Pažnja!
Pri radu u ovom režimu potrebno je koristiti senzor faznog ugla koji sinhronizuje proces merenja sa frekvencijom rotora mašina na koje je senzor podešen.
Sl. 7.50. Radni prozor harmonika vibracija 1x.
Kada je spreman pritisnite (kliknite) dugme "F9-Mjerenje" tada počinje proces mjerenja vibracija istovremeno na dva kanala.
Nakon završetka mjernog procesa u radnom prozoru pojavljuju se dijagrami vremenske funkcije (gornji dijagram) i harmonika vibracija 1x (donji dijagram).
Broj harmonijskih komponenti je iscrtan na X-osi, a RMS brzine vibracije (mm/sec) je prikazan na Y-osi.
Dijagrami vremenske domene vibracija i spektra
Da biste nacrtali dijagram spektra, koristite "F5-Spectrum" tab:
Tada se pojavljuje radni prozor za istovremeni prikaz dijagrama valnog oblika i spektra vibracija.
Sl. 7.51. Radni prozor za prikaz spektra vibracija.
Kada je spreman pritisnite (kliknite) dugme "F9-Mjerenje" tada počinje proces mjerenja vibracija istovremeno na dva kanala.
Nakon završetka mjernog procesa u radnom prozoru pojavljuju se dijagrami vremenske funkcije (gornji dijagram) i spektra vibracija (donji dijagram).
Frekvencija vibracije je iscrtana na X-osi, a RMS brzine vibracije (mm/sec) je nacrtana na Y-osi.
U ovom slučaju, grafikon za prvi kanal je prikazan crvenom, a za drugi kanal zelenom bojom.
Opće upute o radu i održavanju uređaja
8.1 Kriteriji kvalitete balansiranja (Standard ISO 2372)
Kvaliteta balansiranja može se procijeniti korištenjem razina vibracija utvrđenih standardom ISO 2372. Tablica dolje prikazuje prihvatljive razine vibracija za različite klase strojeva:
| Machine Class | Dobro (mm/sec RMS) |
Acceptable (mm/sec RMS) |
Još uvijek prihvatljivo (mm/sec RMS) |
Unacceptable (mm/sec RMS) |
|---|---|---|---|---|
| Class 1 Mali strojevi na krutim temeljima (motori do 15 kW) |
< 0.7 | 0.7 - 1.8 | 1.8 - 4.5 | > 4.5 |
| Class 2 Srednji strojevi bez temelja (motori 15-75 kW), pogonski mehanizmi do 300 kW |
< 1.1 | 1.1 - 2.8 | 2.8 - 7.1 | > 7.1 |
| Class 3 Veliki strojevi na krutim temeljima (oprema preko 300 kW) |
< 1.8 | 1.8 - 4.5 | 4.5 - 11 | > 11 |
| Class 4 Veliki strojevi na laganim temeljima (oprema preko 300 kW) |
< 2.8 | 2.8 - 7.1 | 7.1 - 18 | > 18 |
Napomena: Ove vrijednosti pružaju smjernice za procjenu kvalitete balansiranja. Uvijek se obratite specifičnim specifikacijama proizvođača opreme i primjenjivim normama za vašu primjenu.
8.2 Zahtjevi održavanja
🔧 Redovno održavanje
- ✓Redovna kalibracija senzora u skladu sa specifikacijama proizvođača
- ✓Čuvajte senzore čistim i slobodnim od magnetnog otpada
- ✓Čuvajte opremu u zaštitnoj kutiji kada se ne koristi
- ✓Zaštitite laserski senzor od prašine i vlage
- ✓Redovno provjeravajte kabelske veze na znakove trošenja ili oštećenja
- ✓Ažurirajte softver kako je preporučio proizvođač
- ✓Održavajte sigurnosne kopije važnih podataka o balansiranju
📋 EU standardi održavanja
Održavanje opreme mora biti u skladu sa:
- EN ISO 9001: Zahtjevi sistema upravljanja kvalitetom
- EN 13306: Terminologija i definicije održavanja
- EN 15341: Ključni indikatori performansi održavanja
- Redovne inspekcije sigurnosti prema EU direktivi o mašinama
PRILOG 1. BALANSIRANJE ROTORA
Rotor je telo koje se rotira oko određene ose i drži se površinama svojih ležajeva na nosačima. Površine ležaja rotora prenose težine na nosače preko kotrljajućih ili kliznih ležaja. Koristeći termin "površina ležaja" jednostavno se odnosi na čep* ili površine koje zamjenjuju čep.
*Čep (Zapfen na njemačkom jeziku za "čep", "pin") - je dio osovine ili ose koji se nosi od strane držača (kutije ležaja).
fig.1 Rotor and centrifugal forces.
In a perfectly balanced rotor, its mass is distributed symmetrically regarding the axis of the rotation. This means that any element of the rotor can correspond to another element located symmetrically in a relation to the axis of the rotation. During rotation, each rotor element acts upon by a centrifugal force directed in the radial direction (perpendicular to the axis of the rotor rotation). In a balanced rotor, the centrifugal force influencing any element of the rotor is balanced by the centrifugal force that influences the symmetrical element. For example, elements 1 and 2 (shown in fig.1 and colored in green) are influenced by centrifugal forces F1 and F2: equal in value and absolutely opposite in directions. This is true for all symmetrical elements of the rotor and thus the total centrifugal force influencing the rotor is equal to 0 the rotor is balanced. But if the symmetry of the rotor is broken (in Figure 1, the asymmetric element is marked in red), then the unbalanced centrifugal force F3 begins to act on the rotor.
Tokom rotacije, ova sila mijenja smjer zajedno sa rotacijom rotora. Dinamičko opterećenje proizašlo iz ove sile prenosi se na ležajeve, što dovodi do njihovog ubrzanog trošenja. Pored toga, pod uticajem ove promjenjive sile, dolazi do cikličke deformacije nosača i temelja na kojem je rotor fiksiran, što proizvodi vibracije. Da bi se eliminirala neuravnoteženost rotora i pratećih vibracija, potrebno je postaviti mase za balansiranje koje će obnoviti simetriju rotora.
Rotor balancing is an operation to eliminate imbalance by adding balancing masses.
The task of balancing is to find the value and places (angle) of the installation of one or more balancing masses.
Vrste rotora i nebalansiramosti
Considering the strength of the rotor material and the magnitude of the centrifugal forces influencing it, the rotors can be divided into two types: rigid and flexible.
Rigid rotors at operating conditions under the influence of centrifugal force may get slightly deformed and the influence of this deformation in the calculations may therefore be neglected.
Deformation of flexible rotors on the other hand should never be neglected. The deformation of flexible rotors complicates the solution for the balancing problem and requires the use of some other mathematical models in comparison with the task of balancing rigid rotors. It is important to mention that the same rotor at low speeds of rotation can behave like rigid one and at high speeds it will behave like flexible one. Further on we will consider the balancing of rigid rotors only.
U zavisnosti od raspodjele neubalansirane mase duž dužine rotora, mogu se razlikovati dvije vrste nebalansiranosti – statička i dinamička. Isto tako se razlikuju statičko i dinamičko balansiranje rotora.
The static imbalance of the rotor occurs without the rotation of the rotor. In other words, it is quiescent when the rotor is under the influence of gravity and in addition it turns the “heavy point” down. An example of a rotor with the static imbalance is presented in Fig.2
Fig.2
The dynamic imbalance occurs only when the rotor spins.
An example of a rotor with the dynamic imbalance is presented in Fig.3.
Fig.3. Dynamic imbalance of rotor – couple of the centrifugal forces
In this case, imbalanced equal masses M1 and M2 are located in different surfaces – in different places along the length of the rotor. In the static position, i.e. when the rotor does not spin, the rotor may only be influenced by gravity and the masses therefore will balance each other. In dynamics when the rotor is spinning, the masses M1 and M2 start to be influenced by centrifugal forces FЎ1 and FЎ2. These forces are equal in value and are opposite in the direction. However, since they are located in different places along the length of the shaft and are not on the same line, the forces do not compensate each other. The forces of FЎ1 and FЎ2 create a moment impacted to the rotor. That is why this imbalance has another name “momentary”. Accordingly, non-compensated centrifugal forces influence the bearing supports, which can significantly exceed the forces that we relied on and also reduce the service life for the bearings.
Since this type of imbalance occurs only in dynamics during the rotor spinning, thus it is called dynamic. It can not be eliminated in the static balancing (or so called “on the knives”) or in any other similar ways. To eliminate the dynamic imbalance, it is necessary to set two compensating weights that will create a moment equal in value and opposite in direction to the moment arising from the masses of M1 and M2. Compensating masses do not necessarily have to be installed opposite to the masses M1 and M2 and be equal to them in value. The most important thing is that they create a moment that fully compensates right at the moment of imbalance.
Općenito, mase M1 i M2 mogu biti nejednakog opterećenja, pa će biti kombinacija statičke i dinamičke nebalansiranosti. Teorijski je dokazano da je za eliminaciju nebalansiranosti krutog rotora potrebno i dovoljno ugraditi dva težinska tereta raspoređena duž dužine rotora. Ti će tereti kompenzirati i moment koji proistječe iz dinamičke nebalansiranosti i centrifugalnu silu koja je rezultat asimetrije mase u odnosu na os rotora (statička nebalansiranost). Kao što je uobičajeno, dinamička nebalansiranost je tipična za duge rotore, kao što su vratila, a statička – za uske. Međutim, ako je uski rotor montiran pod kutom u odnosu na os, ili gore, deformiran (takozvana "oscilacija točka"), u tom slučaju će biti teško eliminirati dinamičku nebalansiranost (vidjeti Sl.4), zbog činjenice da je teško postaviti korekcijske terete koji stvaraju pravi kompenzacijski moment.
Fig.4 Dynamic balancing of the wobbling wheel
Since the narrow rotor shoulder creates a short moment, it may require correcting weights of a large mass. But at the same time there is an additional so-called “induced imbalance” associated with the deformation of the narrow rotor under the influence of centrifugal forces from the correcting masses.
See the example:
" Metodička uputstva o balansiranju krutih rotora" ISO 1940-1:2003 Mechanical vibration – Balance quality requirements for rotors in a constant (rigid) state – Part 1: Specification and verification of balance tolerances
This is visible for narrow fan wheels, which, in addition to the power imbalance, also influences an aerodynamic imbalance. And it is important to bear in mind that the aerodynamic imbalance, in fact the aerodynamic force, is directly proportional to the angular velocity of the rotor, and to compensate it, the centrifugal force of the correcting mass is used, which is proportional to the square of the angular velocity. Therefore, the balancing effect may only occur at a specific balancing frequency. At other speeds there would be an additional gap. The same can be said about electromagnetic forces in an electromagnetic motor, which are also proportional to the angular velocity. In other words it is impossible to eliminate all causes of vibration of the mechanism by any means of balancing.
Osnove vibracija
Vibration is a reaction of the mechanism design to the effect of cyclic excitation force. This force can may a different nature.
- Centrifugalna sila koja nastaje zbog nebalansiranosti rotora je nekompenzirana sila koja utječe na "tešku točku". Posebno se ta sila i vibracije koje ona uzrokuje eliminiraju balansiranjem rotora.
- Interacting forces, that have a “geometric” nature and arise out of errors in the manufacture and installation of mating parts. These forces can occur, for instance, due to the non-roundness of the shaft journal, errors in the tooth profiles in gears, the waviness of the bearing treadmills, misalignment of the mating shafts, etc. in case of non-roundness of the necks, the shaft axis will shift depending on the angle of rotation of the shaft. Although this vibration is manifested at the rotor speed, it is almost impossible to eliminate it with the balancing.
- Aerodynamic forces arising from the rotation of the impeller fans and other blade mechanisms. Hydrodynamic forces arising from the rotation of hydraulic pump impellers, turbines, etc.
- Elektromagnetske sile koje nastaju tijekom rada elektičnih strojeva kao rezultat, na primjer, asimetrije rotorskog namotaja, prisutnosti kratko spojenih zavoja, itd.
The magnitude of vibration (for example, its amplitude AB) depends not only on the magnitude of the excitation force Fт acting on the mechanism with the circular frequency ω, but also on the stiffness k of the structure of the mechanism, its mass m, and damping coefficient C.
Various types of sensors can be used to measure vibration and balance mechanisms, including:
- absolute vibration sensors designed to measure vibration acceleration (accelerometers) and vibration velocity sensors;
- relativni senzori vibracija vrtložne struje ili kapacitivni, namijenjeni za mjerenje vibracija.
In some cases (when the structure of the mechanism allows it) sensors of force can also be used to examine its vibration weight.
Particularly, they are widely used to measure the vibration weight of the supports of hardbearing balancing machines.
Therefore vibration is the reaction of the mechanism to the influence of external forces. The amount of vibration depends not only on the magnitude of the force acting on the mechanism, but also on the rigidity of the mechanism. Two forces with the same magnitude can lead to different vibrations. In mechanisms with a rigid support structure, even with the small vibration, the bearing units can be significantly influenced by dynamic weights. Therefore, when balancing mechanisms with stiff legs apply the force sensors, and vibration (vibro accelerometers). Vibration sensors are only used on mechanisms with relatively pliable supports, right when the action of unbalanced centrifugal forces leads to a noticeable deformation of the supports and vibration. Force sensors are used in rigid supports even when significant forces arising from imbalance do not lead to significant vibration.
Rezonancija strukture
We have previously mentioned that rotors are divided into rigid and flexible. The rigidity or flexibility of the rotor should not be confused with the stiffness or mobility of the supports (foundation) on which the rotor is located. The rotor is considered rigid when its deformation (bending) under the action of centrifugal forces can be neglected. The deformation of the flexible rotor is relatively large: it cannot be neglected.
U ovom članku proučavamo samo balansiranje krutih rotora. Kruti (nedeformabilni) rotor se sa svoje strane može nalaziti na krutim ili pokretljivi (fleksibilnim) osloncima. Jasno je da je ova krutost/pokretljivost oslonaca relativna i ovisi o brzini rotacije rotora i veličini rezultirajućih centrifugalnih sila. Konvencionalna granica je frekvencija slobodnih oscilacija oslonaca/temelja rotora. Za mehaničke sisteme, oblik i frekvencija slobodnih oscilacija određeni su masom i elastičnošću elemenata mehaničkog sistema. To znači da je frekvencija prirodnih oscilacija unutarnja karakteristika mehaničkog sistema i ne ovisi o vanjskim silama. Budući odmaknuta iz stanja ravnoteže, oslonci nastoje vratiti se u položaj ravnoteže zbog elastičnosti. Ali zbog inercije masivnog rotora, ovaj proces je prirode prigušenih oscilacija. Te oscilacije su vlastite oscilacije sistema rotor-oslonac. Njihova frekvencija ovisi o odnosu mase rotora i elastičnosti oslonaca.
When the rotor begins to rotate and the frequency of its rotation approaches the frequency of its own oscillations, the vibration amplitude increases sharply, which can even lead to the destruction of the structure.
There is a phenomenon of mechanical resonance. In the resonance region, a change in the speed of rotation by 100 rpm can lead to an increase in a vibration tenfold. In this case (in the resonance region) the vibration phase changes by 180°.
Ako je konstrukcija mehanizma loše projektirana, a radna brzina rotora je blizu prirodne frekvencije oscilacija, rad mehanizma postaje nemoguć zbog neprihvatljivo visokih vibracija. Standardne metode balansiranja su također nemoguće jer se parametri dramično mijenjaju čak i sa malenom promjenom brzine rotacije. Koriste se posebne metode u polju rezonantnog balansiranja, ali nisu dovoljno opisane u ovom članku. Frekvenciju prirodnih oscilacija mehanizma možete odrediti tijekom razgona (kada je rotor isključen) ili udaranjem s naknadnom spektralnom analizom odziva sistema na udar. "Balanset-1" pruža mogućnost određivanja prirodnih frekvencija mehaničkih struktura tim metodama.
For mechanisms whose operating speed is higher than the resonance frequency, that is, operating in the resonant mode, supports are considered as mobile ones and vibration sensors are used to measure, mainly vibration accelerometers that measure the acceleration of structural elements. For mechanisms operating in hard bearing mode, supports are considered as rigid. In this case, force sensors are used.
Linearni i nelinearni modeli mehaničkog sistema
Mathematical models (linear) are used for calculations when balancing rigid rotors. The linearity of the model means that one model is directly proportionally (linearly) dependent on the other. For example, if the uncompensated mass on the rotor is doubled, then the vibration value will be doubled correspondingly. For rigid rotors you can use a linear model because such rotors are not deformed. It is no longer possible to use a linear model for flexible rotors. For a flexible rotor, with an increase of the mass of a heavy point during rotation, an additional deformation will occur, and in addition to the mass, the radius of the heavy point will also increase. Therefore, for a flexible rotor, the vibration will more than double, and the usual calculation methods will not work. Also, a violation of the linearity of the model can lead to a change in the elasticity of the supports at their large deformations, for example, when small deformations of the supports work some structural elements, and when large in the work include other structural elements. Therefore it is impossible to balance the mechanisms that are not fixed at the base, and, for example, are simply established on a floor. With significant vibrations, the unbalance force can detach the mechanism from the floor, thereby significantly changing the stiffness characteristics of the system. The engine legs must be securely fastened, bolted fasteners tightened, the thickness of the washers must provide sufficient rigidity, etc. With broken bearings, a significant displacement of the shaft and its impacts is possible, which will also lead to a violation of linearity and the impossibility of carrying out high-quality balancing.
Methods and devices for balancing
As mentioned above, balancing is the process of combining the main Central axis of inertia with the axis of rotation of the rotor.
The specified process can be executed in two ways.
The first method involves the processing of the rotor axles, which is performed in such a way that the axis passing through the centers of the section of the axles with the main Central axis of inertia of the rotor. This technique is rarely used in practice and will not be discussed in detail in this article.
The second (most common) method involves moving, installing or removing corrective masses on the rotor, which are placed in such a way that the axis of inertia of the rotor is as close as possible to the axis of its rotation.
Moving, adding or removing corrective masses during balancing can be done using a variety of technological operations, including: drilling, milling, surfacing, welding, screwing or unscrewing screws, burning with a laser beam or electron beam, electrolysis, electromagnetic welding, etc.
The balancing process can be performed in two ways:
- balansirani skupovi rotora (u vlastitim ležajima);
- balansiranje rotora na balansnim mašinama.
To balance the rotors in their own bearings we usually use specialized balancing devices (kits), which allows us to measure the vibration of the balanced rotor at the speed of its rotation in a vector form, i.e. to measure both the amplitude and phase of vibration.
Currently, these devices are manufactured on the basis of microprocessor technology and (in addition to the measurement and analysis of vibration) provide automated calculation of the parameters of corrective weights that must be installed on the rotor to compensate its imbalance.
These devices include:
- – measuring and computing unit, made on the basis of a computer or industrial controller;
- dva (ili više) senzora vibracija;
- senzor faznog kuta;
- oprema za montaž senzora na objektu;
- specijalizovani softver namenjen izvršavanju punog ciklusa mjerenja parametara nebalansiranosti rotora u jednoj, dvije ili više ravnina korekcije.
For balancing rotors on balancing machines in addition to a specialized balancing device (measuring system of the machine) it is required to have an “unwinding mechanism” designed to install the rotor on the supports and ensure its rotation at a fixed speed.
Currently, the most common balancing machines exist in two types:
- nadrezonantni (sa fleksibilnim osloncima);
- krut ležaj (sa krutim osloncima).
Over-resonant machines have a relatively pliable supports, made, for example, on the basis of the flat springs.
The natural oscillation frequency of these supports is usually 2-3 times lower than the speed of the balanced rotor, which is mounted on them.
Vibration sensors (accelerometers, vibration velocity sensors, etc.) are usually used to measure the vibration of the supports of a resonant machine.
In the hardbearing balancing machines are used relatively-rigid supports, natural oscillation frequencies of which should be 2-3 times higher than the speed of the balanced rotor.
Force sensors are usually used to measure the vibration weight on the supports of the machine.
The advantage of the hard bearing balancing machines is that they can be balanced at relatively low rotor speeds (up to 400-500 rpm), which greatly simplifies the design of the machine and its foundation, as well as increases the productivity and safety of balancing.
Balancing technique
Balancing eliminates only the vibration which is caused by the asymmetry of the rotor mass distribution relative to its axis of rotation. Other types of the vibration cannot be eliminated by the balancing!
Balancing is the subject to technically serviceable mechanisms, the design of which ensures the absence of resonances at the operating speed, securely fixed on the foundation, installed in serviceable bearings.
The faulty mechanism is the subject to a repair, and only then – to a balancing. Otherwise, qualitative balancing impossible.
Balancing cannot be a substitute for repair!
The main task of balancing is to find the mass and the place (angle) of installation of compensating weights, which are balanced by centrifugal forces.
As mentioned above, for rigid rotors it is generally necessary and sufficient to install two compensating weights. This will eliminate both the static and dynamic rotor imbalance. A general scheme of the vibration measurement during balancing looks like the following:
fig.5 Dynamic balancing – correction planes and measure points
Vibration sensors are installed on the bearing supports at points 1 and 2. The speed mark is fixed right on the rotor, a reflective tape is glued usually. The speed mark is used by the laser tachometer to determine the speed of the rotor and the phase of the vibration signal.
sl. 6. Instalacija senzora tijekom uravnoteživanja u dvije ravnine, korištenjem Balanset-1
1,2-vibration sensors, 3-phase, 4- USB measuring unit, 5-laptop
In most cases, dynamic balancing is carried out by the method of three starts. This method is based on the fact that test weights of an already-known mass are installed on the rotor in series in 1 and 2 planes; so the masses and the place of installation of balancing weights are calculated based on the results of changing the vibration parameters.
Mjesto instalacije težine naziva se ravnina korekcije. Obično se ravnine korekcije biraju u području oslonaca ležaja na koje je rotor montiran.
Početna vibracija se mjeri pri prvom pokretanju. Zatim se na rotor, bliže jednoj od opore, instalira pokusna težina poznate mase. Tada se obavlja drugo pokretanje i mjerimo parametre vibracije koji bi trebali promijeniti zbog instalacije pokusne težine. Zatim se pokusna težina u prvoj ravnini uklanja i instalira u drugoj ravnini. Obavlja se treće pokretanje i mjere se parametri vibracije. Kada se pokusna težina uklonji, program automatski izračunava masu i mjesto (uglove) instalacije uravnoteživačkih težina.
The point in setting up test weights is to determine how the system responds to the imbalance change. When we know the masses and the location of the sample weights, the program can calculate the so-called influence coefficients, showing how the introduction of a known imbalance affects the vibration parameters. The coefficients of influence are the characteristics of the mechanical system itself and depend on the stiffness of the supports and the mass (inertia) of the rotor-support system.
For the same type of mechanisms of the same design, the coefficients of influence will be similar. You can save them in your computer memory and use them afterwards for balancing the same type of mechanisms without carrying out test runs, which greatly improves the performance of the balancing. We should also note that the mass of test weights should be chosen as such so that the vibration parameters vary markedly when installing test weights. Otherwise, the error in calculating the coefficients of the affect increases and the quality of balancing deteriorates.
Priručnik za uređaj Balanset-1 pruža formulu pomoću koje možete približno odrediti masu pokusne težine, ovisno o masi i brzini rotacije uravnoteženog rotora. Kao što možete razumjeti sa sl. 1 centrifugalna sila djeluje u radijalnom smjeru, odnosno okomito na os rotora. Stoga bi senzori vibracije trebali biti instalirani tako da je njihova os osjetljivosti također usmjerena u radijalnom smjeru. Obično je krutost temelja u horizontalnom smjeru manja, tako da je vibracija u horizontalnom smjeru veća. Stoga, da bi se povećala osjetljivost, senzori bi trebali biti instalirani tako da je njihova os osjetljivosti također usmjerena horizontalno. Iako nema temeljne razlike. Osim vibracije u radijalnom smjeru, potrebno je kontrolirati vibraciju u aksijalnom smjeru, duž osi rotacije rotora. Ova vibracija obično nije uzrokovana neravnotežom, već drugim razlozima, uglavnom zbog neusklađenosti i neusklađenosti vratila povezanih kroz spojku. Ova vibracija se ne uklanja uravnoteživanjem, u tom slučaju potrebno je usklađivanje. U praksi, obično u takvim mehanizmima postoji neravnoteža rotora i neusklađenost vratila, što uvelike otežava zadatak uklanjanja vibracije. U takvim slučajevima, prvo morate uskladiti, a zatim uravnotežiti mehanizam. (Iako sa jakim zakretanjem neravnoteže, vibracija se javlja i u aksijalnom smjeru zbog "uvijanja" strukture temelja).
Točnost mjerenja i analiza greške
Razumijevanje točnosti mjerenja kritično je za profesionalne operacije uravnoteživanja. Balanset-1A pruža sljedeću preciznost mjerenja:
| Parameter | Formula točnosti | Primjer (za tipične vrijednosti) |
|---|---|---|
| RMS brzina vibracije | ±(0.1 + 0.1×Vmeasured) mm/sec | Za 5 mm/s: ±0,6 mm/s Za 10 mm/s: ±1,1 mm/s |
| Frekvencija rotacije | ±(1 + 0.005×Nmeasured) rpm | Za 1000 rpm: ±6 rpm Za 3000 rpm: ±16 rpm |
| Mjerenje Faze | ±1° | Stalna točnost na svim brzinama |
⚠️ Kritično za točno uravnoteživanje
- !Pokusna težina mora uzrokovati >20-30% promjenu amplitude and/or >20-30° promjenu faze
- !Ako su promjene manje, greške mjerenja znatno se povećavaju
- !Amplituda vibracije i stabilnost faze ne bi trebale varirati više od 10-15% između mjerenja
- !Ako varijacija prekoračuje 15%, provjerite rezonantne uslove ili mehaničke defekte
Kriteriji za procenu kvalitete mehanizama balansiranja
Quality of rotor (mechanisms) balancing can be estimated in two ways. The first method involves comparing the value of the residual imbalance determined during the balancing with the tolerance for the residual imbalance. The specified tolerances for various classes of rotors installed in the standard ISO 21940-11 «Mechanical vibration – Rotor balancing – Part 11: Procedures and tolerances for rotors with rigid behaviour» (formerly ISO 1940-1).
Međutim, primjena ovih tolerancija ne može u potpunosti garantirati operativnu pouzdanost mehanizma povezanu sa postizanjem minimalnog nivoa vibracija. To je zbog činjenice da se vibracije mehanizma ne određuju samo količinom sile povezane sa rezidualnom neuravnoteženosti njegovog rotora, već zavise i od niza ostalih parametara, uključujući: krutost K strukturnih elemenata mehanizma, njegovu masu M, koeficijent prigušenja i brzinu. Stoga se, da bi se procijenile dinamičke karakteristike mehanizma (uključujući kvalitetu njegovog balansiranja), u nekim slučajevima preporučuje procena nivoa rezidualnih vibracija mehanizma, što je regulirano nizom standarda.
The most common standard regulating permissible vibration levels of mechanisms is ISO 10816-3:2009 Preview Mechanical vibration — Evaluation of machine vibration by measurements on non-rotating parts — Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and 15 000 r/min when measured in situ.»
With its help, you can set the tolerance on all types of machines, taking into account the power of their electric drive.
In addition to this universal standard, there are a number of specialized standards developed for specific types of mechanisms. For example,
- ISO 14694:2003 "Industrijski ventilatori – Specifikacije za kvalitetu balansiranja i nivoe vibracija"
- ISO 7919-1-2002 “Vibration of machines without reciprocating motion. Measurements on rotating shafts and evaluation criteria. General guidance.»
🛡️ Važna Sigurnosna Razmatranja za EU Usklađenost
- !Procena Rizika je Obavezna: Izvedite EN ISO 12100 procenu rizika prije operacija balansiranja
- !Kvalificirani Kadovi: Samo obučeni i sertificirani kadovi trebali bi izvoditi operacije balansiranja
- !Lična zaštitna oprema: Uvijek koristite odgovarajuću zaštitnu opremu prema EN 166 (zaštita očiju) i EN 352 (zaštita sluha)
- !Nužne mjere: Uspostavite jasne procedure hitnog gašenja i osigurajte da su svi operateri upoznati s njima
- !Documentation: Održavajte detaljne zapise svih operacija balansiranja radi pracenja i usklađenosti
EU usklađenost i sigurnosne informacije
Izjava o usklađenosti
Prenosivi balancer Balanset-1A usklađen je sa sljedećim direktivama i standardima Evropske unije:
| EU Direktiva/Standard | Detalji Usklađenosti | Sigurnosni Zahtjevi |
|---|---|---|
| Direktiva o Mašinama 2006/42/EC | Sigurnosni zahtjevi za mašine i sigurnosne komponente | Procena rizika, sigurnosne upute, CE oznaka |
| EMC Direktiva 2014/30/EU | Zahtjevi elektromagnetske kompatibilnosti | Otpornost na elektromagnetne smetnje |
| RoHS Direktiva 2011/65/EU | Ograničenje štetnih supstanci | Komponente bez olova, žive i kadmija |
| WEEE Direktiva 2012/19/EU | Elektrotehna i elektronska oprema kao otpad | Pravilna procedura za odlaganje i reciklažu |
| EN ISO 12100:2010 | Sigurnost mašina - Opće principe za dizajn | Procjena rizika i smanjenje rizika |
| EN 60825-1:2014 | Sigurnost laserskih proizvoda - Dio 1 | Zahtjevi za sigurnost laserskog sistema klase 2 |
| EN ISO 14120:2015 | Zaštitne ograde - Opći zahtjevi | Zaštita od opasnosti rotacijskih mašina |
Standardi električne sigurnosti
- ✓EN 61010-1: Zahtjevi sigurnosti za električne uređaje za mjerenje, kontrolu i laboratorijsku upotrebu
- ✓EN 60950-1: Sigurnost opreme informacijske tehnologije (uređaj napajan USB-om)
- ✓IEC 61000 serija: Standardi elektromagnetne kompatibilnosti
- ✓Radni napon: 5V DC preko USB-a (Ekstranisko niska naponska struja)
- ✓Potrošnja energije: < 2.5W
- ✓Klasa zaštite: IP54 (dust-protected; splash-water resistant)
Sigurnost rotirajuće opreme
⚠️ Obavezni sigurnosni postupci (EN ISO 12100)
WARNING: Pri radu s rotirajućom mašinerijom, poštujte sljedeće sigurnosne zahtjeve:
- !EN ISO 14118: Sprječavanje neželjenog pokretanja - Koristite LOTO postupke prije instalacije senzora
- !EN ISO 14120: Osigurajte da je sva rotirajuća oprema pravilno zaštićena
- !EN ISO 13857: Održavajte minimalnu sigurnu distancu od rotirajućih dijelova (500mm za tijelo, 120mm za prste)
- !Lična zaštitna oprema: Nosite sigurnosne naočale prema EN 166, zaštitu sluha prema EN 352 i izbjegavajte labavu odjeću
- !Nikada ne instaliraju senzore ili ispitne težine na rotirajuće strojeve koji su u pogonu
- !Osigurajte da je stroj potpuno zaustavljen i osiguran prije instalacije senzora
- !Hitna zaustavljanja: Mora biti dostupno na udaljenosti od 3 metra od položaja operatora
- !Samo kvalificirani i certificirani kadrovi trebaju izvršavati operacije balansiranja
Klasifikacija laserske sigurnosti
🔴 Laserski uređaj klase 2 (EN 60825-1:2014)
- Wavelength: 650 nm (crvena vidljiva svjetlost)
- Maksimalna izlazna snaga: < 1 mW
- Beam diameter: 3-5 mm na 100mm udaljenosti
- Divergence: < 1.5 mrad
- Klasifikacija sigurnosti: Sigurno za oko pri kratkotrajnoj izloženosti (< 0.25 sec)
- Obavezna označavanja: "LASERSKO ZRAČENJE - NE GLEDAM U SNOP - LASERSKI PROIZVOD KLASE 2"
- Access class: Neograničeno (pristup dozvoljen opšte javnosti)
Procedure laserske sigurnosti:
- Nikada namerno ne gledam u laserski snop
- Ne usmjeravajte laser na osobe, vozila ili zrakoplove
- Izbjegavajte gledanje u laserski snop sa optičkim instrumentima (teleskopi, dalekozori)
- Budite svjesni spekularne refleksije sa sjajnih površina
- Isključite laser kada nije u upotrebi
- Odmah prijavite bilo koju izloženost lasera očima
- Koristite zaštitne naočale za laser (OD 2+ na 650nm) za duži boravak
Tačnost mjerenja i kalibracija
| Parameter | Accuracy | Frekvencija kalibracije |
|---|---|---|
| Amplituda vibracija | ±5% of reading | Godišnje ili nakon 1000 sati |
| Mjerenje faze | ±1° | Annually |
| Rotation speed | ±0,1% od očitavanja | Annually |
| Osjetljivost senzora | 13 mV/(mm/s) ±10% | Pri zamjeni senzora |
Usklađenost sa zahtjevima okoline
- ✓Okruženje za rad: 5°C to 50°C, < 85% RH bez kondenzacije
- ✓Okruženje za skladištenje: -20°C to 70°C, < 95% RH bez kondenzacije
- ✓Altitude: Do 2000m iznad razine mora
- ✓Otpornost na vibracije: IEC 60068-2-6 (10-500 Hz, 2g ubrzanja)
- ✓Otpornost na udare: IEC 60068-2-27 (15g, trajanje 11ms)
- ✓IP rating: IP54 (dust-protected; splash-water resistant)
Zahtjevi za rad
- ✓Operatori moraju biti obučeni u sigurnosti makinskog rada prema EU standardima
- ✓Procjena rizika obavezna prema EN ISO 12100 prije korištenja
- ✓Održavajte opremu prema specifikacijama proizvođača
- ✓Odmah prijavite sve sigurnosne incidente ili kvarove opreme
- ✓Vodite detaljne zapise svih operacija uravnotežavanja radi praćenja
Zahtjevi za dokumentaciju
Za usklađenost sa EU, čuvajte sljedeću dokumentaciju:
- ✓Dokumentacija procjene rizika prema EN ISO 12100
- ✓Zapisi obuke operatera i sertifikati
- ✓Logovi kalibracije i održavanja opreme
- ✓Zapisi balansiranja sa datumima, operaterima i rezultatima
- ✓Izvještaji o sigurnosnim incidentima i korektivne mjere
- ✓Dokumentacija izmjena ili popravke opreme
Tehnička podrška i servis
Za tehničku podršku, usluge kalibracije i rezervne dijelove:
- ✓Manufacturer: Vibromera
- ✓Location: Narva, Estonija (EU)
- ✓Website: https://vibromera.eu
- ✓Jezici podrške: Svi glavni jezici. Dostupna tekstualna komunikacija.
- ✓Pokrivanje servisom: Dostupna dostava širom svijeta
- ✓Warranty: 12 mjeseci od datuma kupnje
- ✓Usluga kalibracije: Dostupno kroz ovlaštene centre servisa
