Productos
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Balancero portátil y analizador de vibración Balanset-1A
€1,975.00 + IVA (si aplica)
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Balancero dinámico “Balanset-1A” OEM
€1,735.00 + IVA (si aplica)
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Sensor de vibración
€90.00 + IVA (si aplica)
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Sensor óptico (tacómetro láser)
€124.00 + IVA (si aplica)
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Balanset-4
€6,803.00 + IVA (si aplica)
Hydraulic Pump Balancing with the Balanset-1A Device
A practical guide for maintenance engineers and technicians, covering dynamic balancing technology using the portable Balanset-1A device
1. Propósito y Principio de Funcionamiento
El balanceo de bombas hidráulicas es un procedimiento para eliminar el desbalance de las partes giratorias con el fin de reducir la vibración y aumentar la vida útil del equipo.
The balancing process involves measuring the rotor’s vibration and phase, then adding or removing small correction weights on the impeller or shaft. By counteracting the uneven mass distribution, this procedure significantly reduces the centrifugal forces that cause vibration and potential damage.
Causas principales del desbalance:
- Imprecisiones de fabricación del impulsor y el eje
- Desgaste y daños durante la operación
- Daños por corrosión y cavitación
- Montaje incorrecto después de la reparación
Consecuencias del desbalance:
- Aumento de la vibración y el ruido
- Desgaste acelerado de rodamientos y sellos
- Reducción de la eficiencia de la bomba
- Riesgo de falla de emergencia
2. Descripción Técnica del Balanset-1A
Balanset-1A is a portable dual-channel device for dynamic balancing of rotors directly at the workplace (in-situ).
Estructura del Sistema Balanset-1A
Especificaciones técnicas
| Parámetro | Valor | Unidad |
|---|---|---|
| Rango de medición de velocidad de vibración (RMS) | 0.02 - 80 | mm/s |
| Rango de frecuencia | 5 - 1000 | Hz |
| Rango de medición de velocidad de rotación | 100 - 100,000 | rpm |
| Precisión de medición de fase | ±1 | grados |
| Número de planos de corrección | 1 o 2 | - |
| Temperatura de operación | +5...+50 | °C |
Contenido del paquete del dispositivo
Interfaz USB con preamplificadores y ADC
2 acelerómetros con montaje magnético
Sensor de fase con soporte magnético
Para instalación en el eje de la bomba
Para medición precisa de peso
En memoria USB con instrucciones
3. Preparación para el balanceo
Instalación del sensor
Diagrama de instalación del sensor en la bomba hidráulica
- Install vibration sensors on the pump housing near the bearings, oriented perpendicular to the shaft axis
- Attach reflective tape on the pump shaft or coupling
- Mount the laser tachometer on a magnetic stand opposite the reflective tape
- Connect the sensors to the measuring unit
- Connect the measuring unit to the laptop via USB
4. Procedimiento de balanceo
The balancing procedure with Balanset-1A typically follows a three-run method (influence coefficient method) using trial weights. Below is a step-by-step outline of the process, from measuring initial vibration to installing correction weights and verifying the results.
Medición inicial de vibración
- Inicie el software Balanset-1A
- Seleccione el modo de balanceo en un plano o en dos planos
- Start the pump at operating speed
- Press "Run#0" in the software to measure initial vibration
- Record the vibration amplitude and phase values
Instalación del peso de prueba
- Detenga la bomba
- Weigh a suitable trial weight using the electronic scales
- Install the weight on the rotor in the first correction plane
- Enter the weight’s mass and installation radius into the software
- Restart the pump and perform the "Run#1" measurement
Medición del segundo plano (para balanceo en dos planos)
- Stop the pump and remove the trial weight from the first plane
- Attach the trial weight to the second correction plane
- Start the pump and perform the "Run#2" measurement
- The software will automatically calculate the required correction weights
Instalación del peso de corrección
- Stop the pump and remove any trial weights
- Manufacture or select the correction weights as per the software’s calculation
- Secure the weights by welding, bolting, or using clamps
- The installation angle for each weight is measured from the trial weight position in the direction of rotation
Medición de verificación
- Run the pump at operating speed
- Perform a control measurement ("RunTrim")
- Verify that vibration has been reduced to acceptable levels
- Adjust weight masses and repeat measurement if necessary
5. Criterios de evaluación de la calidad del balanceo
Valores aceptables de vibración residual
| Pump category (ISO 10816-7) | Acceptable for long-term operation (zone B limit), mm/s RMS | Risk of damage (zone D), mm/s RMS |
|---|---|---|
| Category I (high-reliability duty), up to 200 kW | ≤ 4.0 | > 6.6 |
| Category I (high-reliability duty), over 200 kW | ≤ 5.0 | > 7.6 |
| Category II (general duty), up to 200 kW | ≤ 5.1 | > 8.5 |
| Category II (general duty), over 200 kW | ≤ 6.1 | > 9.5 |
Signos de un balanceo exitoso
- 70–90% reduction in vibration at the 1× rotational frequency
- Stable and consistent vibration phase readings
- Absence of unusual noise
- Smooth, uniform pump operation
6. Recomendaciones prácticas
Frecuencia de balanceo
Balanceo programado
- New equipment – after initial run-in period
- After major repairs – mandatory
- Anualmente para equipo crítico
- When vibration levels double from baseline
Balanceo no programado
- Upon noticing unusual vibration or noise
- After any impeller replacement
- If vibration exceeds acceptable levels
- After an emergency shutdown
Requisitos para un balanceo de calidad
- Ensure the pump is in good mechanical condition
- Verify the pump is firmly mounted on a stable foundation
- Check that bearings have no excessive play
- Confirm proper alignment between pump and driver
- Maintain stable operating speed during balancing
Documentación de resultados
- Keep a log of all balancing work performed
- Save the Balanset-1A software reports for each balance job
- Document the mass and position of installed correction weights
- Record the final vibration levels after balancing (control measurements)
Conclusión
The portable Balanset-1A device provides effective balancing of hydraulic pumps directly at the workplace. Proper application of this technology allows users to:
- Reduce equipment vibration by a factor of 3–10
- Increase bearing service life by 2–5 times
- Lower energy consumption by 5–15%
- Prevent emergency breakdowns
- Decrease overall maintenance costs
Regular balancing of hydraulic pumps is an important part of the planned preventive maintenance system for industrial equipment.
Preguntas frecuentes (FAQ)
What is hydraulic pump balancing?
Hydraulic pump balancing is the process of correcting the uneven distribution of mass in a pump’s rotating components (such as the impeller and shaft). By adding or removing small weights, the goal is to eliminate excessive vibration and noise, improving performance and extending the pump’s service life.
Why is balancing a hydraulic pump important?
Balancing a pump is crucial because an imbalanced pump can cause excessive vibration and noise, leading to accelerated wear of bearings and seals, reduced efficiency, and an increased risk of sudden failure. Proper balancing helps ensure smooth, efficient, and reliable pump operation.
How do you balance a hydraulic pump?
Hydraulic pump balancing is typically done by using a device like the Balanset-1A. The process involves measuring the pump’s vibration and phase, adding a trial weight to the rotor, measuring the change, and then calculating and installing a correction weight at a specific location. After installing the correction weight, the pump is run again to verify that vibration levels have dropped to acceptable limits.
What equipment is used for pump balancing?
Pump balancing requires a vibration measurement and balancing system. The Balanset-1A kit, for example, includes a USB interface module, two vibration sensors (accelerometers), a laser tachometer (phase reference sensor), reflective tape for the rotor, electronic scales for weighing trial and correction weights, and specialized software running on a laptop to guide the balancing procedure.
How often should a pump be balanced?
Pumps should be balanced whenever there is significant vibration or after events that could cause imbalance. It’s recommended to balance new pumps after an initial run-in period, after major repairs or impeller replacements, and as part of annual maintenance for critical pumps. Unscheduled balancing is advised if unusual vibration or noise appears or after any emergency shutdown.
What are acceptable vibration levels for a balanced pump?
Acceptable vibration levels depend on the pump category and power. ISO 10816-7 (rotodynamic pumps above 1 kW) sets zone B limits — acceptable for unrestricted long-term operation — of 4.0 mm/s (RMS) for Category I (high-reliability) pumps up to 200 kW and 5.0 mm/s above 200 kW; for general-duty Category II pumps the limits are 5.1 mm/s up to 200 kW and 6.1 mm/s above 200 kW. Vibration above the zone C/D boundary (6.6–9.5 mm/s depending on category and power) indicates a risk of damage and needs immediate attention.
Does balancing fix all vibration issues?
No. Balancing addresses vibration caused by rotor mass imbalance. It will significantly reduce vibrations at the rotational frequency, but it cannot fix other sources of vibration such as misalignment, worn bearings, bent shafts, or other mechanical problems. Those issues must be diagnosed and repaired separately.
