One of our esteemed clients operates a facility that designs and constructs waste sorting complexes, waste transshipment stations, and manufactures various equipment for sorting and recycling solid municipal waste. The facility spans a massive 14 hectares, boasting over 20,000 square meters of production area. Their infrastructural prowess includes a modern machine park, large paint chambers, and direct access to railway lines. Interestingly, their need for balancing services is sporadic. Lacking their own specialized equipment for this purpose, our expert team is often called onsite for dynamic balancing tasks.
In this article, I will detail our experience and methodology in dynamically balancing rubberized shafts on a lathe machine – a solution that, admittedly, I was initially skeptical of due to the inherent rigidity and substantial weight of such machinery. Surprisingly, the operation was seamlessly executed, achieving an impressive precision level of g 1 as per ISO 1940 standards.
Dynamic Balancing Process:
- Rotation Frequency: Typically, the working rotation speed of this shafts ranges between 300 to 500 revolutions per minute (rpm). In this particular case, we carried out the balancing at 550 rpm.
- Setup: The rubberized shaft was mounted on the lathe machine, followed by the strategic placement of sensors, as depicted in the accompanying photographs.
- Initial Vibration Readings: Before balancing, the vibration readings stood at 9 mm/sec and 17 mm/sec.
- Trial Weight: A trial weight of 340 grams was welded. This was sufficient to alter the vibration and phase readings by roughly 10%.
- Balancing Adjustments: Post the trial runs with the test weight, our Balanset-1A instrument indicated the need for the addition of 3100 grams on one side of the shaft and 4300 grams on the other. After these adjustments, vibration levels decreased to 2 mm/sec and 4 mm/sec.
- Fine-tuning: To further optimize results, we proceeded to add weights of 400 grams and 700 grams. Subsequently, another round of fine-tuning was executed by adding 200 grams and 400 grams. Due to spatial constraints, the weights were welded atop one another. Ultimately, these temporary weights were replaced with precision-cut, aesthetically pleasing counterweights crafted specifically for this shaft. The final vibration readings were an impressive 0.1 mm/sec in both planes.
In wrapping up, the project has underscored the efficacy of portable balancing equipment, specifically the Balanset-1A, in delivering precise results under challenging conditions. By achieving a balance grade of g 1 according to ISO 1940, this case affirms that non-traditional setups like a lathe machine can be employed successfully for dynamic balancing tasks. This expands the scope of on-site rotor balancing, offering a viable solution for industrial sectors that might not have dedicated balancing machinery.