Balancing Mulcher Rotors: Why and How?

A mulcher is powerful equipment used for shredding vegetation, shrubs, and trees. The mulcher’s rotor, rotating at high speeds, is subjected to significant loads. Rotor imbalance can lead to severe vibrations, noise, and premature wear of the equipment. In this article, we will discuss why balancing the mulcher’s rotor is so important and how to perform it correctly using the portable balancing device Balanset-1A.

Detailed Overview of the Standard Balanset-1A Package

Balanset-1A is a popular portable device for rotor balancing. The standard package includes:

• Control Unit (interface block): The “brain” of the device, processing signals from sensors and controlling the balancing process.
• Vibration Sensors: Two highly sensitive sensors for accurate measurement of rotor vibration parameters.
• Optical Sensor (laser tachometer): Measures the rotor’s rotational speed with high precision.
• Magnetic Stand for the Optical Sensor: Ensures secure mounting and precise positioning of the sensor.
• Electronic Scales: For precise weighing of correction weights.
• Software: An intuitive interface for entering parameters, analyzing data, and calculating the optimal placement of weights.
• Transport Case: A sturdy case for convenient transportation and storage of the kit.

Advantages of Balancing Mulcher Rotors

• Reduction of vibration and noise during operation: Balancing reduces oscillations and makes the mulcher’s operation more comfortable.
• Prevention of premature bearing wear: A balanced rotor reduces the load on bearings, extending their service life.
• Reduction of load on the drive: Decreasing vibrations reduces the load on the engine and transmission.
• Increasing the overall service life of the machine: Proper balancing helps avoid breakdowns and prolongs the mulcher’s operational life.
• Improving productivity and work efficiency: A balanced mulcher operates more smoothly and efficiently.

Preparation for Balancing

Before starting the balancing process, it is necessary to thoroughly prepare the mulcher.

1. Mulcher Inspection

• Check the bearings for play.
• Inspect the housing for cracks.
• Ensure all bolt connections are properly tightened.

2. Structural Preparation

It is recommended to weld the push frame and front curtain to the mulcher’s housing or remove them to eliminate potential interference during balancing.

Step-by-Step Instructions for Balancing a Mulcher Rotor Using Balanset-1A

1. Sensor Installation: Place the vibration sensors perpendicular to the rotor’s axis of rotation. Install the tachometer on the magnetic stand and aim it at the reflective tape affixed to the pulley or rotor.
2. Connecting the Device: Connect the sensors to the Balanset-1A balancing device, then connect it to a laptop.
3. Starting the Software: Launch the software, select two-plane balancing, and enter the rotor data.
4. Entering Calibration Weight Data: Measure the weight and installation radius of the calibration weight, and enter this data into the program.
5. Measuring Initial Vibration Level: Start the rotor to measure the initial vibration level.
6. Installing the Calibration Weight: Install the calibration weight in the first plane opposite the position of the first sensor and perform a measurement. Then move the weight to the second plane, where the second sensor is located, and repeat the measurement.
7. Data Analysis: The program analyzes the data and suggests the weight and installation angle of the correction weights for both planes.
8. Installing Correction Weights: Remove the calibration weight and install the correction weights according to the program’s recommendations.
9. Balancing Verification: Start the rotor to check the success of the balancing. If necessary, make additional adjustments following the program’s recommendations.

This approach allows for precise balancing of the mulcher rotor, reducing vibration and optimizing equipment operation.