Auger Balancing at Flour Milling Plant
Screw conveyors are a key element of the technological process at flour milling enterprises. They ensure continuous transportation of grain and flour between various stages of production. Disruption of auger balancing can lead to serious problems in equipment operation and reduced production efficiency.
This article examines a practical case of screw conveyor balancing using the portable device Balanset-1A.
Role of the Auger in Flour Milling Production
An auger is a metal shaft with a complex helical surface designed for transporting bulk materials. In the flour milling industry, screw conveyors ensure the movement of grain and finished products over considerable distances with specified productivity.
Auger imbalance occurs when mass is unevenly distributed relative to the axis of rotation. This can happen for various reasons: manufacturing inaccuracies, uneven wear, material accumulation in certain zones of the helical surface.
Problem Diagnosis
During technical inspection of the equipment, the following signs of imbalance were identified:
- Increased vibration level of the screw conveyor housing
Measurements showed exceedance of permissible vibration values, which required balancing work.
Balancing Technology
The balancing procedure was performed according to the following methodology:
Preparatory Stage
Equipment technical condition was checked, vibration sensors were installed on bearing housing supports, laser tachometer was configured to measure rotation frequency and phase characteristics.
Initial Measurements
Initial vibration parameters were recorded at the working rotation frequency of the auger. The type of imbalance was determined — for this rotor it is dynamic imbalance, requiring correction in two planes.
Trial Weight Installation
Calibrated trial weights were sequentially installed in each correction plane. The system automatically calculated influence coefficients based on changes in vibration parameters.
Correction Weight Calculation
The software automatically determined the masses and angular positions of permanent correction weights for each correction plane. Weights were installed and securely fastened considering the acting centrifugal forces.
Balancing Results
After completing the balancing procedure, control measurements showed a significant reduction in vibration level to values corresponding to technical requirements. Equipment was returned to operation.
For comparison: when balancing a similar auger weighing 500 kg at LLC "Ufatverdosplav" enterprise, it was possible to reduce the initial unbalance by 50 times. Residual imbalance was 3552 g×mm in the first plane and 2220 g×mm in the second plane — well within the balance quality grade G6.3 tolerance calculated for this auger at its service speed in accordance with ISO 21940-11 (formerly ISO 1940-1 / GOST ISO 1940-1).
Benefits of Quality Balancing
- Increased equipment service life: Reduction of dynamic loads decreases wear of bearings, couplings and other drive elements, extending maintenance intervals.
- Improved work efficiency: A balanced auger ensures uniform material transportation without pulsations and blockages in the technological line.
- Improved operating conditions: Vibration reduction decreases noise impact and creates safer working conditions for personnel.
- Reduced operating costs: Decreased electricity consumption, reduced maintenance and spare parts expenses.
- Increased production reliability: Elimination of unplanned equipment stops ensures technological process stability.
Conclusion
Balancing of screw equipment is an important component of technical maintenance at flour milling enterprises. The use of modern portable devices like Balanset-1A allows effective solution of imbalance elimination tasks directly at the equipment operation site.
Regular performance of balancing work contributes to maintaining high production efficiency, reducing operating costs and ensuring safety of technological processes.
Portable balancer & Vibration analyzer Balanset-1A
Balanset-1A is a portable, USB-powered vibration analyzer and balancer for one- and two-plane balancing of rotors in their own bearings. The Full Kit includes the interface unit, two vibration sensors, optical laser tachometer, reflective tape, Windows balancing software on a USB drive, magnetic stand, digital scale and transport case. Requires a compatible Windows computer with a free USB port; computer …
Vibration sensor
Vibration sensor for Balanset balancing devices, based on the ADXL335 accelerometer. Supplied with a 5 m cable as standard for measuring vibration during rotor balancing and analysis. A 10 m cable option is available.
Optical Sensor (Laser Tachometer)
Optical laser sensor for Balanset balancing devices, based on the modified HS2234 tachometer. Measures rotational speed without contact using a reflective mark on the rotor. Supplied with a 5 m cable as standard; a 10 m cable option is available.
Balanset-4
Balanset-4 is a four-channel vibration analyzer and balancing system for correction in one to four planes. Designed for cardan shafts and rotors supported on four bearings, it can also serve as the measuring system for a balancing machine. The kit includes four vibration sensors, an optical laser tachometer, USB interface, software, magnetic stand, scale and transport case.
Magnetic Stand Insize-60-kgf
Adjustable magnetic stand for positioning the laser RPM sensor in Balanset balancing kits. The switchable magnetic base provides up to 60 kgf of holding force on suitable ferromagnetic surfaces. Adjustable arms and joints help align the sensor with the reflective mark on the rotor.
Reflective tape
Silver self-adhesive reflective tape for the optical laser tachometer in Balanset balancing kits. Apply a small piece to the rotor to provide a reflective reference mark for rotational speed measurement. Supplied as a 1 m length for multiple setups.
Dynamic balancer “Balanset-1A” OEM
Balanset-1A OEM is the core measuring kit for one- and two-plane rotor balancing and vibration analysis. It includes the USB interface unit, two vibration sensors, optical laser tachometer, reflective tape and Windows balancing software on a USB drive. Compared with the Full Kit, the magnetic stand, digital scale and transport case are not included. Requires a compatible Windows computer with …
Nikolai Shelkovenko
Nikolai Shelkovenko is a vibration analysis engineer and the founder and CEO of Vibromera. For more than 15 years he has balanced rotating equipment in the field rather than on a test bench: mulchers, industrial fans, crushers, centrifuges, shafts and spindles. That work is what the Balanset instruments grew out of — they were designed as a tool a specialist can carry to the machine and use alone, on site, not as laboratory equipment. Vibromera was founded in 2017 and has been based in Porto, Portugal, since 2023. Development, assembly and support of the Balanset line all happen here. The flagship instrument is the Balanset-1A, a portable analyser for single- and two-plane balancing and for vibration diagnostics. Nikolai is personally involved in customer support, in working through difficult balancing cases and in the development of the software. He works with customers worldwide, in any language.
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