Drive Shaft Balancing: Comprehensive Guide

Imagine you're driving a truck and suddenly feel a harsh vibration or hear a loud clunk when accelerating or changing gears. This is more than just a nuisance — it could be a sign of an unbalanced driveshaft. For engineers and technicians, such vibrations and noises indicate lost efficiency, accelerated wear on components, and potentially costly downtime if left unaddressed.

In this comprehensive guide, we provide practical solutions to driveshaft balance issues. You'll learn what a driveshaft is and why it needs balancing, recognize the common malfunctions that cause vibration or noise, and follow a clear step-by-step process for dynamic driveshaft balancing. By applying these best practices, you can save money on repairs, reduce troubleshooting time, and ensure your machinery or vehicle runs reliably with minimal vibration.

目錄

• 1. 驅動軸類型
• 2. 萬向節驅動故障
• 3. 驅動軸動平衡校正
• 4. 現代驅動軸平衡機
• 5. 驅動軸動平衡校正準備
• 6. 驅動軸動平衡校正程序
• 7. 剛性轉子推薦平衡精度等級

1. 驅動軸類型

萬向節驅動（驅動軸）是一種在相交於萬向節中心的軸之間傳遞扭矩的機構，這些軸可以以一定角度相對移動。在車輛中，驅動軸在傳統或四輪驅動配置下，將扭矩從變速箱（或分動箱）傳遞到驅動軸。對於四輪驅動車輛，萬向節通常將變速箱的輸出軸連接到分動箱的輸入軸，並將分動箱的輸出軸連接到驅動軸主傳動的輸入軸。

Units mounted on the frame (such as the gearbox and transfer case) can move relative to each other due to the deformation of their supports and the frame itself. Meanwhile, the drive axles are attached to the frame through the suspension and can move relative to the frame and the units mounted on it due to the deformation of the suspension's elastic elements. This movement can change not only the angles of the driveshafts connecting the units but also the distance between the units.

萬向節驅動有一個顯著缺點：軸的旋轉不均勻。如果一根軸均勻旋轉，另一根則不會，且這種不均勻性會隨軸間夾角的增大而增加。這一限制使得萬向節驅動無法應用於許多場合，例如前輪驅動車輛的傳動系統，其主要問題是向轉向輪傳遞扭矩。這一缺點可以通過在同一根軸上使用兩個萬向節來部分補償，這兩個萬向節彼此相錯四分之一轉。然而，在需要均勻旋轉的應用中，通常使用等速萬向節（CV 萬向節）代替。等速萬向節是一種更先進但結構也更複雜的設計，用於實現相同的目的。

萬向節驅動可以由一個或多個通過驅動軸和中間支撐連接的萬向節組成。

圖 1. 萬向節驅動示意圖：1, 4, 6 — 驅動軸；2, 5 — 萬向節；3 — 補償連接；u1, u2 — 軸間夾角

In general, a universal joint drive consists of universal joints 2 and 5, driveshafts 1, 4, and 6, and a compensating connection 3. Sometimes the driveshaft is installed on an intermediate support attached to the vehicle frame cross member. Universal joints ensure the transmission of torque between shafts whose axes intersect at an angle. Universal joints are divided into non-uniform and constant velocity types. Non-uniform velocity joints are further classified into elastic and rigid types. Constant velocity joints can be ball-type with dividing grooves, ball-type with a dividing lever, and cam-type. They are typically installed in the drive of the leading controlled wheels, where the angle between the shafts can reach 45°, and the center of the universal joint must coincide with the intersection point of the wheel's rotation axes and its turning axis.

Elastic universal joints transmit torque between shafts with intersecting axes at an angle of 2...3° due to the elastic deformation of the connecting elements. A rigid non-uniform velocity joint transmits torque from one shaft to another through the movable connection of rigid parts. It consists of two yokes – 3 and 5, into the cylindrical holes of which the ends A, B, V, and G of the connecting element – the cross 4, are installed on bearings. The yokes are rigidly connected to shafts 1 and 2. Yoke 5 can rotate around axis BG of the cross and at the same time, along with the cross, rotate around axis AV, thereby enabling the transmission of rotation from one shaft to another with a changing angle between them.

圖 2. 剛性不等速萬向節示意圖

如果軸 7 繞其軸線旋轉角度 α，則軸 2 在同一週期內將旋轉角度 β。軸 7 和 2 的旋轉角度關係由以下表達式確定 tanα = tanβ * cosγ, where γ is the angle at which the axes of the shafts are positioned. This expression indicates that the angle β is sometimes less than, equal to, or greater than angle α. Equality of these angles occurs every 90° of rotation of shaft 7. Therefore, with uniform rotation of shaft 1, the angular velocity of shaft 2 is non-uniform and varies according to a sinusoidal law. The non-uniformity of shaft 2's rotation becomes more significant as the angle γ between the shaft axes increases.

如果軸 2 的不均勻旋轉傳遞到單元軸，傳動系統中將產生額外的脈動負荷，並隨角度 γ 的增大而增加。為了防止軸 2 的不均勻旋轉傳遞到單元軸，萬向節驅動中使用兩個萬向節。它們的安裝方式使得角度 γ1 和 γ2 相等；固定在非均勻旋轉軸 4 上的萬向節叉頭應位於同一平面內。

The design of the main parts of universal joint drives is shown in Figure 3. A non-uniform velocity universal joint consists of two yokes (1) connected by a cross (3). One of the yokes sometimes has a flange, while the other is welded to the driveshaft tube or has a splined end (6) (or sleeve) for connection to the driveshaft. The trunnions of the cross are installed in the eyes of both yokes on needle bearings (7). Each bearing is housed in a case (2) and held in the yoke's eye with a cap, which is attached to the yoke with two bolts locked by tabs on the washer. In some cases, the bearings are secured in the yokes with snap rings. To retain lubrication in the bearing and protect it from water and dirt, there is a rubber self-tightening seal. The inner cavity of the cross is filled with grease through a grease fitting, which reaches the bearings. The cross typically has a safety valve to protect the seal from damage due to the pressure of the grease being pumped into the cross. The splined connection (6) is lubricated using the grease fitting (5).

圖 3. 剛性不等速萬向節細節

The maximum angle between the axes of shafts connected by rigid non-uniform velocity universal joints usually does not exceed 20°, as efficiency significantly decreases at larger angles. If the angle between the shaft axes varies within 0...2%, the trunnions of the cross are deformed by the needle bearings, causing the universal joint to fail quickly.

In the transmissions of high-speed tracked vehicles, universal joints with gear coupling types, which allow the transmission of torque between shafts with axes intersecting at angles up to 1.5...2°, are often used.

驅動軸通常採用管狀結構，使用特殊鋼材的無縫或焊接管。萬向節的叉頭、花鍵套筒或端頭焊接到管上。為了減少作用在驅動軸上的橫向負荷，在萬向節組裝後進行動平衡校正。不平衡通過在驅動軸上焊接平衡板或有時在萬向節軸承蓋下安裝平衡板來校正。萬向節驅動在工廠組裝和平衡後，花鍵連接部件的相對位置通常用特殊標籤標記。

萬向節驅動的補償連接通常採用花鍵連接形式，允許萬向節驅動部件的軸向移動。它由一個插入萬向節驅動花鍵套筒的花鍵端頭組成。潤滑脂通過潤滑脂嘴注入花鍵連接，或在組裝時塗抹，並在車輛長期使用後更換。通常安裝密封件和蓋板以防止潤滑脂泄漏和污染。

對於長驅動軸，萬向節驅動中通常使用中間支撐。中間支撐通常由一個螺栓固定在車輛車架橫樑上的支架組成，支架中安裝有橡膠彈性環內的球軸承。軸承兩側用蓋板密封並配有潤滑裝置。彈性橡膠環有助於補償組裝誤差和因車架變形可能產生的軸承不對中。

帶滾針軸承的萬向節（圖 4a）由叉頭、十字軸、滾針軸承和密封件組成。帶有滾針軸承的軸承杯安裝在十字軸的銷軸上並用密封件密封。軸承杯用卡環或用螺絲固定的蓋板固定在叉頭中。萬向節通過十字軸內的內鑽孔和潤滑脂嘴進行潤滑。安全閥用於消除萬向節內的過剩油壓。當驅動叉頭均勻旋轉時，從動叉頭旋轉不均勻：它在每轉中兩次超前和滯後於驅動叉頭。為了消除不均勻旋轉並減少慣性負荷，使用兩個萬向節。

在前驅動輪的驅動系統中安裝等速萬向節。GAZ-66 和 ZIL-131 車輛的等速萬向節驅動由叉頭 2、5（圖 4b）、四個鋼球 7 和中心鋼球 8 組成。驅動叉頭 2 與內軸一體成型，而從動叉頭與外軸鍛造成型，輪轂固定在外軸的末端。扭矩從叉頭 2 通過沿叉頭內圓形溝槽移動的鋼球 7 傳遞到叉頭 5。中心鋼球 8 用於叉頭定心，並由螺柱 3、4 固定。由於機構相對於叉頭的對稱性，叉頭 2、5 的旋轉頻率相同。軸長的變化由叉頭與軸的自由花鍵連接確保。

圖 4. 萬向節：a — 萬向節：1 — 蓋板；2 — 軸承杯；3 — 滾針軸承；4 — 密封件；5, 9 — 叉頭；6 — 安全閥；7 — 十字軸；8 — 潤滑脂嘴；10 — 螺絲；b — 等速萬向節：1 — 內軸；2 — 驅動叉頭；3, 4 — 螺柱；5 — 從動叉頭；6 — 外軸；7 — 鋼球；8 — 中心鋼球

2. 萬向節驅動故障

萬向節驅動故障通常表現為車輛行駛時萬向節內的劇烈敲擊聲，特別是在換檔和發動機曲軸轉速突然增加時（例如，從發動機制動過渡到加速時）。萬向節故障的跡象可能是其溫度升高到高溫（超過 100°C）。這是由於萬向節的襯套和銷軸、滾針軸承、十字軸以及花鍵連接嚴重磨損，導致萬向節不對中並對滾針軸承產生顯著的衝擊軸向負荷。萬向節十字軸的軟木密封件損壞會導致銷軸及其軸承迅速磨損。

在維護期間，通過手動向兩個方向劇烈旋轉驅動軸來檢查萬向節驅動。軸的自由旋轉程度決定了萬向節和花鍵連接的磨損情況。每 8-10 千公里，檢查變速箱輸出軸法蘭和主傳動齒輪輸入軸與端部萬向節法蘭的螺栓連接情況，以及驅動軸中間支撐的固定情況。同時檢查花鍵連接上的橡膠防護套和萬向節十字軸的軟木密封件的情況。所有固定螺栓必須完全擰緊（鎖緊扭矩 8-10 kgf·m）。

萬向節的滾針軸承使用傳動單元用的液態油進行潤滑；大多數車輛的花鍵連接使用潤滑脂（US-1、US-2、1-13 等）進行潤滑；嚴禁使用潤滑脂潤滑滾針軸承。在某些車輛中，花鍵連接使用傳動油進行潤滑。安裝在橡膠套筒中的中間支撐軸承實際上不需要潤滑，因為它在工廠組裝時已進行潤滑。ZIL-130 車輛的支撐軸承在定期維護（每 1100-1700 公里）期間通過壓力嘴用潤滑脂進行潤滑。

圖 5. 萬向節驅動：1 — 固定驅動軸的法蘭；2 — 萬向節十字軸；3 — 萬向節叉頭；4 — 滑動叉頭；5 — 驅動軸管；6 — 帶封閉端的滾針軸承

萬向節驅動由兩個帶滾針軸承的萬向節、連接它們的空心軸以及帶漸開線花鍵的滑動叉頭組成。為了確保可靠的防塵保護並提供良好的花鍵連接潤滑，連接到變速箱二軸 (2) 的滑動叉頭 (6) 放置在連接到變速箱殼體的延伸段 (1) 中。此外，這種花鍵連接的位置（在萬向節之間的區域之外）顯著增加了萬向節驅動的剛性，並減少了滑動花鍵連接磨損時軸振動的可能性。

The driveshaft is made of a thin-walled electric-welded tube (8), into which two identical yokes (9) are press-fitted at each end and then welded by arc welding. Needle bearing housings (18) of the cross (25) are press-fitted into the eyes of the yokes (9) and are secured with spring retaining rings (20). Each universal joint bearing contains 22 needles (21). Stamped caps (24) are press-fitted onto the protruding trunnions of the crosses, into which cork rings (23) are installed. The bearings are lubricated using an angular grease fitting (17) screwed into a threaded hole in the center of the cross, connected to through channels in the cross's trunnions. On the opposite side of the universal joint cross, a safety valve (16) is located in its center, designed to release excess grease when filling the cross and bearings, and to prevent pressure build-up inside the cross during operation (the valve activates at a pressure of about 3.5 kg/cm²). The necessity of including a safety valve is due to the fact that excessive pressure increase inside the cross can lead to damage (extrusion) of the cork seals.

圖 6. 驅動軸組件：1 — 變速箱延伸段；2 — 變速箱二軸；3 和 5 — 防塵擋板；4 — 橡膠密封件；6 — 滑動叉頭；7 — 平衡板；8 — 驅動軸管；9 — 叉頭；10 — 法蘭叉頭；11 — 螺栓；12 — 後橋主傳動齒輪法蘭；13 — 彈簧墊片；14 — 螺母；15 — 後橋；16 — 安全閥；17 — 角向潤滑脂嘴；18 — 滾針軸承；19 — 叉頭孔；20 — 彈簧卡環；21 — 滾針；22 — 帶環形端墊片；23 — 軟木環；24 — 衝壓蓋板；25 — 十字軸

The driveshaft, assembled with both universal joints, is carefully dynamically balanced at both ends by welding balancing plates (7) to the tube. Therefore, when disassembling the shaft, all its parts must be carefully marked so that they can be reassembled in their original positions. Failure to follow this instruction disrupts the shaft's balance, causing vibrations that can damage the transmission and vehicle body. If individual parts wear out, especially if the tube bends due to impact and it becomes impossible to dynamically balance the shaft after assembly, the entire shaft must be replaced.

可能的驅動軸故障、原因及解決方案

故障原因	解決方案
驅動軸振動
1. 軸因撞擊障礙物而彎曲	1. 校直並對組裝後的軸進行動平衡校正，或更換組裝後的軸
2. 軸承與十字軸磨損	2. 更換軸承與十字軸，並對組裝後的軸進行動平衡校正
3. 伸長管襯套與滑動叉磨損	3. 更換伸長管與滑動叉，並對組裝後的軸進行動平衡校正
啟動與滑行時的敲擊聲
1. 滑動叉花鍵或變速箱二軸磨損	1. 更換磨損零件。更換滑動叉時，需對組裝後的軸進行動平衡校正
2. 固定法蘭叉至後橋驅動齒輪法蘭的螺栓鬆動	2. 鎖緊螺栓
萬向節密封處甩油
萬向節密封處的軟木環磨損	更換軟木環，重新組裝時保持所有傳動軸零件的相對位置。若十字軸與軸承有磨損，則更換軸承與十字軸，並對組裝後的軸進行動平衡校正

3. 驅動軸動平衡校正

傳動軸修復並組裝後，需在平衡機上進行動平衡校正。圖 7 展示了一種平衡機的設計。該機台由底板 (18) 與安裝在四根垂直彈性桿 (3) 上的擺錘框架 (8) 組成，確保其在水平面內擺動。支架與前頂針座 (9) 安裝在支架 (4) 上，並固定在擺錘框架 (8) 的縱向管上。後頂針座 (6) 位於可移動橫梁 (5) 上，允許對不同長度的傳動軸進行動平衡校正。頂針座主軸安裝在精密滾珠軸承上。前頂針座 (9) 的主軸由安裝在機台底座內的電動機透過 V 帶驅動與中間軸驅動，中間軸上裝有刻度盤 (10)。此外，機台底板 (18) 上還安裝有兩個帶有可伸縮鎖定銷 (17) 的支架 (15)，用於根據傳動軸前端或後端的平衡需求，固定擺錘框架的前後端。

圖 7. 傳動軸動平衡機

1—夾具；2—減震器；3—彈性桿；4—支架；5—可移動橫梁；6—後頂針座；7—橫杆；8—擺錘框架；9—前驅動頂針座；10—刻度盤；11—毫伏計；12—換向器整流子軸臂；13—磁電感測器；14—固定支架；15—固定支架；16—支撐座；17—固定銷；18—支撐板

固定支架 (14) 安裝在機台底板後方，其上安裝有磁電感測器 (13)，並透過桿件連接至擺錘框架末端。為防止框架產生共振，支架 (4) 下方安裝有填充油液的減震器 (2)。

During dynamic balancing, the driveshaft assembly with the sliding yoke is installed and secured on the machine. One end of the driveshaft is connected by a flange-yoke to the flange of the front driving headstock, and the other end by the support neck of the sliding yoke to the splined sleeve of the rear headstock. Then the ease of rotation of the driveshaft is checked, and one end of the machine's pendulum frame is fixed using the fixator. After starting the machine, the limb of the rectifier is rotated counterclockwise, bringing the millivoltmeter needle to its maximum reading. The millivoltmeter reading corresponds to the magnitude of the imbalance. The millivoltmeter scale is graduated in gram-centimeters or grams of counterweight. Continuing to rotate the rectifier limb counterclockwise, the millivoltmeter reading is brought to zero, and the machine is stopped. Based on the rectifier limb reading, the angular displacement (angle of imbalance displacement) is determined, and by manually rotating the driveshaft, this value is set on the intermediate shaft limb. The welding place of the balancing plate will be on the top of the driveshaft, and the weighted part at the bottom in the correction plane. Then the balancing plate is attached and tied with thin wire at a distance of 10 mm from the weld, the machine is started, and the balance of the driveshaft end with the plate is checked. The imbalance should be no more than 70 g cm. Then, releasing one end and securing the other end of the pendulum frame with the fixator stand, dynamic balancing of the other end of the driveshaft is performed according to the technological sequence described above.

傳動軸具有一些平衡特性。對於大多數零件，動平衡的基準是支撐軸頸（例如電機轉子、渦輪機、主軸、曲軸等），但對於傳動軸，基準則是法蘭。組裝過程中，不同連接處不可避免地存在間隙，導致不平衡。若在平衡過程中無法達到最小不平衡量，則該軸判定為不合格。影響平衡精度的因素如下：

• 傳動軸法蘭配合帶與左右支撐頂針座夾緊法蘭內孔之間的連接間隙；
• 法蘭基準面的徑向與端面偏擺；
• Gaps in the hinge and splined connections. The presence of grease in the cavity of the splined connection can lead to “floating” imbalance. If it prevents achieving the required balancing accuracy, the driveshaft is balanced without grease.

某些不平衡可能完全無法校正。若發現傳動軸萬向節摩擦增大，校正平面之間的相互影響將增加。這會導致平衡性能與精度下降。

According to OST 37.001.053-74, the following imbalance standards are established: driveshafts with two joints (two-support) are balanced dynamically, and with three (three-support) – assembled with the intermediate support; the flanges (yokes) of driveshafts and couplings weighing more than 5 kg are statically balanced before assembling the shaft or coupling; the residual imbalance norms for driveshafts at each end or at the intermediate support of three-joint driveshafts are evaluated by specific imbalance;

The maximum permissible specific residual imbalance norm at each end of the shaft or at the intermediate support, as well as for three-joint driveshafts in any position on the balancing stand, should not exceed: for transmissions of passenger cars and small-load trucks (up to 1 t) and very small buses – 6 g-cm/kg, for the rest – 10 g-cm/kg. The maximum permissible residual imbalance norm of the driveshaft or three-joint driveshaft should be ensured on the balancing stand at a rotation frequency corresponding to their frequencies in the transmission at the maximum vehicle speed.

For driveshafts and three-joint driveshafts of trucks with a load capacity of 4 t and above, small and large buses, a reduction in the rotation frequency on the balancing stand to 70% of the transmission shafts' rotation frequency at the maximum vehicle speed is allowed. According to OST 37.001.053-74, the balancing rotation frequency of driveshafts should be equal to:

n_b = (0.7 ... 1.0) n_r,

其中 n_b – balancing rotation frequency (should correspond to the main technical data of the stand, n=3000 min^-1；n_r – maximum working rotation frequency, min^-1.

在實際操作中，由於萬向節與花鍵連接處的間隙，傳動軸無法在推薦的旋轉頻率下進行平衡。在此情況下，需選擇另一旋轉頻率進行平衡。

4. 現代驅動軸平衡機

圖 8. 長度達 2 公尺、重量達 500 kg 的傳動軸平衡機

該型號配備 2 個支架，允許在 2 個校正平面進行平衡。

長度達 4200 mm、重量達 400 kg 的傳動軸平衡機

圖 9. 長度達 4200 mm、重量達 400 kg 的傳動軸平衡機

該型號配備 4 個支架，允許同時在 4 個校正平面進行平衡。

圖 10. 用於傳動軸動平衡校正的水平硬支撐平衡機

1 – 平衡物件（傳動軸）；2 – 機台底座；3 – 機台支撐座；4 – 機台驅動裝置；機台支撐座的結構元件如圖 9 所示。

圖 11. 傳動軸動平衡校正機台支撐座元件

1 – 左側不可調支撐座；2 – 中間可調支撐座（2 個）；3 – 右側不可調固定支撐座；4 – 支撐框架鎖定手柄；5 – 可移動支撐平台；6 – 支撐垂直調整螺母；7 – 垂直位置鎖定手柄；8 – 支撐夾緊支架；9 – 中間軸承可移動夾具；10 – 夾具鎖定手柄；11 – 夾緊支架鎖定；12 – 用於安裝物件的驅動（主動）主軸；13 – 從動主軸

5. 驅動軸動平衡校正準備

以下將介紹機台支撐座的設定與平衡物件（四支撐傳動軸）在機台支撐座上的安裝。

圖 12. 過渡法蘭在平衡機主軸上的安裝

圖 13. 傳動軸在平衡機支撐座上的安裝

圖 14. 使用氣泡水平儀在平衡機支撐座上將傳動軸水平調平

圖 15. 固定平衡機中間支撐座以防止傳動軸垂直位移

手動旋轉物件一整圈。確保其在支撐座上旋轉自由且無卡滯。完成此步驟後，機台的機械部分設定完成，物件安裝完畢。

6. 驅動軸動平衡校正程序

以下將以 Balanset-4 測量系統為例，介紹傳動軸在平衡機上的平衡過程。Balanset-4 是一款便攜式平衡套件，設計用於對在自身軸承中旋轉或安裝在平衡機上的轉子進行一、二、三及四個校正平面的平衡校正。該設備包含最多四個振動感測器、一個相位角感測器、一個四通道測量單元及一台便攜式電腦。

整個平衡過程，包括測量、處理及顯示校正配重的大小與位置資訊，均自動執行，無需使用者具備說明書之外的額外技能與知識。所有平衡操作的結果均儲存於平衡檔案中，必要時可列印為報告。除了平衡校正外，Balanset-4 還可作為常規振動測速儀使用，允許在四個通道上測量總振動的均方根 (RMS) 值、振動旋轉分量的 RMS 值，並監控轉子旋轉頻率。

此外，該設備還可顯示振動速度隨時間變化的函數圖與振動頻譜，這對於評估已平衡機器的技術狀態非常有用。

圖 16. Balanset-4 設備外觀，作為驅動軸平衡機的測算系統使用

圖 17. Balanset-4 設備作為驅動軸平衡機測算系統使用範例

圖 18. Balanset-4 設備使用者介面

The Balanset-4 device can be equipped with two types of sensors – vibration accelerometers for measuring vibration (vibration acceleration) and force sensors. Vibration sensors are used for operating on post-resonance type balancing machines, while force sensors are used for pre-resonance type machines.

圖 19. 在平衡機支撐座上安裝 Balanset-4 振動感測器

The direction of the sensors' sensitivity axis should match the direction of the support's vibration displacement, in this case – horizontal. For additional information on sensor installation, see BALANCING ROTORS IN OPERATING CONDITIONS. The installation of force sensors depends on the machine's design features.

1. 將振動感測器 1、2、3、4 安裝在平衡機的支撐座上。
2. 將振動感測器連接至接頭 X1、X2、X3、X4。
3. 安裝相位角感測器（雷射測速儀）5，使被平衡轉子的徑向（或端面）表面與感測器外殼之間的標稱間隙在 10 至 300 mm 範圍內。
4. 在轉子表面貼上寬度至少為 10-15 mm 的反射膠帶標記。
5. 將相位角感測器連接至接頭 X5。
6. 將測量單元連接至電腦的 USB 埠。
7. 使用市電供電時，將電腦連接至電源供應器。
8. 將電源供應器連接至 220 V、50 Hz 電網。
9. 開啟電腦並選取「BalCom-4」程式。
10. 按下「F12-four-plane」按鈕（或電腦鍵盤上的 F12 功能鍵），選取使用連接至測量單元輸入端 X1、X2、X3 和 X4 的振動感測器 1、2、3、4，同時在四個平面測量振動的模式。
11. 電腦顯示器上會出現說明在四個測量通道上同時測量振動過程（或在四個平面進行平衡過程）的助記圖，如圖 16 所示。

在進行動平衡校正之前，建議先在測振儀模式（F5 按鈕）下進行測量。

圖 20. 測振儀模式測量

If the total vibration magnitude V1s (V2s) approximately matches the rotational component magnitude V1o (V2o), it can be assumed that the main contribution to the mechanism's vibration is due to rotor imbalance. If the total vibration magnitude V1s (V2s) significantly exceeds the rotational component V1o (V2o), it is recommended to inspect the mechanism – check the condition of the bearings, ensure secure mounting on the foundation, verify that the rotor does not contact stationary parts during rotation, and consider the influence of vibrations from other mechanisms, etc.

Studying the time function graphs and vibration spectra obtained in the "Graphs-Spectral Analysis" mode can be useful here.

圖 21. 振動時間函數與頻譜圖

The graph shows at which frequencies the vibration levels are highest. If these frequencies differ from the rotational frequency of the balanced mechanism's rotor, it is necessary to identify the sources of these vibration components and take measures to eliminate them before balancing.

此外，還應注意測振儀模式下讀數的穩定性 – 測量期間振動的振幅與相位變化不應超過 10-15%。否則，機件可能正在共振區域附近運轉。在此情況下，應調整轉子轉速。

When performing four-plane balancing in "Primary" mode, five calibration runs and at least one verification run of the balanced machine are required. Vibration measurement during the first machine run without a trial weight is performed in the "Four-Plane Balancing" workspace. Subsequent runs are performed with a trial weight, sequentially installed on the driveshaft in each correction plane (in the area of each balancing machine support).

在每次後續運轉之前，應採取以下步驟：

• Stop the rotation of the balanced machine's rotor.
• 移除先前安裝的試重。
• 在下一個平面安裝試重。

圖 23. 四平面動平衡校正工作區

After completing each measurement, the results of the rotor's rotation frequency (N_ob) 以及被平衡轉子旋轉頻率下的振動有效值 (V_o1，V_o2，V_o3，V_o4) 與相位 (F₁, F₂, F₃, F₄) of the vibration at the rotational frequency of the balanced rotor are saved in the corresponding fields in the program window. After the fifth run (Weight in Plane 4), the "Balancing Weights" workspace (see Figure 24) appears, displaying the calculated values of the masses (M₁, M₂, M₃, M₄) 與安裝角度 (f₁，f₂，f₃，f₄) 的計算值。

圖 24. 四個平面校正配重計算參數工作區

注意！ After completing the measurement process during the fifth run of the balanced machine, it is necessary to stop the rotor's rotation and remove the previously installed trial weight. Only after this can you proceed with installing (or removing) the corrective weights on the rotor.

The angular position for adding (or removing) the corrective weight on the rotor in the polar coordinate system is measured from the location of the trial weight installation. The angle measurement direction coincides with the rotor's rotation direction. In the case of balancing by blades, the blade of the balanced rotor conditionally considered as the 1st blade coincides with the trial weight installation location. The numbering direction of the blades indicated on the computer display follows the rotor's rotation direction.

In this version of the program, it is assumed by default that the corrective weight will be added to the rotor. This is indicated by the mark set in the "Add" field. If correcting the imbalance by removing the weight (e.g., by drilling) is necessary, set the mark in the "Remove" field using the mouse, after which the angular position of the corrective weight will automatically change by 180 degrees.

After installing the corrective weights on the balanced rotor, press the "Exit – F10" button (or the F10 function key on the computer keyboard) to return to the previous "Four-Plane Balancing" workspace and check the effectiveness of the balancing operation. After completing the verification run, the results of the rotor's rotation frequency (N_ob) 與有效值 (V_o1，V_o2，V_o3，V_o4) 與相位 (F₁, F₂, F₃, F₄) of the vibration at the rotational frequency of the balanced rotor are saved. Simultaneously, the "Balancing Weights" workspace (see Figure 21) appears over the "Four-Plane Balancing" workspace, displaying the calculated parameters of additional corrective weights that need to be installed (or removed) on the rotor to compensate for its residual imbalance. Additionally, this workspace shows the values of the residual imbalance achieved after balancing. If the values of residual vibration and/or residual imbalance of the balanced rotor meet the tolerance requirements specified in the technical documentation, the balancing process can be completed. Otherwise, the balancing process can be continued. This method allows for correcting possible errors through successive approximations that may occur when installing (removing) the corrective weight on the balanced rotor.

If the balancing process continues, additional corrective weights must be installed (or removed) on the balanced rotor according to the parameters specified in the "Balancing Weights" workspace.

The "Coefficients – F8" button (or the F8 function key on the computer keyboard) is used to view and save in the computer's memory the rotor balancing coefficients (dynamic influence coefficients) calculated from the results of the five calibration runs.

7. 剛性轉子推薦平衡精度等級

表 2. 剛性轉子推薦平衡精度等級。

剛性轉子推薦平衡精度等級

機器類型（轉子）	平衡精度等級	值 eper Ω mm/s
大型低速船用柴油機驅動曲軸（結構不平衡）（活塞速度低於 9 m/s）	G 4000	4000
大型低速船用柴油機驅動曲軸（結構平衡）（活塞速度低於 9 m/s）	G 1600	1600
安裝在隔振器上的驅動曲軸（結構不平衡）	G 630	630
安裝在剛性支撐上的驅動曲軸（結構不平衡）	G 250	250
裝配用於轎車、卡車及機車的往復式引擎	G 100	100
汽車零件：車輪、輪轂、車輪組、變速箱
安裝於隔振器上的驅動曲軸（結構平衡）	G 40	40
農業機械	G 16	16
安裝於剛性支撐上的驅動曲軸（已平衡）
破碎機
驅動軸（傳動軸、螺桿軸）
航空渦輪機	G 6.3	6.3
離心機（分離機、沉降機）
軸高至少 80 mm 的電動機與發電機，最大額定轉速達 950 min-1
軸高小於 80 mm 的電動機
風機
齒輪傳動
通用機械
金屬切削機床
造紙機械
泵浦
渦輪增壓器
水輪機
壓縮機
電腦控制傳動	G 2.5	2.5
軸高至少 80 mm 的電動機與發電機，最大額定轉速超過 950 min-1
燃氣與汽輪機
金屬切削機床傳動
紡織機械
音響與視訊設備傳動	G 1	1
研磨機驅動裝置
高精度設備的主軸與傳動	G 0.4	0.4

Frequently Asked Questions about Drive Shaft Balancing

What is drive shaft balancing?

Drive shaft balancing is the process of correcting any mass imbalance in a drive shaft so that it rotates smoothly without causing vibrations. This involves measuring where the shaft is heavier on one side and then adding or removing small amounts of weight (for example, welding on balancing weights) to counteract that imbalance. A balanced drive shaft runs evenly, which prevents excessive vibration and wear on vehicle components.

Why is drive shaft balancing important?

An unbalanced drive shaft can lead to strong vibrations, especially at certain speeds, and may cause clunking noises during acceleration or gear shifts. Over time, these vibrations can damage bearings, universal joints, and other drivetrain components. Balancing the drive shaft eliminates these vibrations, ensuring a smoother ride, reducing strain on parts, and preventing costly damage or downtime.

What are common symptoms of an unbalanced drive shaft?

The typical symptoms of an unbalanced or faulty drive shaft include noticeable vibration or shuddering felt in the vehicle floor or seat, particularly as speed increases. You might also hear knocking or rattling sounds when shifting gears or during acceleration and deceleration. In some cases, the universal joint may overheat due to imbalance. If you observe these signs, it's likely the drive shaft needs balancing or repair.

How do you balance a drive shaft?

Drive shaft balancing is usually done using a specialized balancing machine. The drive shaft is mounted and spun at high speed while sensors detect any imbalance. A technician then attaches small weights to the drive shaft (or removes material) at specific positions based on the machine's readings. This process is repeated until the drive shaft rotates without significant vibration. Modern systems like the Balanset-4 can guide this process and calculate exactly where and how much weight to add for precise balancing.

結論

In conclusion, proper drive shaft balancing is essential for safety, performance, and cost savings. By detecting and correcting imbalance, you prevent unnecessary wear on parts, avoid damaging breakdowns, and maintain optimal machine performance. Modern balancing systems like our Balanset-1 and Balanset-4 devices make the process efficient, helping even small workshops achieve professional results.

If you're facing persistent driveshaft vibrations or need a reliable balancing solution, don't hesitate to act. Apply the steps outlined in this guide or consult with our experts for assistance. With the right approach and equipment, you can ensure your driveshaft runs smoothly and reliably for years to come. Contact us to learn more or to explore the best drive shaft balancing equipment for your needs.