LECTURE 2 - FIELD BALANCING OF ROTORS Balancing of rotors in the field is necessary for the following reasons:

(i) the rotor would have been balanced in a commercial balancing machine running at 400 or 500 rpm, but
would be operating at a much higher speed of 3000 rpm. This may necessitate balancing afresh.

(ii) A heavy rotor which would have been operating at site for a long time and would have under gone
structural changes during shut down necessitating rebalancing at site.

(iii)

Some machines such as fans and blowers may develop unbalance as a result of erosion. All these cases necessitate the field balancing of rotors.

.2.1 Single Plane Balancing: Quite often we come across rotors whose diameter is large in relation to its length.(more than 2).These units can be treated as single plane plane. objects. The resulting unbalance can be assumed to be in the same same plane. Let us

As a consequence the balance weight can be assumed to be located in the

assume that the rotor is held overhanging from the

supports shown in Fig2.1. Let us assume that the

dynamic response at the support is linearly proportional to the unbalanced force. It can be measured using a vibration transducer. Let the reading be

a . Let us choose a known weight and fix it at a known

location on the rotor(hereafterwards called zero degree position). Let the reading be b . It may be noted that

a and b are complex quantities since the magnitudes and phases of these responses need not be the
o

same(Fig8.2). Let us take the same known mass and place it at a location 180 away from the earlier

c . They are shown vectorially in Fig.2.2.3. OA represents a , OB represents b and OC represents c . Let AD be equal to
position.(hereafterwards called 180 degree position). Let the reading be

OA . It is easy to visualise that the quadrilateral OCDB is a parallelogram. Since OA is equal to AD and
AC is equal to AB. AC and AB are the effects of the same known mass and hence their magnitudes must be the same. In the triangle OCB, since OA is the meridion, one can express AB as
AB =

( OC 2 + OB 2 ) / 2 +OA 2

( c2 +b 2 ) / 2 a 2

(2.1)

If the figure drawn is correct, using cosine rule one can write

OA 2 + OB 2 AB 2 a 2 + b 2 AB 2 cos 1 = = 2(OA )(OB) 2ab

Mathematically the two admissible solutions are 1 and 2. Similarly

(2.2)

a 2 + c 2 AC 2 cos 2 = 2ac

(2.3)

To find out which one of the two is correct ,we can take the fourth reading by shifting the known mass to 90 degree position .If 1 is correct, OE should be the reading and if 2 is correct, OF will be the correct reading. With these four readings the system can be balanced. Example 2.1: Compute the magnitude and location of the balance weight needed to balance a rotor in the field using the single plane balancing technique. Trial mass tried is weighing 100N at a radius of 1 meter. Vibration reading at the support = 10mm/sec. Known mass at 0 location = 12 mm/sec. Known mass at 180 location = 14mm/sec. Known mass at 90 location = 2.2mm/sec. Fig.2.3 gives the relative positions.
AB = ( 196 +144) / 2 100 = 70 = 8.36
o o o

cos 1 = ( a 2 + b 2 70) / 2 ab = (100 + 144 70) / 240 = 174 / 240

Hence 1 =43.53
o

From Eq(8.5) cos 2=(100+196-70)/(280). Hence 2=36.18 cos =(144-70-100)/(28.3610)= -0.155 hence =99 . hence OE =10 +(8.36) -2108.36cos 99=4.85 Hence OE=2.2 This is the recorded measurement also. Otherwise it would have been OF. The correction weight needed is 10/8.36 times the trial mass and is to be placed at a radius of 1meter at a location 99 from zero degree position in the counterclockwise sense. In the foregoing discussion it was indicated that four trials were needed to locate the phase and magnitude of the correct weight. If the phase angles can be directly measured, one of trials can be saved. .2.2 Two Plane Balancing: If the rotor has a length comparable to the diameter( more than 0.5 times the diameter) it is not correct to assume that the balancing can be done by adding masses in one unique plane. Then two plane balancing becomes a necessity. This is usually done by the seven run method. The format for the seven run method is indicated in Table(2.1)
2 2 2 o

Table2.1 Format for the seven run method run 1 2 3 4 5 6 7 trial weight nil near end 0 180 90
o o o o

near end amplitude AL1 BL1 CL1 DL1 BL2 CL2 DL2

far end amplitude AR1 BR1 CR1 DR1 BR2 CR2 DR2

far end 0 180 90

o o

Let the two planes in which the trial weights are added be referred to as near end and far end planes and the two locations where the measurements are made (which are usually the left and the right bearings) be referred to as the left and the right side.(Fig 2.4)The readings obtained are tabulated in Table2.1. The following information as contained in Table2.2 is to be extracted from Table2.1. From the logic adopted for single plane balancing one can visualise L 0 and R0 are the same as AL1 and AR1. The readings BL1,CL1 and DL1 will help in locating L 1 and BR1, CR1. And DR1 will locate R 1. Similarly the other six readings will be used to determine L2 and R2.

Table 2.2 Six vectors for two plane balancing Run trial wt. Near end amplitude 1 2 3 0 W plane 1 W plane 2 L
0

phase

far end amplitude

phase

R0 R1 R2

0 1 2

L1 L2

1 2

These are shown in Fig8.7. It is seen from this figure that the effect of trial weight in plane1 on the first

A A bearing is (represented as a complex quantity ),on the second bearing . Similarly the effect of the B . It may be noted that and trial mass in plane 2 on the right bearing is B and on the left bearing
have to be real numbers whose magnitudes have to be less than 1. This is because they must be equal to the ratios of distances of planes of balance from the left and right side supports which in all cases will be

less than 1. If the final solution to the problem is in the form of times the trial weight in plane 1 and times the trial weight in plane2 (both and complex numbers) the solution can easily be written as

L o + A + B = 0 R o + A + B = 0
Hence

(2.4)

L o B Ro B ( L o + R o ) B = = A B AB( 1 ) A B
Similarly

(2.5)

( L o R o ) A = AB( 1 )

(2.6)

The main advantage of the seven run method is that no phase angle measurement is needed. The technique is easy to use and no sophisticated measuring equipment other than the vibrometer is needed. This will be explained through an example. Example 8.2 The readings obtained by the seven run method are shown in Table 2.3 Compute the balancing mass needed in both the planes for complete balance. Table 2.3 readings by seven run method run 1 2 3 4 5 6 7 near end (mm/sec) 10.0 15.9 5.4 8.9 8.5 14.3 5.8
0

far end (mm/sec) 16.4 18.3 14.5 16.8 19.4 17.9 7.6

Let us assume that Lo=10 0 . Obviously L1= 15.9 and L2=8.5. Similarly Ro=16.4, R1=18.3 and R2=19.4. The phase angles corresponding to L1, L2, Ro,R1 and R2 have to be determined. Referring to Fig8.8 one can observe

A=

5.4 2 + 15.9 2 10 2 = 6.4272 2

15.9 2 + 10 2 6.4272 2 cos 1 = 2 15.9 10

Hence 1=11.6 Now L1= 15.9 11.6
o

Hence A=L1-Lo=6.4272 30 . Similarly

A =

14.5 2 + 18.3 2 16.4 2 = 1.9 2

cos 1 =

18.3 2 + 16.4 2 1.9 2 2 18.3 16.4

Hence 1=0 . A=1.9 30

o

=1.9/6.4272=.3

A
But

must have the same phase angle as

A since the ratio between them must be a number less than 1.

A = R 1 R o = 18.330 o 16.430 o = 1.930 o

Since A has a phase angle 30 R1 and R2 must have the same phase angle. Referring to Fig 8.8 likewise we observe

B =

8.53 2 + 14.3 2 10 2 = 6.21 2

19.4 2 + 17.9 2 16.4 2 = 8.91 2

B=

Hence =6.21/8.91=.7 Likewise 2=38.12

o

cos 2 =

8.53 2 + 10 2 6.212 20 8.53

B =8.53 38.15 o 10 0 o = 6.21 122 o

B = 19.4 2 16.430 o = 8.91122 o

Hence B = 19.4 57.11o

=0.21 Hence

R o L o A( 1 )

= 0.82 32.6 o = 2.73 185.87 o

L o R o B( 1 )

C PROG. 12 C-------------------------------------------------------------------C PROGRAM TO COMPUTE THE UNBALANCED FORCE FOR TWO PLANE BALANCING C METHOD WITH 7 TRIAL RUNS C Ref:-'TWO PLANE IN-SITU BALANCING' ,V.RAMAMURTI,K.ANANTARAMAN, C JSV(1989),134(2),pp 343-352 C---------------------------------------------------------------------C READINGS WITH LOADS ON PLANE 1 C AL1,AR1---READINGS ON THE LEFT & RIGHT BEARINGS WITH NO WTS. C BL1,BR1---READINGS WITH TRIAL WEIGHT AT 0 DEGREE POSITION C CL1,CR1---READINGS WITH TRIAL WIEGHT AT 180 DEGREE POSITION C DL1,DR1---READINGS WITH TRIAL WEIGHTS AT 90 DEGREE POSITION C (4TH RUN IS FOR CHECK) C READINGS WITH LOADING IN PLANE 2 C BL2,BR2---READINGS WITH TRIAL WEIGHT AT 0 DEGREE POSITION C CL2,CR2---READINGS WITH TRIAL WIEGHT AT 180 DEGREE POSITION C DL2,DR2---READINGS WITH TRIAL WEIGHTS AT 90 DEGREE POSITION C NOTATIONS ARE ALL IN THE ANTICLOCKWISE SENSE C---------------------------------------------------------------------IMPLICIT REAL*8(A-H,O-Z) REAL L0,LAMBDA,MU,LAM_ANG,MU_ANG CHARACTER*32 INPFILE,OUTFILE COMMON PI PI=4*ATAN(1.0) con=PI/180 WRITE(*,*)'ENTER THE INPUT FILE NAME' READ(*,*)INPFILE WRITE(*,*)'ENTER THE OUTPUT FILE NAME' READ(*,*)OUTFILE OPEN(15,FILE=INPFILE) OPEN(16,FILE=OUTFILE) READ(15,*)ICHOICE IF(ICHOICE.EQ.1)THEN WRITE(16,*)'----------------------------------------------------' WRITE(16,*)' SINGLE PLANE BALANCING:' WRITE(16,*)'----------------------------------------------------' READ(15,*)AL1

READ(15,*)BL1 READ(15,*)CL1 READ(15,*)DL1 ENDIF IF(ICHOICE.EQ.2)THEN WRITE(16,*)'----------------------------------------------------' WRITE(16,*)' TWO PLANE BALANCING:' WRITE(16,*)'----------------------------------------------------' READ(15,*)AL1,AR1 READ(15,*)BL1,BR1 READ(15,*)CL1,CR1 READ(15,*)DL1,DR1 READ(15,*)BL2,BR2 READ(15,*)CL2,CR2 READ(15,*)DL2,DR2 ENDIF C---------------------------------------------------------------------C gamma_A is the inclination of A with L0(OR AL1) C gamma_aA IS THE INCLINATION OF aA WITH R0(OR AR1) C gamma_R IS THE INCLINATION OF R WITH L0 C gamma_B IS THE INCLINATION OF B WITH R0 C---------------------------------------------------------------------CALL SOLVE(AL1,BL1,CL1,A,gamma_A) CALL RUN4(AL1,BL1,CL1,DL1,A,gamma_A) IF(ICHOICE.EQ.1)THEN L0=AL1 LAMBDA=L0/A unbal_ang=(PI-gamma_A)/con WRITE(16,6)unbal_ang WRITE(16,2) WRITE(16,5)LAMBDA GOTO 10 ENDIF CALL SOLVE(AR1,BR1,CR1,aA,gamma_aA) CALL RUN4(AR1,BR1,CR1,DR1,aA,gamma_aA) gamma_R=gamma_A-gamma_aA CALL SOLVE(AR1,BR2,CR2,B,gamma_B) CALL RUN4(AR1,BR2,CR2,DR2,B,gamma_B) C CONVERTING THE gamma_B W.R.TO L0 gamma_B=gamma_B+gamma_R CALL SOLVE(AL1,BL2,CL2,bB,gamma_bB) CALL RUN4(AL1,BL2,CL2,DL2,bB,gamma_bB) C gamma_B &gamma_bB should be the same beta=bB/B alpha=aA/A L0=AL1 R0=AR1 C---------------------------------------------------------------------C THE SYSTEM WILL BE IN BALANCE WITH LAMBDA TIMES THE TRIAL MASS C IN PLANE1 & MU TIMES THE MASS IN PLANE2 C NOTE:-L0,R0,A,B ARE VECTORS C LAMBDA=(-L0+R0*beta)/(A*(1-alpha*beta)) C MU=(-R0+L0*alpha)/(B*(1-alpha*beta))

C---------------------------------------------------------------------C=-L0+R0*beta*COS(gamma_R) S=R0*beta*SIN(gamma_R) CALL POLAR(C,S,R1,theta_Lam) LAMBDA=R1/(A*(1-alpha*beta)) lam_ang=theta_lam-gamma_A C1=L0*alpha-R0*COS(gamma_R) S1=-R0*SIN(gamma_R) CALL POLAR(C1,S1,RR1,theta_mu) MU=RR1/(B*(1-alpha*beta)) mu_ang=theta_mu-gamma_bB A_INC1=(lam_ang-gamma_A)/CON A_INC2=(mu_ang-gamma_A)/CON IF(A_INC1.GE.360)A_INC1=A_INC1-360 IF(A_INC2.GE.360)A_INC2=A_INC2-360 WRITE(16,1)A_INC1 WRITE(16,3)A_INC2 WRITE(16,2) WRITE(16,7)LAMBDA WRITE(16,4)MU 10 WRITE(16,*)'----------------------------------------------------' 1 FORMAT(2X,'PHASE ANGLE OF LAMBDA W.R.TO THE 0 degree POSITION * =',F11.5) 2 FORMAT(2X,'THE WEIGHTS TO BE ADDED TO REMOVE THE UNBALANCE IS:') 3 FORMAT(2X,'PHASE ANGLE OF MU W.R.TO THE 0 degree POSITION * =',F11.5/) 4 FORMAT(2X,'MU =',F11.5,'*TRIAL MASS IN PLANE1'/) 5 FORMAT(2X,'LAMBDA=',F11.5,'*TRIAL MASS') 6 FORMAT(2X,'PHASE ANGLE OF LAMBDA W.R.TO 0 degree POSITION IS:', * F11.5/) 7 FORMAT(2X,'LAMBDA=',F11.5,'*TRIAL MASS IN PLANE 2') STOP END C---------------------------------------------------------------------SUBROUTINE SOLVE(A0,A1,A2,A,theta) C---------------------------------------------------------------------IMPLICIT REAL*8(A-H,O-Z) COMMON PI A=DSQRT((A1**2+A2**2)/2-A0**2) theta=ACOS((A0**2+A**2-A1**2)/(2*A0*A)) RETURN END C---------------------------------------------------------------------SUBROUTINE POLAR(C,S,R,theta) C---------------------------------------------------------------------IMPLICIT REAL*8(A-H,O-Z) COMMON PI R=DSQRT(C**2+S**2) theta=ATAN(S/C) IF(C.LT.0)THETA=PI+theta RETURN END C---------------------------------------------------------------------SUBROUTINE RUN4(OA,OB,OC,OD,AB,theta) C---------------------------------------------------------------------IMPLICIT REAL*8(A-H,O-Z)

COMMON PI theta1=theta-PI/2 OD1=DSQRT(OA**2+AB**2-2*OA*AB*cos(theta1)) error1=abs(OD1-OD) theta2=theta+PI/2 OD2=dsqrt(OA**2+AB**2-2*OA*AB*cos(theta2)) ERROR2=ABS(OD2-OD) IF(ERROR1.LE.ERROR2)THEN theta=PI-theta ELSE theta=PI+theta ENDIF RETURN END EXAMPLE 8.2 INPUT FILE:2 10 16.4 15.9 18.3 Fig 2.1 Over hanging disc 5.4 14.5 8.9 16.8 8.5 19.4 14.3 17.9 5.8 7.6 OUTPUT FILE:---------------------------------------------------TWO PLANE BALANCING: ---------------------------------------------------PHASE ANGLE OF LAMBDA W.R.TO THE 0 degree POSITION PHASE ANGLE OF MU W.R.TO THE 0 degree POSITION THE WEIGHTS TO BE ADDED TO REMOVE THE UNBALANCE IS: LAMBDA= 1.09265*TRIAL MASS IN PLANE 2 MU = 1.96269*TRIAL MASS IN PLANE1 ----------------------------------------------------

= =

32.16496 63.71981

B E 90o O A F

C Fig 2.2 Single plane balancing

Measuring plane

Measuring plane

Near end plane l1 l4 l2 12

Far end plane B l3

Fig 2.4 Two plane balancing =l1/l2,=l /l 90o 3 4 E 2.2 A O 10 14 L2 C Fig L 2.3 Single plane balancing
1

R2 R1

(2-0) 1 L0 Fig 2.5 Two plane balancing (1-0) R0

L1=15.9<11.6o A=6.42<30.33 R1=18.3<36.330 RA

L0=10<0 R-0=16.4<30.330

Fig 2.6 Trial weight plane I

L2=8.53<38.12
o

B=6.21<12 20 580

R2=19.4<57.1

B=8.9<1220

38.12o L0=10<0

R0=16.4<300 Fig 2.7 Trial weight plan II