Field Balancing Tips

BY LANCE BISINGER, UNIVERSAL TECHNOLOGIES, INC.

Abstract
An unbalance condition has been confirmed on the machine; now it is time to conduct the balancing operation. This paper will provide you with time saving
techniques that take you outside the data collectors balancing program.

INTRODUCTION

Number of measurement planes

A common misconception that continues throughout industry is if the

machine is vibrating it must be out of balance. Many hours can be wasted
by attempting to balance a non balance machinery problem. By adopting a
systematic approach when asked to balance a machine, the analyst can
ensure that unbalance is truly the problem. Once performing the balancing
process, following these simple, but effective, tips can decrease the amount
of time spent.

A measurement plane is defined as the location where vibration data is

to be collected. One key point to remember is the number of measurement
planes must be greater than or equal to the number of weight planes.

THE BALANCING PROCESS

Visual Machine Inspection

Equipment setup
While most balancing programs will allow the user to place the sensor(s),
tachometer and reflective tape anywhere, giving some consideration of
where these items are placed can allow some timesaving measures to be
used during the balance.

Identification

Reflective tape
Lining up one edge of the reflective tape to a position that corresponds to
a blade, pin or a balancing ring set screw will assist in saving time when
conducting the balance. This can be further refined by understanding if your
balancing program triggers off the leading or lagging edge of the tape.

Collect data to confirm unbalance is the problem. Recall, unbalance is

defined as the center of mass is not at the center of rotation. It is
recommended that spectrum, waveform and phase data be reviewed for
confirmation.

Sensor(s)
Place your sensor(s) is the measurement orientation desired. Always
place your sensor(s) in the direction of highest 1x RPM amplitude.

One of the first steps that should be taken is a general visual inspection
of the machine. Look for loose hold downs, cracked structures, bearing
access for the vibration sensors, and rotating element access.

Spectrum
The spectrum characteristics should be as follows:
1. Vibration peak at 1x RPM of the component to be balanced.
2. 2x RPM should be < 50% of the 1x RPM amplitude.
3. Little or no multiples of running speed.
4. The ratio of horizontal to vertical amplitudes should not exceed 3:1.
5. 1x RPM in the axial direction should be < 50% of the 1x RPM radial
amplitude.

Photo tach
Configure your photo tach to strike the reflective tape at the same
position of your sensor. While this is not required to conduct the balance, it
does simplify the calculation used to estimate the trial weight position.

Waveform
The waveform characteristics should be as follows:
1. Sinusoidal shape.
2. Little or no impacting.

Trial Run
The trial run is used to solve for the system response to a known weight
being placed at a known location. All future balance solutions are based on
this information. As a general rule of thumb, the trial weight should cause a
30% change in vibration amplitude or a 30 shift in phase. If one of these
does not occur, then the trail run must be repeated. What if a calculation
could be done to estimate the location of the heavy spot?

Phase
When initially collecting phase ensure the averaging feature is disabled.
The phase characteristics should be as follows:
1. Steady phase within 5.
2. Phase shift when measuring horizontal to vertical is 90 20

THE BALANCING PROCESS

Reference Run
This is the as found condition of the component to be balanced.

Estimating the Heavy Spot

The heavy spot on the rotating component can be estimated using the
follow equation.

BALANCING SETUP
Number of weight planes
A weight plane is defined as the location on the rotating element where
weight will be added or removed. In most cases, a dual plane balance is
conducted on a rotating element that is center hung and a single plane
balance is conducted on a rotating element that is overhung. A ratio rule of
height to width is commonly used as a thumb rule to recommend which type
of balance is recommended. If the ratio of height to width is greater than or
equal to four, then a single plane balance should be adequate, otherwise a
dual plane balance is recommended. As with any thumb rule there are
exceptions, so evaluate the machine to be balanced.

378

RELIABILITY WORLD 2005 CONFERENCE PROCEEDINGS

Phase angle between vibration sensor and photo tach (reference). If the
sensor and photo tach where positioned as described earlier, then this
correction is 0. Otherwise, the angular difference must be accounted for in
the equation. Dont forget this must be determined based on whether the
balancing program used calculates this angle in the direction or opposite
the direction of rotation.
Measured phase
The phase measured during the reference run.

Amplitude units
The amplitude units used for the balance.
1. Displacement - 0
2. Velocity - 90
3. Acceleration - 180
System lag
The mechanical system lag is defined as the amount of lag that occurs
between the heavy spot passing the vibration sensor and the location the
sensor measures. If the system lag has not been determined, then it can be
estimated. If the rotating component is operating below its first critical,
then use 45. If the rotating component is operating above its first critical,
then use 135. Figure 1 shows the typical system response curve.

Weight addition
Adding weight is much easier. If nuts, washers, and bolts are used; they
can be weighed on any accurate scale. Dont forget to account for the
weight of spacers or washers in the correction weight to be added if they
will be removed Stick-on, Clip-on and C-clamp eights are also available.
Figures 2, 3 and 4 are pictures of the stick-on, clip weights and C-clamp
types respectively.

Figure 2. Stick-on Weights for Pulleys, Sheaves, and Automotive.

Figure 3. Balancing Clips for Squirrel Cage Fans.

Figure 1. Resonance Response Curve.

Correction Run - Weight Correction

The rotating component will dictate whether weight(s) will be added on a
continuous weight plane or added at discrete locates such as blades or
rods. The key is making any weight correction at the same radius used for
the trial weight location. Make sure that the trial weight is removed or
accounted for in the weight correction if left on.
Weight removal
It is difficult to know how much weight it being removed when drilling, so
tables have been established to assist. Grinding is even more difficult. One
procedure says to grind for 10 seconds with even pressure, and take a
reading. The amount of reduction of the weight callout can be related to the
grinding time for a rough calibration. When in doubt, always grind less than
needed. One can always grind more.

Figure 4. Balancing Clamps.

RELIABILITY WORLD 2005 CONFERENCE PROCEEDINGS

379

Welding correction weights

Sometimes it is necessary to replace the balancing clamps with more
permanent correction weights. Welding rod is often used to attach
permanent weights such as steel plate to a fan. If not allowed for the
weight of the weld deposited can cause errors in the correction.
To calibrate a rod:
1. Mark a couple of welding rods with chalk at 1 inch intervals.
2. Find a suitable piece of scrap steel and weigh it.
3. Ask the welder to weld 10 of rod on the scrap steel and remove the slag.
4. Weigh the plate again
5. Divide the difference in weight by 10 to get the amount of weight per
inch of weld.
6. Prior to applying a final weight ask the welder to estimate how many
inches of rod will be used to attach the weight. (Always estimate high)
7. Multiply the inches of rod by the weight per inch and reduce the size of
the correction weight by this amount.
8. Adjust the correction weight accordingly.
Be careful when welding weights to not overheat the rotor as this might
cause distortion and further unbalance the rotor.

at the CG of the temporary weight. The CG of any weight can be located by

balancing the weight in a knife-edge such as a steel rule clamped in a vise.
Trim Run
If the results of the first correction run do not meet the balancing criteria,
then further correction will be required. The most common problem
encountered during the trim run portion of the balancing process is
unsteady phase and/or solutions that ask for weight to be added
approximately 180 from the previous weight position. These are all good
indications that the influence coefficient needs to be recalculated or the
rotating component has been balanced to the limits achievable in its
current configuration.

Summary
The key to any successful balance is confirming the actual problem is
unbalance. Once this confirmation has been made through spectrum,
waveform and phase analysis, the process begins to determine if
modifications will be required to conduct the balance. Estimating the trial
weight location, weight addition/removal and placement of equipment are
tips presented to save time during the balance procedure.

References
When replacing the temporary weights with welded plate remember that
the effective radius and angle are located at the center of gravity of the
temporary weight. It is necessary to position the CG of the permanent weight

380

RELIABILITY WORLD 2005 CONFERENCE PROCEEDINGS

1. Maximizing Machinery ReliabilityPrecision Field Balancing, Universal

Technologies, Inc., Aspen Park, CO, 2000.