Beruflich Dokumente
Kultur Dokumente
Single-plane balancing
The ISO standard 1925 [3] defines single-plane balancing as "A procedure by which the mass distribution of a rigid rotor is adjusted in order to ensure that the residual static unbalance is within specified limits". As a rule single-plane balancing is necessary and sufficient for disc-shaped rotors, provided the disc is accurately mounted perpendicular to the shaft axis and any variations from the design and construction drawings are small.
Figure 3.1: The disc-shaped rotor mounted with minimum axial swash motion (A and B) requires only single-plane balancing. Rotors with mounting errors similar to (C and D) exhibit unacceptable moment unbalance and must be balanced in two planes.
Limiting parameters by which a rotor can be defined as disc-shaped or limit values for permissible variation from the construction drawings cannot be specified. In case of any doubt, the residual fundamental frequency vibrations at both bearings of the rotor should be examined after single-plane balancing to assess whether single-plane balancing is sufficient, or a higher quality balancing procedure should be used as described in chapters 4 and 5.
In the following section single-plane balancing is explained using an example. In this regard the preconditions, preparations and advice given for unbalance measurement and unbalance correction are of a general nature and can be used for any machine and any rotor.
3.1
Before starting single-plane balancing, the following points should be especially noted:
A=S
S ua A1 A2 ua2
ua1
A=S
A A . Correction planes ua1 = ua x d__ c+d c__ c+d
A1
A2
ua2 = ua x
Figure 3.2: For single plane balancing the unbalance correction should be done in the same radial plane as the centre of gravity (A), or the correction mass uA can be divided and applied at any two other radial planes Al and All (B).
A ua
A ua
Figure 3.3: Single-plane balancing using correction plane A-A and measuring point "1"
Permanent magnet
Figure 3.4: Some possible methods for mounting the electro-dynamic or piezoelectric sensor at the measuring point.
Depending on the type of reference mark chosen, and if the balancing instrument requires the trigger to be set, the following appropriate trigger setting should be selected at the balancing instrument:
Positive
90 % (or 5'1 %)
90
= in-coming light mark = 1/4 revolution opposite to rotation direction = out-going dark mark =1/4 revolution opposite to rotation direction
Negative
10 % (or 50 %)
0 90 t
?
Figure 3.5: Reference marks, balancing instrument settings and angle references when using a photo-electric sensor
If the reference signal trigger is set up as described in Fig. 3.5, an angle reference, which is important for later transferring the actual position of the measured angle on the rotor, will be established between the balancing instrument and the rotor to be balanced as shown in Figures 3.5 and 3.6.
0 270 90 180
Figure 3.6: Establishing the angle and speed reference with a photo-electric sensor and a reference mark (reflective tape).
It is important that the reference sensor delivers only one impulse for each revolution of the rotor (i.e. there is only one reference mark on the rotor), and that this impulse is clearly prominent. The speed display at the balancing instrument indicates whether the reference impulse is adequate and the reference sensor is correctly aimed at the reference mark. If the speed display is steady and constant when the rotor speed is constant, it is safe to assume there is a good clear reference signal. The circumferential position of the reference mark is not important. However its position on the rotor should not be changed during balancing.
Figure 3.7: Start-up/run-down curve of the machine to be balanced (see Basic Vibrations seminar). A balancing speed in the resonance range (shaded) should be avoided if possible.
The trial weight must be large enough to cause a clear, measurable change (> 25% in amplitude and/or 30 in angle) in the unbalance value. The actual mass cannot be determined in advance, and therefore it is recommended that a variety of trial weights be prepared. If there has been no previous experience with the rotor, the mass of the trial weight can be made up using the following "rule-of-thumb" formula (this should be used with circumspection and is not a rigid rule):
trial
= 30 x M rotor R trial
where M trial M rotor R trial = Mass of the trial weight, in g = Rotor mass in kg = Radius at which the trial weight will be added, in mm
A larger trial weight than the one calculated using this formula may be necessary in the case of heavy, slow-running machines, while a considerably smaller trial weight may be adequate for machines with a lower dynamic stiffness or in the case of high-speed machines. The simplest way to find out if the trial weight is adequate or if the mass should be changed is by carrying out a test run. In some cases during the trial run it is found that because the initial vibrations are reduced, the trial weight can be used as a correction weight and therefore can remain permanently on the rotor. It is simpler for the trial weight and correction weights to be effected by the addition of mass to the rotor instead of removal by drilling or grinding. Apart from the fact that weight addition is more accurate, weight removal should only be used when weight addition is not possible, e.g. for reasons of safety.
3.2.1 Arrangement
An external view of the layout and construction of the fan which had a constant service speed of n = 2,200 rpm is shown in Fig. 3.8.
Figure 3.8: External view (left) and construction diagram (right) of the unbalanced fan. The measuring plane "1" and correction plane 'A" are indicated.
Because the width of the fan was small in relation to the diameter, and therefore it was considered near enough to a disc-shape, it was assumed that single-plane balancing would be sufficient to reduce the unbalance of the rotor and therefore the fundamental frequency vibrations at each bearing plane
to permissible values.
3.2.2 Preparations
After bringing the portable balancing instrument to the fan, the angle and phase reference was established. A piece of self-adhesive, reflective tape was attached to the outside edge of the pulley and the rotational direction marked. Using a magnetic stand the photo-electric reference sensor was mounted and adjusted so that the light of the lamp reflected by the reflective tape would be directly detected by the photo-diode.
Figure 3. 9: The portable balancing instrument is brought to the fan and set up ready for use on a suitable work surface. (new pic with VT60?)
In addition a vibration sensor was mounted using a mounting magnet at the prescribed measuring plane. In this case a piezo-electric acceleration sensor was used, but the same results would also be obtained if an electro-dynamic vibration sensor were used. The reference sensor and vibration sensor were then connected to the balancing instrument using the appropriate cables.
Figure 3.10: The reference mark attached to the pulley and the photo-electric sensor mounted in the magnetic stand (left). The piezo-electric acceleration sensor mounted using a mounting magnetic stand.
Figure 3.12: The position of the initial unbalance vector marked on the diagram with an X
The closest available trial weight amounted to 40 g. This weight was attached to the back plate of the fan at an angle of 0, the fan started and again run at the service speed. The new unbalance vibrations were measured and the balancing report automatically updated.
Figure 3.13: Clamp-on trial weights for attaching in the correction plane of the rotor (new pic with VT60)
Figure 3.14: Due to the trial weight the unbalance vibrations of 7.8 mm/s at an angle of 50 changed to 6.6 mm/s at an angle of 160.
First the initial unbalance angle position (50) is marked as a thin line, and on this line, which radiates outward from the origin of the coordinate, the amount of the initial unbalance vibration (7.8 mm/s rms) is entered using any arbitrary scale. With a scale of 10 mm = 2 mm/s rms, the initial unbalance vector is 39 mm long. The unbalance vibration of 6.6 mm/s rms at 160 measured in the test run is entered in the same way using the same scale, i.e. on a line at 160 an amount of 6.6 mm/s = 33 mm is entered on the coordinate diagram.
Test run with a 40g test mass at 0 6.6 mm/s at 160 Test run 180 Correction mass at 32 (0 + 32 ): ua = 40 g (b) 39 mm = 26.5g (a) 59 mm
a b
target 270
41
The initial unbalance position is joined with the test run position and an arrow is drawn in the direction of the test run position because the changed occurred in this direction. This line is called the trial vector To. Whenever a trial weight or correction weight is added to the rotor at the 0 angular position, the unbalance will change in the direction of the trial vector To. A trial weight with double the mass will result in a vector twice as long, and a trial weight half the mass will result in a vector half as long. This relationship is exhibited by the mass scale which is given by the quotient of the length of the trial vector (= 59 mm) and the size of the trial weight (M trial = 40 g). Mass scale = Trial weight = Trial vector 40 g = 0.68 g_ 59 mm
mm
To completely balance the rotor, the initial unbalance position must be moved to the origin of the diagram (target). This can be achieved if the trial vector is rotated by an angle of 32 in an anti-clockwise direction, and its length is reduced to the length of the original initial unbalance vector.
In terms of unbalance correction, this means that at the rotor
a correction weight with a mass ua = 39 mm x 0.68 g/mm = 26.5 g must be added at an angle of 32. An observation: There is a fixed relationship between the angle division of the rotor and the angle division on the diagram. Each shift of a trial weight or correction weight in a positive angular direction (e.g. from 0 to 32 or from 270 to 45) results in a counter-clockwise rotation of the respective trial or correction vector and vice versa.
of the statistical correction weight. The corresponding result for the "fan" example is displayed in the report print-out in Fig. 3.16.
Figure 3.16: The calculated mass and phase angle of the required correction weight are given by the instrument
Figure 3.17: Part 4 of the balancing report The initial unbalance vibration of 7.8 mm/s at 50 has been reduced to 0.62 mm/s at 334 by the first correction weight. A further improvement is possible by addition of the recommended correction weight.
This trim correction can be done as many times as necessary, although as a rule only one or two corrections are required. With single-plane balancing the unbalance correction ratio with one correction step is between 7:1 and 20:1 under normal circumstances.
Figure 3.18: After completion of the entire balancing procedure a detailed report with all the measurement results and correction steps is available in digital and graphic form. (new pic with VT60)
3.3
Balancing tolerances
The objective in balancing is not to strive to achieve a "perfectly balanced rotor"; rather to achieve and maintain a technically permissible and economically sensible balancing tolerance. There are two methods of evaluating the balancing quality and answering the question about the required balancing tolerance.
By making a comparison between the residual unbalance displayed by the balancing instrument and the permissible limit value recommended by VDI 2060 or ISO 1940, it is possible to determine whether the recommended tolerance has been reached.
Figure 3.19: Permissible residual unbalance dependent on the maximum service speed for various balance quality grades G [4]
Rotor or machines. Examples Crankshaft drives of rigidly-mounted slow marine diesel engines with uneven number of cylinders Crankshaft drives of large rigidly-mounted two-cycle engines Crankshaft drives of rigidly-mounted slow marine diesel engines with uneven number of cylinders Crankshaft drives of large rigidly-mounted two-cycle engines Crankshaft drives of rigidly-mounted four-cycle engines Crankshaft drives of soft-mounted marine diesel engines Crankshaft drives of rigidly-mounted fast four cylinder diesel engines Crankshaft drives of fast diesel engines with six or more cylinders. Complete engines (gasoline or diesel) for cars, trucks and locomotives Car wheels, rims, wheel sets, drive shafts. Crankshaft drives of soft-mounted fast four-cycle engines (gasoline or diesel) with six or more cylinders. Crankshaft drives for cars, trucks and locomotives Driveshafts with special requirements. Parts of crushing and agricultural machines. Components of car, truck, locomotive engines. Crankshaft drives of six and more cylinder engines with special requirements
G 1600
1600
G 4000
4000
G 1600
1600
G 630
630
G 250
250
G 100
100
G 40
40
G 16
16
G 2,5
2,5
G1
Rotors or machines. Examples Parts of process plant machines. Marine main turbines (merchant service). Centrifuge drums Fans. Assembled aircraft gas turbine engines. Fly wheels. Pump impellers. Machine tool and general machinery parts. Normal electrical armatures. Components of engines with special requirements. Gas and steam turbines incl. marine main turbines (merchant service). Rigid turbo-generator rotors Computer storage drives and discs. Turbo-compressors. Machine tool drives. Medium and large electric armatures with special requirements. Small electric armatures not covered by G 6.3. Turbine-driven pumps. Tape recorder and phono drives Grinding machine drives Small electric armatures with special requirements Spindles, discs, and armatures of precision grinders Gyroscopes
G 0,4
0,4
3.3.1.1
After the first correction step the fan in chapter 3.2 has a residual unbalance of u = 2.1 g (see Fig. 3.17) at a correction radius of r = 500 mm. The rotor mass m = 420 kg. The maximum service speed n = 2,200 rpm. Has the permissible residual unbalance according to VDI 2060 or ISO 1940 been achieved, or is a further correction step necessary? Solution: The fan rotor is classified in quality grade G 6.3. At a service speed of n = 2,200 rpm, the permissible residual unbalance is
eper = 25 g mm kg
The actual achieved residual unbalance is calculated as
eres eres
ures * r m
2.1 g * 500 mm 420 kg
eres
2.5 g mm kg
This value is within the unbalance tolerance recommended by VDI 2060 and ISO 1940 and therefore a further correction step is not necessary.
g mm kg
G 6,3
20 10
G 2,5 G 1,0
G 0,4
0,2
30
50
100
200
500
1000
2000
5000 10000
Figure 3.22: Determining the permissible residual unbalance for the fan using the nomogram in Fig. 3.19
can be measured. Methods of measurement, measured variables and evaluations standards for this method are extensively described in the Basic Vibration seminar.
3.3.2.1
On the fan in chapter 3.2, the unbalance vibrations at the measuring point " 1" (left bearing) had a vibration velocity value of V rms = 0.62 mm/s
Has the achieved balance quality resulted in a machine condition which has reached the evaluation limit of "good" as described by VDI 2056, is a further correction step required, or are other measures necessary to improve the machine condition? To be able to answer these questions, the "rms value of vibration velocity" of the absolute bearing vibrations in the frequency range 10 to 1,000 Hz must be measured respectively in the horizontal, vertical and axial directions at both bearings of the fan. In the case of the fan in this example, the axial vibrations at the right-hand bearing have to be ignored because this measuring point is not accessible. The vibration velocity values measured at all the remaining points are listed in Fig. 3.24.
2 3
Figure 3.23: Vibration measuring points on the fan to evaluate the machine condition according to VDI 2056
Measuring points
Figure 3.24: Measured values at the vibration measuring points in Fig. 3.22.
The largest measured value of vibration severity on the machine is vrms = 1.0 mm/s This value is compared to the limit value of the VDI guideline 2056 for the evaluation. By definition the fan, which is driven by a 50 kW motor, is classified in the machine group M. In this class the evaluation step "Good" includes all vibration severity values lower than vrms < 1.1 mm/s.
Therefore the vibration behavior of the fan can be regarded as "good" and further balancing is not necessary. ISO 10816, Group 2: Medium sized machines with power ratings aver 15 kW to 300 kW; electrical machines with shaft height 160 mm > H <315 mm
Sub-group
Evaluation
zones
A
rigid
B C D
37 71 113
flexible
B C D
Measured vibration: vrms = 1.0 mm/s Limit value Group 2 - DIN ISO 10816-3 vrms = 1.4 mm/s
Figure 3.25: Limit values for evaluating mechanical vibrations of machines according to ISO 10816
3.4
Repeat balancing
With many rotors a one-time balance is sufficient for the rotor to maintain the unbalance within a permissible limit for many years. However if the rotor is subject to a lot of wear as in the case of grinding discs, atomizer discs and impact pulverisers, or has a deformation or material build-up tendency such as ventilators, blowers and air separators, a regular check and trimming of the unbalance may be necessary. To be able to evaluate the unbalance faster, and therefore more cost-effectively in the case of this type of repeat balancing task, modem balancing instruments offer the possibility to store the rotor data - so-called influence coefficients - at the close of a balancing task. The relationship between unbalance and vibration is contained in this rotor data, namely for the particular machine at the selected balancing speed. If balancing is done with stored rotor data it is important that the same machine is being balanced and the machine has not undergone any changes between the first and the repeat balance, the machine supports should not have changed, the same balancing speed is selected, measurements are taken at the same point and in the same direction, the same type of vibration sensor is being used,
the position of the reference sensor must be the same, the position of the reference mark on the rotor must be the same and unbalance correction is made in the same correction plane.
If these preconditions are met, the test run and the addition of trial weights can be waived. The instrument displays the mass and phase angle of the required correction weight after the first measuring run (which it regards as a check run because stored rotor data is being used). Any number of further check runs can be made to reduce the unbalance, as described in chapter 3.2.8, because the computer has access to the stored data to make the necessary calculations. Therefore using this method of balancing with stored rotor data the unbalance of the rotor can be measured and determined without switching the respective machine off or any other mechanical work such as removing the covers to add trial weights for a test run.
3.5
Although field balancing normally proceeds according to the descriptions in chapters 3.1 to 3.4, special cases can sometimes occur in practice which require a deviation from the standard procedure.
If this is not the case, it can be deduced that the rotor exhibits an amount of moment unbalance which cannot be ignored and which requires a two-plane balancing procedure for correction. Fig. 3.27 shows a graphic case of this type. The unbalance vibrations at either bearing 1 (case A) or at bearing 2 (case B) can be reduced to "zero" by single plane balancing, or they can be optimized at both bearings (case C). But they cannot be eliminated at both bearings simultaneously by a single-plane balancing procedure. In this case this can only be done using a two-plane balancing procedure.
Figure 3.27: An example where the unbalance vibrations at either bearing 1 (case A) or bearing 2 (case 8) can be eliminated or can be optimized (case C) by single-plane balancing
loose parts on the rotor or a loose inner race of a rolling-element bearing, disturbing vibrations of almost the same frequency as the unbalance vibrations, e.g. from rotors with a small difference in rotational speed, the magnetic field in asynchronous machines, or from adjacent machinery.
Depending on the cause of the variation, the graphic display can either jump or have a circling motion. When there is a circling motion, this is caused by a beat vibration where the frequency of the circling motion is the difference between the frequency of the unbalance vibration and the disturbance vibration. Good quality balancing instruments have a capability of statistical averaging to permit successful balancing even when unstable vibrations occur. After selecting the corresponding algorithm, the average value of a number of measurements taken during one measuring run is calculated and displayed. In the case of a circling motion, this results in a steady, constant display which is at the center of the circular motion. This averaging process provides the precondition for calculating the correct balancing mass and angle, i.e. a relatively steady and constant measurement.
Figure 3.28: A vector diagram of the unbalance vibration display when a beat vibration exists. a) Without averaging: a circling display. b) During averaging: a spiral-shaped approach to the center point. c) After successful averaging: a steady, constant display.
If this is not the case, the reasons for the non-repeatability could be, amongst others: loose mounting of the machine on the workshop floor, on wooden blocks or wedges (see chapter 3.1.6), loose foundation bolts or clamps, wandering unbalance, i.e. moving from one run to the next (e.g. caused by machining or casting particles in a hollow roll), thermal influence which leads to deformation of the rotor and resulting changes in unbalance, a loose bearing inner race which causes a change in rotational axis from one measuring run to the next.
If the difference between the individual measurements is large (> 20%), the causes of the non-repeatability must be traced and eliminated. If this is not possible, new types of balancing instruments can store the measurements from a number of separate measurement runs, e.g. 1 to 9, and automatically calculate the average value from all measurement runs. An attempt is then made during balancing to reduce this average value to the point of origin of the coordinate. The calculation of the correction mass is then exclusively based on the average value. The scatter in the measured values will still be present after unbalance correction but will be confined to a region around the center of the coordinate origin. Thus the vibration behavior of the machine will be improved overall, and the optimum achieved under the circumstances.
Figure 3.29: With non-repeatable measured values, the measurements from a number of individual measurement runs (7 to 9) can be stored and the average value (M) calculated
Graphic and computerized methods of field balancing presuppose a linear behavior of the system to be balanced. Linear in this sense means that the trial vector change is proportional to the change in amount and phase of the trial weight. As a rule most machines are linear in behavior, but there are cases in which the relationship between unbalance and unbalance vibrations is to a large extent not linear. Normally the cause of this is in the rotor bearings or the support structure of the machine. Machines which are installed on rubber-to-metal bonded supports or machines equipped with bearings mounted in rubber for the purpose of constructional vibration isolation especially exhibit a non-linear behavior. As far as balancing is concerned, non-linearity means that a standard computerized or a graphical solution will not succeed. The most modern instruments available today have a sub-function within their balancing programs that can be selected to automatically compensate for non-linear rotor behaviour during balancing. When such a sub-routine is selected in the program, the initial stages of the program function as normal. Initial runs to determine the unbalance condition before balancing, and the first test runs with test weights are carried out as normal. After the calculation of the first correction weights has been done, the correction weights have been added and the first check run has been carried out, the program checks the response of the rotor to the first correction. If there really is non-linear behaviour on the part of the rotor for whatever reason the program identifies this and automatically compensates for it in the calculation of the next set of correction weights. This procedure continues, with compensation for non-linear response being made at each step until the unbalance condition of the rotor is within the acceptable tolerance and the job is completed. Such sub-routines of the computerized balancing program are extremely successful and as a result, the task of balancing rotors that exhibit non-linear behaviour has become almost a standard procedure, saving time and money. A routine method of testing whether a rotor is non-linear or not consists of the following steps: 1. The initial unbalance is measured and plotted on a vector diagram (e.g. figure 3.30). The repeatability of this initial condition should be checked by making 3 or 4 separate runs, without changing anything. If the amount and angle remain within 10% at each run, the values can be regarded as repeatable and the rotor is stable. Presuming the individual measurements are sufficiently repeatable (variations < 10 %) 4 test runs are made. In test run 1 a trial weight is attached at 0, in test run 2 the same weight is moved to 90, in test run 3 the weight is moved to 180 and in test run 4 to 270. The magnitude and phase measured at each test run is plotted in the diagram and each respective point is then joined to the initial unbalance point on the diagram. If the behaviour is linear, the 4 individual vectors will be approximately of the same length, and displaced by approximately 90 from each other.
2.
3.
An example of this relationship is shown in figure 3.30A If the behaviour is non-linear the individual vectors may not be all the same length and/or displaced from each other by approx. 90. Furthermore the amplitude response of the rotor may not be linear, i.e. the attachment of various size weights may also produce vectors that are not linear in length. An example of a vector diagram showing non-linear rotor behaviour is shown in figure 3.30B.
Figure 3.30: With a linear behavior the 4 test runs with a trial weight moved by 90 between each run will produce a display similar to A. A nonlinear-behavior-may produce a display similar to B.
With the example shown in Fig. 3.30 B, an instrument having a sub-routine for non-linear rotors can be used normally successfully.
Figure 3.31: Examples of trial weights which are (A) too small, (B) too large and (C) correct.
3.5.6.1
Polar correction
With polar correction the unbalance correction is done by adding or removing correction mass at only one angular position, namely at the light spot or the heavy spot on the rotor.
Figure 3.32: With polar correction the unbalance a is compensated by a correction weight ua at one angular position.
3.5.6.2
Component correction
With component correction the unbalance is corrected by adding or removing correction weights at two angular positions in the same plane.
Figure 3.33: With component correction the unbalance a is compensated by two or more correction weights, e.g. Ua1 and Ua2 in two angular positions at each plane.
This type of unbalance correction is selected, when unbalance correction weights can only be added or removed at fixed angular positions or so-called components (e.g. at the blades of a fan impeller) or when fixed locations are prepared on the rotor during manufacturing (e.g. threaded holes for screwing in the correction weights).
As a rule component correction is economical (less mechanical work is required during the balancing procedure because of the prepared locations) and very accurate (no errors can be made by adding or removing weight at the wrong angle). Fig. 3.33 shows unbalance correction made using four locations arranged at 90 to one another. Here the unbalance a is compensated by two weights, Ua1 and Ua2 at 90 and 0 respectively. The components can be determined graphically or by computer. The maximum number of possible components is arbitrary, but at least 3 components are necessary.
Example 3.1:
The following polar correction weight was determined for a rotor: ua = 50g at an angle of 60. This correction weight is to be divided into two components and the number of possible locations is fixed at 4. What should the mass of each of the components be, and at which locations should they be fixed? A) Graphic solution
Figure 3.34: Dividing the correction weight ua into the two components ua1 and ua2.
B) Calculated solution Ua1 = Ua * cos Ua1 = 50 g * cos 60 Ua1 = 25.0 g Ua2 = Ua * sin Ua2 = 50 g * sin 60 Ua2 = 43.3 g
(located at 0)
(located at 90)
C) Technical instrument solution Microprocessor controlled balancing instruments display the corresponding components immediately after the desired number of components is selected.
Figure 3.35: A modern balancing instrument showing component correction for a polar weight of 50 gr. at 60
3.5.6.3
On some machines, e.g. grinding machines, 2, 3 or 4 sliding weights are available for unbalance correction, and all weights have the same mass. Only the position and dividing angle between the weights can be changed. This is also a component unbalance correction, but this time not with fixed correction weight locations but with fixed correction masses.
Figure 3.36: Unbalance correction with two fixed masses ua1 = ua2
To determine the initial unbalance with unit mass correction, the built-in sliding weights are first neutralized, i.e. when 3 sliding weights are available they are positioned 120 apart from one another. For the test run, one or two sliding weights are positioned so their vector sum has the same effect as one trial weight. The measurement results can be finally evaluated graphically or by computer calculation. The results obtained are the final positions of the sliding weights for correction of the unbalance.
Figure 3.38: The eddy-current sensor measures the relative motion between rotor shaft and bearing housing without making contact.
The measured signal from the eddy-current sensor consists of three components: a DC voltage proportional to the static distance between the sensor and the rotor shaft, an AC voltage proportional to the rotor shaft motion as a result of vibrations and an AC voltage which is due to "run-out".
The term "run-out" means a combination of all the faults in the measuring track of the shaft which simulate a vibration. These faults can be: geometric deviations of the measuring track from an ideal circle, grooves, scratches, non-homogeneous properties, carbon inclusions or blowholes in the measuring track, residual magnetic field in the measuring track.
To eliminate the effects of these faults, some balancing instruments offer the possibility to electronically compensate for the run-out. To do this the AC voltage from the eddy-current sensor at a low shaft speed (e.g. 100 rpm), where no vibrations of any nominal value are to be expected, is measured and stored. This measurement which constitutes the run-out corresponds to the vector a b in Fig. 3.39.
Figure 3.39: With a compensator circuit the synchronous run-out vector a-b is subtracted from the measured signal a-c and the unbalance vector b-c is obtained.
The rotor is run at its service speed. Now a signal is obtained from the eddy-current sensor which is the vector sum of the unbalance vibration signal and the run-out signal. This measured signal is shown by the vector a - c in Fig. 3.39.
Figure 3.41: Detecting a slot (A) or a projection (B) to provide a speed and angle reference
Depending on whether a slot or projection is detected, the setup of the instrument can be made according to Fig. 3.42. This results in the phase reference displayed in Fig. 3.41.
This provides the following angle reference: 0 = in-coming projection 90 = 1/4 revolution opposite to rotation direction 0 = in-coming slot 90 = 1/4 revolution opposite to rotation direction)
10 % (or 50 %)
Figure 3.42: Setup of the balancing instrument and angle reference when using a non-contacting inductive or eddy-current sensor as reference generator.