Low Cost Rotor Balance Training Design
Low Cost Rotor Balance Training Design
https://doi.org/10.1007/s40799-023-00650-4
Received: 3 June 2022 / Accepted: 25 April 2023 / Published online: 12 May 2023
© The Author(s) 2023
Abstract
This work proposes the low-cost design and manufacture of an experimental rotor for specialized undergraduate training in
the field of mechanical vibrations. Likewise, the plane balancing methodology is presented using the influence coefficient
method. To keep costs low, a commercial rotating element will be used in which balancing planes will be assembled at the
ends, ensuring that the rotating system’s nominal speed passes through two of its natural frequencies. This training prototype
will improve learning by theoretically and experimentally analyzing the concepts of influence coefficient balancing using
an international standard.
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178 Experimental Techniques (2024) 48:177–185
as in 2004, this branch represented 28% of Singapore’s gross Table 1 Experimental rotor elements
domestic product. In [5], Ahmad and Sosa present a case study Number of Identification of elements Cost
in which full-scale prototypes were developed with students in Elements
their final semesters from the interior design, graphic design,
1 ½ hp 3,600 rpm bench grinder 2,800.00 MXN
visual arts, and multimedia areas, interacting with technologi-
2 4140 steel balancing planes 4,000.00 MXN
cal tools such as numerical control, welding, sheet bending,
10 1/8 coarse thread screws of differ- 30.00 MXN
and 3D printing machines, allowing participants to develop ent weights
practical skills that they will require in their careers, result-
ing in a high degree of commitment on the part of students to
obtain 80% of the finished products. However, this is limited Python languages as the most widely used. Additionally, [16]
by the relatively small number of students who can be trained discusses a proposal for the design of the necessary libraries to
in this manner. In [6], the authors proposed starting the vibra- be developed in the control software of a robotic system with
tion and control laboratory equipment via projects developed industrial or training applications. Expansion of the develop-
by students who are taking the subject, using specific analysis ment of graphical interfaces in other areas of mechanics which
systems studied during the course, and found an improvement seek to improve undergraduate learning in the subject should
in learning compared to theoretical teaching of the subject. be highlighted, such as mechanism analysis, as stated in [17],
The use of simulations and experimentation is presented in by developing a user interface with Matlab software to imple-
[7], mainly in the control area, as a tool to improve the teach- ment the kinematic equations that govern a four-bar crank-
ing of historically theoretical courses, achieving an increase in rocker mechanism. This type of mechanism is used in [18] at
retention of the field’s concepts, as well as in problem-solving the training level to know the performance of a sliding mode
ability. Likewise, a mechanical system was developed in [8] movement control when using a direct current (DC) motor.
to analyze the critical speed and imbalance effects in a Jeffcott Likewise, simulation of the application of a PID control in the
rotor coupled to an electric motor with a flexible coupling. dynamic equations of the crank-rocker mechanism is presented
In [9], the analytical, numerical, and experimental study of in [19], considering a DC motor with a gear speed reducer.
the concept of stress by mechanical deformation is illustrated, In [20], the input speed variation in a crank-rocker mecha-
which will allow generating significant training in machine nism using a CVT transmission is proposed, this being the
element design or related subjects, with application at the link between an alternating current (AC) motor and the 4-bar
undergraduate and postgraduate levels. Likewise, an analysis mechanism, using the simulation to present the conclusions.
of the Computer Science area in a Malaysian University is [21] presents the design of a rehabilitation prototype using
presented in [10], which proposes an online tool that allows a 5-link planar mechanism made with additive manufactur-
increasing the number of passes in Introduction to Program- ing, while [22] uses the educational level mathematical tool
ming. Along the same line of work, [11] explains an analysis called GeoGebra to determine the displacement, velocity, and
that allows knowing the learning styles applied in introduc- acceleration parameters of a 4-bar mechanism. In [23], the
tory programming courses, finding that the Soleman-Felder SolidWorks tool is used to determine the speed, acceleration,
model is the most widely used in this area. In [12], the design, and output force of two coupled crank-rocker mechanisms.
development, and implementation of a complementary tool for The same type of mechanism is used in [24] when applying the
onsite classes is presented to improve the learning process at Lagrange method to obtain the corresponding kinematic equa-
the Modibbo Adama Technological University in Yola, Nig- tions and their simulation using Matlab's Simulink without
era; this was applied to third-year Computer Science students,
and the results show an increase in the student’s use of knowl-
edge development in comparison to the traditional methodol-
ogy (fully in person). Related to the original topic, another
area of interest where practical training in students is high is
the field of robotics, where the use of commercial computer
packages is often chosen for instruction and learning. In [13]
and [14], two methodologies for mapping the development and
application of software tools commonly used in robotics are
discussed, finding that the largest number of articles published
focus on software design and construction and also present-
ing the databases where the relevant research articles can be
found. In [15], an empirical study is presented through appli-
cation in the industrial and academic sectors for the develop-
ment of software applied to robotics, identifying the C + + and Fig. 1 3,600 rpm commercial grinder
Experimental Techniques (2024) 48:177–185 179
presenting some type of verification of the characteristic pat- evaluated. However, due to the high costs involved in train-
terns obtained. In [25], a specific approach for the balancing ing prototypes, and since these are subjects at the end of
of a crank-rocker mechanism is shown using the optimization professional training, it is difficult to obtain the necessary
process called Differential Evolution when using Cartesian resources and equipment. For example, an RK-4 training
coordinates, while in [26], the experimental balancing proce- rotor from Blenty Nevada was quoted at $21,176.00 USD
dure in a crank-rocker is studied, considering an elastodynamic (plus tax) in 1984, not considering any type of electronic
behavior in the links. A review of the state of the art for the
dynamic balancing of mechanisms is presented in [27].
Therefore, for courses focused on mechanical vibrations
in rotating systems at the undergraduate level, an area of
opportunity is identified by designing a low-cost training
rotor for balancing training as well as the development of the
methodology via the influence coefficient method on a plane.
( )
Va1𝑅𝑒al + Va1𝐼𝑚ag
P1 = − (6)
𝛼
where P1 is the correction weight on plane one)in its real and
imaginary parts, the term Va1𝑅𝑒al + Va1𝐼𝑚ag is the origi-
(
a) b)
Experimental Techniques (2024) 48:177–185 183
Of course. This standard provides a kind of refuge or shield (as almost all rules do)
were used for this case study, as well as an optical tachom-
Because it covers all the theoretical information on which this class is based
vibration vector. The equipment used was the DSP Logger
X
X
and an 0.8-g weight for hole 26. When remeasuring with these
Yes
Yes
Yes
Yes
No
No
No
No
seg
is shown graphically in Fig. 8.
2 Do you consider the use of ISO 10816–3 important for the mechanical balancing
Survey Analysis
a plane. Validation was carried out by solving balancing instrumentation (vibration sensors, optical tachometer,
problems with data stored from runs from previous courses, acquisition and processing cards, and interpretation soft-
such as that shown in Fig. 7. ware). However, the high cost of completing the necessary
Meanwhile, the January-May 2022 group used the stages can barely be covered by public universities. Another
equipment presented in Fig. 9 below. additional problem is the reduced number of students who
Figure 9 (a) shows the training rotor in operation dur- take the subject, since it is commonly offered as an elective.
ing the training process, with an imbalance weight being A 2014 quote for a training rotor was priced at $21,176.00
placed arbitrarily, while Fig. 9 (b) shows the system's USD, demonstrating how valuable this specialized training
acquisition interface with the test weight. equipment is. However, as long as rotating equipment which
After this second analysis group’s normal semesters, requires maintenance is used in the industry, professionals
a survey was developed and the two study groups were specialized in the area of mechanical balancing will still
asked to respond, with the interest group which had most be needed. Therefore, the subject begins with the design of
recently received the training showing greater participa- a low-cost experimental rotor, whose approximate value is
tion in filling out the survey. $6,830 MXN, with applications in training in balancing and
Therefore, the answers from the first analysis group identification of specific faults when analyzing mechanical
respondents are presented in the table below. vibrations. This reduction in cost is 98.4%, considering an
The above table presents the survey results from an Elec- exchange rate of $20 MXN to the dollar. In addition to the
tromechanical Engineering group studying the eighth semes- high cost of specialized training equipment, the use of bids
ter specialization course entitled "Mechanical Vibrations" is a federal requirement in national public universities, so
online during the August-December 2021 semester. Access the price can increase from 20 to 30% when an interme-
to the institutional laboratory was not allowed at that time, diary enters the acquisition process. The second necessary
so it was not possible to carry out the hands-on balancing element has to do with the balancing methodology to be
training. 100% of the students surveyed consider hands-on used, since this is difficult to find in specialized material
training and the application of an international standard nec- in such a way that allows the proposed expressions to be
essary for mechanical vibration control. The same instru- applied practically in the balancing process; therefore, it is
ment was applied during the January-May 2022 semester, necessary to resort to commercial equipment with balanc-
obtaining results similar to those presented in Table 3. ing programming, such as the equipment used in this article
The above table shows that student perception is that (DSP Logger MX 300), which generates little understanding
training with balancing equipment which they may see from the point of view of engineering training. This article
applied to rotating systems diagnosis or balancing in the presented a plane balancing methodology for using influence
regional industry is fundamental, as is making the theoreti- coefficient at the system’s working speed. Therefore, there
cal result converge with that obtained in industrial equip- is a significant advance that allows supporting training in
ment. However, this way of working in subjects which are specific skills in the area of mechanical vibrations, such as
to be promptly applied to solving problems in the industry, balancing rotating systems.
due to the instructor’s high training cost and low resources
Acknowledgements The authors would like to thank the PROFAPI
for the renewal of industrial balancing equipment, means 2023 project of Technological Institute of Sonora for the financial sup-
that it has been in use for 7 years as of today. Likewise, the port given to this study.
latter is an area of opportunity for researching and devel-
oping low-cost equipment at the same University. Declarations
Conflict of Interest On behalf of all authors, the corresponding author
states that there is no conflict of interest.
Conclusions
Open Access This article is licensed under a Creative Commons Attri-
It is common to find the subject of Mechanical Vibrations bution 4.0 International License, which permits use, sharing, adapta-
tion, distribution and reproduction in any medium or format, as long
in terminal degrees related to mechanics, and one approach as you give appropriate credit to the original author(s) and the source,
offered in the subject is the balancing of rotating systems. provide a link to the Creative Commons licence, and indicate if changes
However, to develop the technical skills needed in this criti- were made. The images or other third party material in this article are
cal process (a poorly placed correction weight can increase included in the article's Creative Commons licence, unless indicated
otherwise in a credit line to the material. If material is not included in
vibrations to levels so high that equipment may fail at work- the article's Creative Commons licence and your intended use is not
ing speed or during startup and shutdown), it is necessary permitted by statutory regulation or exceeds the permitted use, you will
to complete 3 stages: obtain a training balancing rotor, plan need to obtain permission directly from the copyright holder. To view a
a clear balancing methodology, and acquire the necessary copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.
Experimental Techniques (2024) 48:177–185 185