DEFINITION OF

UNBALANCE
• ISO DEFINITION

THAT CONDITION WHICH

EXISTS IN A ROTOR WHEN
VIBRATORY MOTION IS
IMPARTED TO THE BEARINGS
AS A RESULT OF
CENTRIFUGAL FORCES

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 OTHER DEFINITIONS
• UNEQUAL DISTRIBUTION OF
WEIGHT OF THE ROTOR ABOUT ITS
ROTATING CENTRE LINE

• IT IS ALSO DEFINED AS MCD

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 GRAPHICAL REPRESENTATION

R W

R = RADIUS IN CM
W = UNBALANCE MASS IN GMS.
UNBALANCE ‘U’ = W X R GM CM

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 CAUSES FOR
UNBALANCE
• UNBALANCE IS GENERALLY
CAUSED DUE TO

1. PRODUCTION PROCESS
2. SERVICE EFFECTS

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 WHAT IS
BALANCING?
• THESE CAUSES FOR UNBALANCE
EXIST IN A ROTOR TO SOME
EXTENT

• THE VECTOR SUMMATION OF ALL

THESE CAN BE CONSIDERED AS
CONCENTRATED AT A SPOT
KNOWN AS HEAVY SPOT

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 WHY BALANCING IS REQUIRED?

F = 1.77 X (RPM/1000)2 X OUNCE INCHES

F = 1/16 X (RPM/1000)2 X GRAM INCHES
F = 0.01 X (RPM/1000)2 X GRAM CM

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 THE CENTRIFUGAL FORCE F VARIES
AS THE SQUARE OF THE SPEED.

IF THE SPEED IS DOUBLED THEN THE

FORCE WILL BE FOUR TIMES MORE.

THEREFORE IN HIGH SPEED

MACHINES SMALL UNBALANCE CAN
PRODUCE LARGE FORCES.

THE FORCES CREATED BY

UNBALANCE ARE DETRIMENTAL TO
THE LIFE OF BEARINGS,ROTOR AND
SUPPORT STRUCTURE

UNWANTED VIBRATION AND POOR

PRODUCT QUALITY CAN RESULT
FROM FORCES OF UNBALANCE
e.g GRINDER

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 BENEFITS OF
BALANCING
• REDUCED VIBRATION
• REDUCED WEAR
• REDUCED
STRESS/FATIGUE
• REDUCED NOISE
• INCREASED EFFICIENCY
• INCREASED ACCURACY
TO SUM UP
• INCREASED MACHINE LIFE

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 IN - SITU
BALANCING
• THE PROCESS OF BALANCING A
PART WITH OUT TAKING IT OUT
OF THE MACHINE IS CALLED IN -
SITU OR FIELD BALANCING
• ELIMINATES COSTLY,TIME
CONSUMING DISASSEMBLY AND
PREVENTS THE POSSIBILITY OF
DAMAGING THE ROTOR DURING
ITS REMOVAL

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WHY IS IN-SITU BALANCING
NEEDED ?

1. UNBALANCE INTRODUCED
WHEN STRIPPED AND DURING
REASSEMBLY
2. ROTORS RUNNING ABOVE
CRITICAL SPEED - MAY NEED
TRIM
3. DIRTY PROCESS
4. HEAT DISTORTION
5. TO COMPENSATE FOR WEAR

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 CONDITIONS FOR
IN-SITU BALANCING
• THERE MUST BE PROVISION FOR
MAKING WEIGHT CORRECTION
• THERE MUST BE PROVISION FOR
OBTAINING VIBRATION
AMPLITUDE AND PHASE ANGLE
• IT MUST BE POSSIBLE TO START
AND STOP THE MACHINE FOR
MAKING WEIGHT CORRECTIONS
AND FINALLY

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 THE VIBRATION
PROBLEM MUST BE
DUE TO UNBALANCE

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RECOGNISING VIBRATION
DUE TO UNBALANCE
• UNBALANCE WILL ALWAYS
PRODUCE VIBRATION AT
ROTATIONAL SPEED
• VIB. AMPLITUDE IS DIRECTLY
PROPORTIONAL TO UNBALANCE
• VIBRATION IS RADIAL IN NATURE.
FOR OVERHUNG ROTORS IN AXIAL
DIRECTION ALSO.
• STEADY PHASE READINGS
• SHIFTING THE VIB. PICKUP BY 900
WILL RESULT IN SHIFT IN PHASE
ANGLE BY 90 0

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TYPES OF BALANCE
PROBLEMS
L/D BALANCE CORRECTION
RATIO
1P 2P GT.2P
0-1000 ABOVE
GT. 0.5 1000 N.A
RPM
UPTO 2 RPM
0-150 150 - ABOVE
LESS 2000 2000
RPM
THAN RPM * RPM *
O.5
MORE 0-100 ABOVE
THAN RPM 100 *
2 RPM *

* ABOVE 70% OF 1ST CRITICAL

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 SINGLE PLANE
BALANCING
• THE LOCATION AND THE
AMOUNT OF UNBALANCE IS
UNKNOWN
• THE VIBRATION READINGS
REPRESENT ORIGINAL
UNBALANCE
• A TRIAL WEIGHT NEED TO BE
ADDED TO KNOW THE
SYSTEM RESPONSE TO
UNBALANCE

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 WHAT IS THE SAFE TRIAL
WEIGHT

• THE GENERAL RULE IS THE

TRIAL WEIGHT ADDED
SHOULD PRODUCE A FORCE
AT THE BEARINGS EQUAL TO
10% OF THE ROTOR WEIGHT
F = 0.01X(RPM/1000)2 X W XR
WHERE
F = FORCE IN KG FORCE
W = TRIAL WEIGHT IN GMS
R = RADIUS IN CMS

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 AN EXAMPLE
ROTOR WEIGHT = 1000 Kg
F = 10% OF 1000 = 100
RPM = 3000 R = 50 cms
APPLYING THE FORMULA
F = 0.01X(RPM/1000)2XWXR
100 = 0.01X(3000/1000)2XWX50
100 = 0.01X(3)2XWX50
100 = 0.01X9XWX50
100 = 0.01X450XW
100 = 4.5XW
W = 100/4.5
W = 22.22 gms

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 TRIAL WEIGHT -
GUIDELINES
• AFTER THE ADDITION OF TW
THERE MUST BE ATLEAST 30%
CHANGE IN AMPLITUDE
• ALTERNATIVELY THE PHASE
ANGLE MUST HAVE CHANGED
BY 300
• IF THE ABOVE CONDITIONS
ARE NOT MET THEN TRY WITH
HEAVIER TRIAL WEIGHT
• THE ABOVE GUIDELINES IF
FOLLOWED GENERALLY GIVES
GOOD CALIBRATION

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 EFFECTS OF ADDITION OF
TRIAL WEIGHT

1. INITIAL READINGS
20 MICRONS AT 600
2. READINGS AFTER TRIAL
WEIGHT ADDITION
27 MICRONS AT 600

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 WHAT DOES THIS INDICATE ?

OA - ORIGINAL VIBRATION READING

OB - VIBRATION READING AFTER
ADDITION OF TRIAL WEIGHT

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 OA - ORIGINAL READING
OB - READINGS AFTER ADDITION OF
TRIAL WEIGHT

A
B

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 WHAT DOES THIS VECTOR PLOT
INDICATE ?

OA - ORIGINAL READINGS
OB - READINGS AFTER ADDING TW

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 SINGLE PLANE BALANCING
VECTOR METHOD
• OPERATE THE ROTOR AT THE
BALANCING SPEED AND WITH
ANALYSER FILTER TUNED TO
1XRPM PROCEED TO MEASURE AND
RECORD THE ORIGINAL UNBALANCE
DATA - AMPLITUDE AND PHASE. ‘ O ‘
• STOP THE ROTOR AND ADD A TRIAL
WEIGHT. RECORD THE AMOUNT OF
TRIAL WEIGHT.
• AGAIN,OPERATE THE ROTOR AT THE
BALANCING SPEED AND OBSERVE
AND RECORD THE NEW UNBALANCE
DATA. THIS IS RECORDED AS ‘ O+T ‘

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 MORE ......
• USING POLAR GRAPH PAPER
CONSTRUCT VECTORS ‘ O ‘ &
‘O+T‘
O+T

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 MORE........
• CONSTRUCT VECTOR ‘ T ‘ BY
CONNECTING THE ENDS OF
VECTORS ‘ O ‘ AND ‘ O + T “. THE
VECTOR ‘T’
O+
T

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 MORE ....
• MEASURE THE LENGTH OF VECTOR “
T “ AND USE THE FORMULA TO
DETERMINE THE CORRECT
BALANCE WEIGHT NEEDED
• CORRECT WEIGHT = TRIAL
WEIGHT X O / T
• USING THE PROTRACTOR MEASURE
THE INTRUDED ANGLE BETWEEN “ O
“ AND “ T “

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 0

T THETA
O+
T

270 90
O

180

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 APPLYING BALANCE CORRECTION
BY TRANSPOSING “ T “ VECTOR

T
O+
T

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 APPLYING CORRECTION....

• REMOVE THE TRIAL WEIGHT

AND APPLY THE CORRECTION
WEIGHT.
• Always move the correction weight
opposite to the direction of rotation
after plotting the vectors in the
direction of rotation

• IN CASE TRIM BALANCING IS

REQUIRED CARRY OUT THE
SAME REPEATING THE
PROCEDURE.

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 THREE POINT CIRCLE
METHOD

• WITH THE ROTOR OPERATING AT

NORMAL SPEED, MEASURE AND
RECORD ORIGINAL VIBRATION
AMPLITUDE AS “ O “
• DRAW A CIRCLE WITH RADIUS
EQUAL TO “ O “ AS SHOWN IN FIG.1
• STOP THE ROTOR. MAKE THREE
POINTS A,B,C APPROX. 1200 APART.
THESE POINTS NEED NOT BE
EXACTLY 1200 APART. BUT THE
ANGLES OF SEPERATION MUST BE
KNOWN.
• MARK A,B,C ON THE ORIGINAL
CIRCLE AS SHOWN IN FIGURE.2

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 O

FIGURE .1

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 A

C B

FIGURE.2

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 THREE POINT CIRCLE
METHOD
• SELECT A SUITABLE TRIAL
WEIGHT AND ATTACH AT “A” ON
THE ROTOR
• START THE ROTOR. RUN IT TO
NORMAL SPEED AND RECORD THE
NEW VIBRATION AMPLITUDE AS
“O + T1”
• WITH POINT “A” AS CENTRE DRAW
A CIRCLE WITH RADIUS “O+T1” AS
SHOWN IN FIGURE.3
• STOP THE ROTOR AND MOVE THE
TRIAL WEIGHT TO POSITION “B”
ON THE ROTOR

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 T1
A O+

B
FIGURE.3

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 MORE ......
• START THE ROTOR AND RUN IT TO
NORMAL SPEED. MEASURE AND
RECORD THE NEW VIBRATION
AMPLITUDE AS “O+T2”
• WITH “B” AS THE CENTRE POINT
DRAW A CIRCLE WITH RADIUS
EQUAL TO “O+T2” AS SHOWN IN THE
FIGURE.4
• STOP THE ROTOR AND MOVE THE
TRIAL WEIGHT TO POSITION “C”

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 A

O+T2
B

FIGURE.4

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 MORE .....
• START THE ROTOR AND RUN IT
TO THE NORMAL SPEED.
MEASURE AND RECORD THE
NEW VIBRATION AMPLITUDE
AS “O+T3”
• WITH POINT “C” AS THE
CNETRE DRAW A CIRCLE WITH
A RADIUS EQUAL TO “O+T3”
• THE THREE CIRCLES DRAWN
FROM POINTS A,B,C WILL
INTER-SECT AT A COMMON
POINT “D” AS SHOWN IN
FIGURE.5

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 A

O+
T3 D

C C

FIGURE.5

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 MORE .....
• DRAW A LINE FROM THE CENTRE
OF THE ORIGINAL CIRCLE TO
POINT “D” AND LABEL THE LINE
AS “T”
• MEASURE THE LENGTH OF THE
LINE “T” USING THE SAME SCALE
• BALANCE CORRECTION WEIGHT
CW = TW X ( O / T ), WHERE
CW = CORRECTION WEIGHT
TW = TRIAL WEIGHT
O = THE ORIGINAL UNBALANCE
VIBRATION READING
T = THE MEASURED
RESULTANT VECTOR

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 A

D
T
O
C C

FIGURE 6

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 MORE .....
• USING PROTRACTOR MEASURE THE
ANGLE BETWEEN LINE “T” AND
LINE “OA” AS SHOWN IN FIGURE.7.
• THE MEASURED ANGLE IS THE
ANGULAR LOCATION OF THE
CORRECT WEIGHT LOCATED
RELATIVE TO POINT “A” ON THE
ROTOR
• STOP THE ROTOR AND REMOVE THE
ORIGINAL TRIAL WEIGHT FROM
POINT “C”

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 A

D
O
C C

FIGURE 7

• ATTACH THE CORRECTION WEIGHT ON

THE ROTOR AT THE ANGULAR POSITION
DETERRMINED FROM THE FIGURE.7

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 BALANCE WEIGHT

C B

FIGURE.8

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 SINGLE PLANE BALANCING
CHART SOLUTION
• IT IS A SIMPLE AND QUICK METHOD
FOR SOLVING SINGLE PLANE
BALANCING PROBLEMS
• IT USES TABULAR DATA AS
OPPOSED TO MAKING A GRAPHIC
VECTOR DIAGRAM
• THEREFORE PAPER ,TOOLS AND
TIME REQUIRED FOR SUCH
DIAGRAMS ARE NOT NEEDED
• THE RESULTS ARE FAIRLY
ACCURATE AND MORE THAN THREE
RUNS MAY BE REQUIRED
• IF THE NUMBER OF RUNS
PERMISSIBLE IS LIMITED THEN
GRAPHIC VECTOR SOLUTION IS
RECOMMENDED

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 PROCEDURE
1. MEASURE VIBRATION AMPLITUDE (O)
AND ANGULAR POSITION OF THE
REFERENCE MARK (PHASE) OF
UNBALANCED PART
O = --------- AT ----------- DEGREES
2. ADD A KNOWN TRIAL WEIGHT
3. MEASURE THE RESULTING AMPLITUDE
O+T AND PHASE O+T = ----------- AT
---------- DEGREES
4. CALCULATE THE “ RATIO OF
UNBALANCE “ = (O+T) / O
5. DETERMINE THE AMOUNT AND
DIRECTION OF PHASE SHIFT OF “O+T”
RELATIVE TO “O”
6. CHOOSE PHASE SHIFT TO NEAREST 10
DEGREE INCREMENT

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 MORE .....
7. LOCATE ANGLE OF PHASE SHIFT
COLUMN IN TABLE WHICH
CORRESPONDS TO STEP 6 VALUE
8. IN RATIO OF UNBALANCE COLUMN
LOCATE RATIO NEAREST TO VALUE
CALCULATED IN STEP 4
9. OPPOSITE THIS RATIO LOCATE
ANGLE AND FACTOR VALUES IN
PREVIOUSLY DEFINED PHASE SHIFT
COLUMN
10. MULTIPLY THE TRIAL WEIGHT
AMOUNT BY FACTOR
VALUE. THIS IS THE CORRECT
BALANCE WEIGHT REQUIRED

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 MORE .....
11. THE ANGLE VALUE IS THE NUMBER OF
DEGREES THE CORRECT BALANCE
WEIGHT IS TO BE MOVED FROM THE
TRIAL WEIGHT LOCATION.THE WEIGHT
IS MOVED OPPOSITE THE DIRECTION
OF PHASE SHIFT NOTED IN STEP 5
12. IF FURTHER CORRECTION IS NEEDED
CONSIDER THIS AS “O+T” RUN AND
REPEAT THE PROCEDURE FROM STEP.4

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 BALANCING OVERHUNG ROTORS
PLANE A
PLANE B

BRG 2
BRG 1

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 BALANCING OVERHUNG ROTORS
1. USING PROCEDURE SIMILAR TO SINGLE
PLANE VECTOR SOLUTION FIND THE
AMPLITUDE AND PHASE IN BEARING NO.1

2. ADD A TRIAL WEIGHT TO THE ROTOR IN

PLANE B AND NOTE THE AMPLITUDE AND
PHASE READINGS.

3. USING SINGLE PLANE VECTOR SOLUTION

COMPUTE THE LOCATION AND AMOUNT
OF CORRECTION WEIGHT AND BALANCE
UNTIL THE DESIRED VIBRATION LEVEL IS
REACHED IN BEARING 1.

4. OBSERVE THE VIBRATION READING IN

BEARING N0.2.IF THE VIBRATION LEVEL
IS WITHIN THE PERMISSIBLE LEVEL THEN
ONLY SINGLE PLANE BALANCING WILL
SUFFICE.

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5. IF THE VIBRATION IN BEARING 2 IS NOT
ACCEPTABLE,THEN ADD TWO EQUAL AND
OPPOSITE TRIAL WEIGHTS IN PLANES
A AND B. NOTE THE NEW AMPLITUDE AND
PHASE READINGS.

6. USING THE VIBRATION READINGS FROM

STEP 4 AND STEP 5, COMPUTE THE
COUPLE CORRECTION REQUIRED USING
SINGLE PLANE VECTOR SOLUTION.

7. APPLY THE CORRECTION WEIGHTS IN

BOTH THE PLANES AS A COUPLE UNTIL
ACCEPTABLE LEVEL IS REACHED.

8. CHECK THE VIBRATION IN BEARING 1

AND IF ANY FRESH CORRECTION IS
REQUIRED PROCEED WITH STEPS 1 TO 4
AGAIN.

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ONE RUN BALANCING USING FLASH
ANGLE TECHNIQUE
THIS IS A VERY USEFUL TECHNIQUE FOR
BALANCING ROTORS WHICH REQUIRE
BALANCING FREQUENTLY.

THE TECHNIQUE IS BASED ON THE

FOLLOWING PREMISES;

1. THE UNBALANCE CONSTANT FOR A

ROTOR GENERALLY REMAINS SAME

2. REGARDLESS OF WHERE THE

UNBALANCE SHIFTED, IT ALWAYS
APPEARED UNDER THE STROBE LIGHT
AT THE SAME ANGULAR LOCATION

FLASH ANGLE OF A ROTOR

IT IS THE ANGLE MEASURED IN THE
DIRECTION OF SHAFT ROTATION BETWN.
THE POSITION OF PICKUP AND THE
POSITION OF HEAVY SPOT UNDER STROBE
LIGHT

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 FLASH ANGLE - MEASUREMENT

FLASH
ANGLE

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