The concept of balance can be summarized with the working principle of a simple scale. When equal weights are placed on both sides of a scale, there is balance in this scale. In rotors, balance of mass distribution is sought according to the rotation axis. Unwanted imbalance causes centrifugal forces, vibration and noise, which become stronger as the speed increases during rotation and damage the system.
Since the importance of balance is still not fully known in many small and medium-sized companies, this step is not taken seriously enough. One of the most important steps of Ünsal Makina's manufacturing process is balancing.
As today's technology increases, it is aimed to increase manufacturing speeds. High-speed machines are being developed to increase production speeds. In short, there is a tendency to reach higher powers with higher revs. Among these developments, the balance factor is gaining increasing importance day by day. The desired performance is achieved thanks to high quality balances.
Let's explain the importance of balance for businesses, one by one, in terms of the burdens it imposes as costs:
Machines with unbalanced rotors will generally have a shorter life than expected. Therefore, in addition to increasing investment costs, the replacement of broken and worn parts will also increase costs.
Since an unbalanced rotor will cause more energy consumption, energy costs increase.
Unbalance is one of the biggest (40%) causes of failure in machines with rotating elements.[1] Considering this high ratio, maintenance costs increase as the level of unbalance increases.
The quality of the product coming out of a machine with an unbalanced rotor is negatively affected. For example, a lathe with an unbalanced element produces poor surface quality as a result of high revolutions. Therefore, poor quality and rework costs will increase.
An unbalanced machine will cause a decrease in performance and therefore a decrease in production speed and an increase in production costs.
Quiet and vibration-free operation is always a sign of quality. The success of a tool with excessive vibration or a noisy machine in the market will be weakened, which weakens the competitiveness.
Vibration caused by imbalance can cause fittings to loosen, which can lead to serious dangers for both people and machines. This will result in unwanted occupational health and safety costs.
In balancing service, the experience of the machine and the operator in which the unbalance is detected is very important. With the help of the right machine, unbalance can be reduced to very small limits. After the balancing process, there will be a slight unbalance in the rotating elements. These acceptable limits are determined according to information such as rotor speed, kg and diameter in the ISO 1940 standard.
In the TS 2576 standard, each rotor group is shown with a "grade number". This degree number indicates the "balancing quality" for that rotor group.
At Ünsal Makina, unbalances are detected and removed with SCHENK brand, Hm30 and Hm40 model machines produced with high German technology. Generally in the range G0.4-G16, unless details are given, G6.3 grade, max. 3500 Kg and max. Rotors up to 3500 mm are successfully balanced.
As a result, unless the unbalance in the rotors is corrected, the operating systems will be damaged and costs will increase proportionally. The way to prevent it is to entrust the balancing service to professional hands like Ünsal Makina.
resources
[1] Olsson M. (1991), On the fundamental moving load problem, Journal of Sound and Vibration, 145, 299- 307,
Comments