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Documenti di Professioni
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By
Dr. Rajiv Tiwari
Department of Mechanical Engineering
Indian Institute of Technology Guwahati 781039
on
Introduction
The unbalance in rotors will not only cause rotor vibrations, but also
transmit rotating forces to bearings and to the foundation structure.
The force thus transmitted may cause damage to machine parts and its
foundation. If the transmitted force is large enough, it might affect even the
neighboring machines and structures.
Thus, it is necessary to remove the unbalance of a rotor, to as large an
extend as possible, for its smooth running. The residual unbalance
estimation in rotor-bearing system is an age-old problem.
From the state of the art of the unbalance estimation, the unbalance can be
obtained with fairly good accuracy [1-5].
Now the trend in the unbalance estimation is to reduce the number of test
runs required, especially for the application of large turbo generators where
2
the downtime is very expDer.nRs.iTviewa[r6i (,r7tiw].ar
i@iitg.ernet.in)
Static balancing:
Single plane balancing
Dynamic balancing :
(i) Two plane balancing: For rigid rotors only.
<
cr
((ii)
10
11
This vibration is due to all the unbalance in plane II, since the unbalance in
plane I has no moment about F1.
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
12
Make a plot of this amplitude for different location of the same trial mass
(see Fig. 2). The trial mass for correction is added at the location where the
amplitude of vibration is minimum.
Increase or decrease the trial mass at the same locations, until the desired
level of balance is achieved. Similar procedure can be repeated by Fixing F
2
and releasing F1. This procedure is tedious and sometimes may be time
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
13
consuming.
8 = 9O0, where
8
is measured from a
This procedure has to be repeated for two cases (e.g. when fulcruming at F
1
and then for F2 ).
(1) Let OA is the amplitude measured with trial run
(2) OB is the amplitude measured in trial run by addition of a trial mass Wt
14
Hence the vector AB will represent the effect of trial mass Wt.
15
Construction Procedure :
D
E
C
~9O
16
Erect a line OAD equal to 2OA. With O as the center and OB & OC as radii
and D as center and OC & OB as radii draw arcs to intersect at B & C (point
B and C we will be obtained by above construction). .
Draw a circle with BC as diameter and A as center. Construct the
parallelogram OBDC.
Now AB represent O0 position (i.e. reference line) and AC 18O0 position on
the rotor (AO is actual unbalance). The angular measurement may be
clockwise or CCW and is determined from the fourth observation.
The observation could be either OE or OE (+9O0 or 9O0 ). If the value
observed is in the vicinity of OE, then the angle to be measured CCW.
However it will be CW if OE is the reading observed in test (the fourth run
also checks the validity of the linearity used in the balancing procedure).
The magnitude of trial mDars. sR.tWTiwaisri (prtirwoapri@ AB.
oriittgio.enrnaelt.itno)
17
18
9O
+ve
180O
9O
9OO
E
180O
E
O
9O
27OO
27OO
Unbalance position
at shaft location,
(ccw direction +ve)
Location of fourth
measurement for
trial mass at 900
(ccw dir. +ve)
9O
180O
Unbalan
ce
position
at shaft
location
(ccw dir.9O
O
+ve)
Location of
fourth
measurement for
trial mass at 900
(cw dir. +ve)
+ve
E
27OO
180O
B
O
Location of fourth
measurement for
trial mass at 2700
(ccw dir. +ve)
27OO
Unbalance position
at shaft location,
(ccw direction +ve)
O
O
B
O
27O
O
Location of
fourth
measurement for
trial mass at 2700
(cw dir. +ve)
Dr. R. TiwariF(ritgiwuarrei@4iitg.ernet.
in)
+ve
+ve
27OO
Unbalan
ce
position
at shaft
location
(ccw dir.
+ve)
19
The ideal rotor, unbalanced only with a unit unbalance (and thus not containing the
residual unbalance), will have certain amplitude, which we cannot measure.
Call that amplitude x. Let the unknown location of the original unbalance be .
an ambiguity sign.
Solve x and in terms of and show that in this answer there is
Thus four runs are necessary to solve the problem completely.
U R
0 ),
1
Dr.
R. Tiwari (rtiwari@iitg.ernet.in)
2O
Figure 3.5 shows variation parameters involved in the present problem. From
OAB
, we have
a02 + OB 2 a 21
cos =
(A)
2a0 OB
and
2
cos (
Since
a0 + OC
a2
(B)
2a0 OC
cos
OB =OC
, we have
a 2 +OB 2 a 2
2
= 0
2a OB
(C)
0
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
21
x
Reference
line
a2
a0
a1
(D)
which gives
2
2a02 + 2OB 2 (a
+2
1
a 2)
22
OB = x, since OB
of unit magnitude.
or
x = (a1 + a2 ) / 2
a0
x=
(a + a )
(E)
a
2
x = 2a x cos a +
0
0
and a
1
2
x
=
(F)
2
2a0 x cos a0 + a2
(G)
(H)
Equation (E) gives the magnitude of the unbalance and equation (H) gives the
magnitude of the phase angle, the direction or sense of the phase cannot be
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
23
obtained from only above measurements.
amplitude 6.O m
amplitude
5.O m
amplitude
1O.O
amplitude
m
1O.5
m
Find the weight and location of the correction. Take the trial and balancing
masses at the same radius.
24
Answer:
C
A
line
e
c
ren
Refe
B
O
OA = AD = 6 cm
DB =1O cm
OB = 5 cm
OE = 1O.5 cm
AB = 6.3 cm
Imbalance position
= angle BAO
= 71 deg. CCW
25
BAE
BA0
x=
(a + a ) a = 4.09
gm
and 2
= 52.8 deg
26
y11
y21
(7)
y12
y22
y12 = F
12 2
y22 =
12 F2
27
F2
y1
y2
y1 = y11 + y12 =a 11 F1 + a 12 F2
y2
=
or
y 21 +y 22 =
a
r yl
1
21
F1 + a
Ia 11
=
l y 2 J La
21
22
F2
a 12 1 r F1 l
a
22
J l F2 J
Figure 7
11
y 11 ,
=
F1
y 21
et
F 1 (rtiwari@iitg.ernet.in)
c.
Dr. R. Tiwari
21
28
l1
y1
No trial mass
1
aaR
l1
R1
R1
l2
y2
2
abR
R2
abl
l1
R3
y3
B3
R1
Trial mass Tl
aal
l3
29
and 51 respectively.
3O
t2
Spike due to
notch in the
shaft surface
reference signal
t1
2
T
t2
radians
Figure 6
Dr. R.
Tiwari (rti
wari@iitg.
ernet.in)
31
The phase angles are measured with the same reference during the test
and their relative locations with respect to rotor is initially known.
In the second run, place a trial mass TR at a convenient location in plane R
= (R
R1) / T
aR
= (L
L1 ) / T
and repeat
32
and a = (L L ) /
3
1
aL
(3,4)
With the help of equations (1) to (4), we can obtain influence coefficient
TL
TL
experimentally.
a bL = (R3 R1 ) /
- -
- -
R1 =WRabR
and
- -
- -
=WRaaR +WLaaL
(5)
Correction
+WLabL masses will produce vibration equal and opposite to the
vibration due to unbalance masses.
L1 Hence,
r R-1 l
l L1 J
IIa-
bR
aR
a
L
l
a- bL 1 rW R
a
aL
(6)
I W
Jl LJ
Ia
L
I
b 1
d
1 I
1
= I
d
L
I
J
c
1a I
J
where
= (ad cb)
which gives
WR=
-R .a
1 aL Ra L
-
an
d
WL= -
L
.
1abR
-aR
-
R1 .a
a bL R .a
.a
aR
L
.a
34
Accelerometer (or
proximity probes
on the shaft near
to the bearing)
Photo electric
Probe
Measurement
Plane a
Measurement
Plane b
Charge
Amplifier
Vibration
meter
Phase
meter
Oscilloscope
Maximum
displacement
location
35
Example 3.3 A rigid rotor machine is exhibiting vibration problems caused by imbalance.
The machine is symmetric about its center-line. A trial balance mass of O.3 kg is sited at
end 1 at an angle of 3OO relative to some reference position; this causes changes in
vibration vectors of 5O m at 61O at end 1 and 42 m at 13OO at end 2.
Determine the influence coefficients for use in balancing the machine, and calculate the
balance mass required at each end of the machine if the measured imbalance vibrations
are 3O m at 23OO at end 1 and 7O m at 33OO at end 2.
isplacement in plane 2:
L2 = 42 m at
1300
m
p,hwasheich can be written
as
L2 = ( 26.997 + j 32.173)
36
O
In plane 1: R1 = -3Om at 23O
phase
bR
=a =
In plane 2:
11
R = (19.2836 + j
R2 - R1
TR
= (48.8919 + j 51.63766)
x1O -6
m/kg
and
a
12
=a
aR
TR
m/kg
37
= IIa11
a12 1 r wR l
I
l - L1 J La 21 a 22 J l wL J
(m/kg)2
-3
+ j 7.123 x1O
and
-3
wL = 3.9O356 x1O
at
-35
-3
-3
-3
- j 2.7136 x1O
-3
4.7541x1O kg
38
39
Run the rotor in a suitable hard bearing balancing machine, to a safe speed
approaching the first critical speed and record the bearing vibrations or
forces.
Choose an appropriate location for the trial mass.
For first critical speed, this should be roughly in the middle for a
symmetrical rotor in its axial distribution of mass. Record the readings a
t
the same speed as before.
Using the above two readings, the correct mass and location can be
determined. (single plane balancing). With this correction mass, it should be
possible to run the rotor through the first critical speed without appreciable
vibration.
Next, run the rotor to a safe speed approaching the second critical speed, if
the operating speed is near the second critical or above the second critical
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
4O
speed.
Figure 9
Note the readings. Add a pair of trial masses 18O0 apart in two
planes
without a affecting the first mode. (in fact if we try to balance one particular
mode it will not affect balancing of other modes).
Note the readings at the same speed near the second critical speed.
Two readings can be used to determined the correction mass required.
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
41
y
Figure 10
42
iYi ( x )
where Yi ( x) is the mode shape in the ith mode and is unknown constant.
i
The deflection y(x) can be measured experimentally.
For example for simply supported end conditions the mode shapes are
I Mode
II Mode
y 1(x) = sin
y 2( x) = sin
2 x
i th Mode
i x
y ( x) = sin l
43
For other end conditions mode shapes can be obtained by free vibration
analysis. Modal series for eccentricity can also be written as
a( x) =
La
i Yi (
x)
(9)
It can be written in terms of mode summation since the y(x) is the result of
a(x). The main objective is to find out for the eccentricity distribution to be
known.
Multiplying (8) by the mass per unit length m(x) and the mode shape
Y j ( x) and integrate from O to
1.
l
(1O
)
i
noting the orthogonality condition
of mode shapes
l
Jm ( x)Y ( x)Y
i
( x)dx = Dr.
O R. Tiwari
for all
i j
(rtiwari@iitg.ernet.in)
(11)
44
Equation (1O)
gives
Y j (x)dx =
J m(x)Y
(12)
(x)dx
which can be written as
1
M j
j
=
(13)
m ( x ) y ( x )Y ( x ) dx
j
(=
is given as
m ( x )Y j ( x )
= J
dx
O
45
dx
[EI ( x) y ,,( x) ]
= 2 m( x)[ y ( x)
(14)
+ a( x) ]
where w is the rotor speed. On substituting for y(x) and a(x) from equation
(8) and (9), we get
I
d2
dx
I EI ( x)
IL
Li
Ir
11
i Y i,,( x) I = 2 m ( x) I
J IJ
IL l
i i
i i
L
Y
(
x)
a
+
{
L Y
i
J
(15)
I
o
dx
1r
(x
I EI ) 1l
L
I
"
i Yi
11
(x)
( x )1 I Y j
1J dx
I
46
Y j(x)
d
dx
[Ei
(x)
i Yi ,,
I
o
r
d I
1
I Ei ( x )
dx I
l
L
1 11
L
i
i Yi ,,( x )
1J JI
IY
j,,(
x)
dx
{ (since
( x ) }it]is - zero for all boundary
1
First term vanishes
conditions), on taking
l
L
- Y , ( x ) [Ei ( x )
i Yi ,,
I
r1
I Ei ( x )
1l
L
11
L Y ,,( xJ)
i
(x)
I
dx J
j,,
Y
I the
(x)
First term again vanishes
for+ all boundary conditions. On noting
1
orthogonality condition equation (11), we get
}]
l
2
I Ei ( x ) [Y ,,(x ) ] dx
j
(16)
2
j
I
o
Ei ( x ) Y j,, ( x ) Dr.
dxR. Tiwari (rtiwari@iitg.ernet.in)
47
From right hand side of equation (15), noting equation (8) and (9), we have
2
j
+a
(17)
jK
2
=M
+ aj
jj
)M
K
a
/M
j
2
(18)
Once
be found from
a j is obtained, then distribution of eccentricity a(x) can
equation (9). Equation (18) requires m(x), y(x), Y (x) and p = K / M .
j
j
j
j
The m(x) can be accurately found out, y(x) is difficult to obtained, Y ( x) is
j
th
obtained by eigen analysis and p j is natural frequency in i mode = ( K j M
which can be obtained by eigen value analysis.
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
48
a2
Rigid
s
h
a
ft
<<
a,
11
21
p1
p1
Figure 11
p
a 2,
,1
1,
F1
Flexible shaft
a1,,1
p2
planes
Balanc
ing
x
q
z
Measuring planes
Frii(grtuiwraeri@1ii2tg
Dr. R. Tiwa
.ernet.in)
49
Ia- 11
1
1a
=1
11a
L
q1
21
a- 12
a
22
,U
a- 1 p 1 r U1 1
1 1U
2p 1 1 2 1
1- qp 11 1 p 1
J
a 1J
lU
(19)
1
where
is the vibration measurement
at
the
measuring plane.
5O
-1
-1
-1
l
l
.
. a 11
a
a
1
12
1 p
1
I - 1
- 1
- 1 I
.
v- 2 I
a 21
22
I
a
a 2p I
I
:
I :
: I
I -1
-1
-1 I
1
.
v I
I a q1
a q 22
a- q2 p I r - 1 l
-- q2
- 2
I I - I
.
v1 I
I a 11
u
a 12
a 1p
I
I
I
u
I - 2 I
:
:
:
I :
(20)
or
- 2
- 2
- 2 I I u 3 I
- 2 I [
a
]
{
u
}
I
.
vq I
{v }
Ia q1
a q2
a qp I
:
:
I :
:
: I I - I
I
- n
-n
- n
I - n
Il u Ip JI
I
.
v
a
I 1n I
a 1n2
a 1np
I 1n1
I
-v
:
2
22
2
I 1 I
Ia 1
a
a p I
I : I
:
I
I -: n
- n
-: I
I v- n I
ILa q 1
.
n
q
a q2
a q p JI
I
I
I
I
I
I
I
I
I
Once
I the
I influence coefficients [a ] are known for all speeds equation (20)
r
I
I
I
I
I
I
I
I
canl be used
to obtained unbalances :
J
{u } -
([a
]T
[a ]
-1
{v}
(21)
51
rv11 l
1 -1 1
1v 21 1
. -1
1a 11
-1
-1
-1
1a 21 a 12
22
1 : 1 11 :
:
1v - 1 1 1 - 1
l
q1 J
2p
a -q 2
1a
L
-1 l r
a 1 u 1 + TR l
- 11 p 11
1
1 u2
a
a - 1J1l
1qp
q1
: 11
J
1
(22)
p
1
On subtracting equation (22)
from
first q equation in equation (19), we get
1
r v 11 - v11 l
1- 1
. -1
1a 11
-1
1
1
1v 21 - v2 1
1a 21
1 11 :
1v - 1 - v- 1 1
qJ
l q1
1 -1
1a
L
q1
-1
- 112
a 22
:
a-
-1 l a 1 rT Rl
- 11 p 11 o 1
1 1
a
2p
1 :
: 11
11 o 1
a - 1J l 1J
1q 2
(23)
1qp
1
11
1
- v12
- 1 v21
- 1
,.
- v1 ,
a21 - Dr. R. TiRwari (rtiwari@iitg.ernTeRt.in)
1
v11
-1
a
q1
1
v q1
- v 1q
TR
(24)
52
53
54
55
56
References
[1] W. Kellenburger 1972 Transactions of the American Society of Mechanical
Engineers, Journal of Engineering for Industry 94, 584-560. Should
a
flexible rotor be balanced in N or N+2 planes?
[2] J. Drechsler 1980 Institution of Mechanical Engineers Conference on
Vibrations in Rotating Machinery, Cambridge, UK, 65-70. Processing
surplus information in computer aided balancing of large flexible rotors.
[3] P. Gnilka 1983 Journal of Vibration 90, 157-172. Modal balancing of
flexible rotors without test runs: an experimental investigation.
[4] J.M. Krodkiewski, J. Ding and N. Zhang 1994 Journal of Vibration 169,
685-698. Identification of unbalance change using a non-linear
mathematical model for rotor bearing systems.
[5] M.S. Darlow 1989, Springer Verlag, Balancing of High-Speed Machinery,
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
57
[6] S. Edwards, A.W. Lees and M.I. Friswell 2000 Journal of Sound and
Vibration, 232(5), 963-992. Experimental Identification of Excitation and
Support Parameters of a Flexible Rotor-Bearings-Foundation System from
a Single Run-Down.
[7] R. Tiwari, 2005, Mechanical System and Signal Processing, Conditioning
of Regression Matrices for Simultaneous Estimation of the Residual
Unbalance and Bearing Dynamic Parameters (in press).
[8] IS 5172 : 1969 Specification for Balancing Bench,
[9] IS 13274 : 1992/ISO 1925 : 1990 Mechanical vibration Balancing
Vocabulary.
[10] IS 13275 : 1992/ISO 2371 : 1974 Description and evaluation of field
balancing equipment.
[11] IS 13277 : 1992/ISO 2953 : 1985 Balancing machine - Description
and evaluation.
Dr. R. Tiwari (rtiwari@iitg.ernet.in)
58
59
Thank you
60