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1.0 UNBALANCE AND ITS EFFECT

Unbalance is a material non-uniformity (not symmetric distribution) around an axis of rotation.
Let us consider a section of a rotor.

Figure 1

The unbalance of section i (Local unbalance) is defined as:

(1) (mass static moment)

where mj = mass portion of section i

rj = distance of mass portion from the axis of rotation

According to definition [ U ] is measured

as. gr x mm or ounce x inches

mass x distance
1 ounce x inch. = 28.35 gr x 25.4 mm = 720 gr. mm.

Considering Unbalance definition and formula (1) it follows:

a) We cannot speak of Unbalance without defining an axis of rotation.
b) Unbalance is a way to describe mass distribution around an axis.
c) Local Unbalance is a vector (that is a value and an angular position).
Now, considering that a real rotor has an axial extension and that the whole rotor can be divided
into different sections we define Ut (total Unbalance) as:

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(2)
The total Unbalance of a body is a set of different local unbalances.

Figure 2

Formula 2 means:

a) Total Unbalance [Ut] is composed by different local Unbalance. (Ui)

b) It is difficult to know and measure the values of local unbalances.
c) Local unbalances are vectors starting on the axis of rotation and laying on parallel planes
(normal to rotation axis).
d) Knowing total Unbalance Ut means knowing all local Unbalances Ui.

What normally we do know and measure is the dynamic unbalance of a body.

The dynamic unbalance of a body is defined as the unbalances U1 + U2 (two Unbalances on two
arbitrary different planes) equivalent (having some resultant and moment) to total Unbalance.
This definition of Dynamic Unbalance means that:
(3)

(4)
where M = vector moment = U x d
d = distance between vector U and a common reference point on the axis of rotation.

The demonstration that the total Unbalance Ut as defined by (2) is equivalent to a dynamic
unbalance (as defined by (3) and (4)) can be obtained mathematically using the rules of vector
summation.
Here we point out only a practical demonstration.

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When a body rotates, the unbalance originates a centrifugal force which increases with the speed
so there is a direct relationship unbalance-centrifugal force. This way the demonstration becomes
easier to be understood and we consider forces instead of unbalances
Let us consider a body which rotates around an axis in the space at a certain fixed speed.
We can keep it running by placing two bearings in two arbitrary positions.
Bearing function is to supply two forces which compensate for all the local centrifugal forces
distributed around the body axis.

Figure 3
The two vectors F1 + F2 are opposite and equivalent to all local centrifugal forces Fi.
Local centrifugal forces remain the some while the value of F1 and F2 depends on the axial
position of the bearings.
The very same situation applies to Unbalance.
The local unbalances are always the same while the equivalent dynamic unbalance (vectors U1 +
U2) changes with the position of the balancing planes.
When a body rotates the local unbalance originates a centrifugal force according to following
formula.

(5) F = M.R . ω2
where F = centrifugal force (measured in N = Newton)
M x R = Unbalance measured in [ Kg. x m ]
ϖ = rad. / s =

where Kg. x m = (gr. x mm) / 1.000.000

(6) ω=2πN

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 60
with N = rev/min

Figure 4

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2 . UNBALANCE AND ECCENTRICITY
Let us first introduce the concept of center of mass.
The center of mass of a body is a virtual point where we can think that all the body mass is
concentrated or that point which makes equal to zero the mass static moment around it.
Mathematically with reference to the center of mass formula (7) is valid:

(7) where mi = single mass

ri = distance single mass-center
of mass

Example for center of mass calculation for two masses m1 and m2 placed at a distance l.

Figure 5
The position of the center of mass is placed near the bigger mass at a distance of 25.
The mass static moment with referred to the center of mass is zero in accordance to formula 7;

m1 x d1 = 3 x 25 = 75 leftwards (static moment of mass 1)

m2 x d2 = 1 x 75 = 75 rightwards (static moment of mass 2)

Considering formula 1 and 7 we can see that:

a section is balanced (Ui = 0) if its center of mass lies on the axis of rotation.

Now let us consider what happens by adding an unbalance in a perfectly balanced section.

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 Figure 6

The added unbalance U= M x R moves away the center of mass of the section by a value E
(microns) called Eccentricity.

So we define eccentricity of a section/body as the distance (measured in microns) between the

center of mass and the axis of rotation. Following formula is valid:

(8)

where E = Eccentricity (microns)

U = Unbalance (gr. mm)
M = Total mass (Kg)

Formula 8 shows that:

a) on a big mass M, the applied unbalance U causes a small rotor eccentricity.
b) An unbalance is created mounting a workpiece eccentric (non properly centered with reference
to the axis of rotation).
In this case an unbalance U = M x E is created.

Example: Disk shaped rotor (m = 10 Kg)

Unbalanced by adding 10 grams on the external radius = 100 mm.
U = 10 gr. x 100 mm = 1000 gr. mm
The unbalance originates an eccentricity (distance center of mass - axis of rotation)

E= 1000 gr. mm = 100 microns . ~ 4mills

10 Kg 25.4

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Note : theoretically, at this point, it is necessary to introduce the concept of rotor axis of inertia
which is outside the scope of this job.

3.0 Static / Couple Unbalance compensation

3.1 Static Unbalance

A static Unbalance occurs when the unbalance is concentrated in one plane containing the center
of mass.

Figure 7
The original unbalance can be compensated in different ways as shown by following pictures.

a) First way of balancing by adding one Unbalance in the plane where original unbalance was.

b) second way of balancing by adding unbalance in two different planes symmetric with respect
to the center of mass.

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c) Third way of balancing by adding unbalance in two different planes.

In all three examples after balancing the dynamic unbalance is zero, but local unbalances are
different. Only with example (a) Ut = 0

3.2 Couple Unbalance

A couple Unbalance occurs when the total Unbalance UT is composed by two unbalances placed
on two different planes as shown on following sketch.

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 Figure 8They are a lot of ways to compensate for this type of original unbalance; among
them:
a) Best way requiring minimum work.

where: Uo1 = Uo2 = Original unbalance on planes 1,2

Ue1 = Ue2 = Uo1 = Uo2 Compensating unbalance

b) Compensating on two different planes

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Compensation masses increase: Uc1 = Uc2 = Uo1 x 2 (this because the distance between
balancing planes is lower).

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4.0 Unbalance Transducers and Balancing Supports.
First of all we consider the flow-chart of the events.

Physical parameter UNBALANCE

to be measured

Event generated by CENTRIFUGAL FORCE Related transducer

Unbalance (Piezoelectric pick-
up)

Movement caused SUPPORT OSCILLATION Related transducer

by centrifugal forces (Seismic pick-up)

Soft bearing machines measure the oscillations generated by the centrifugal forces related to
Unbalance during rotation. Machine supports have a movable part.
Actual displacement depends on Unbalance (Centrifugal force) and rotor weight (Inertia).
Normally seismic pick-ups are used and the signal is integrated in order to measure the
displacement.

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 Figure 9
Schematic drawing of a soft bearing support

The seismic pick-up is composed by an electric coil around a permanent magnet which is tied to
the oscillating cradle.

Figure 10
Seismic Electromagnetic pickup

(9) Vu = Ks
when Vu = tension output (mm.V)
s = speed (mm/s)

Piezo hard bearing machines measure the centrifugal force directly caused by unbalance during
rotation.

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 Figure 11
Schematic drawing of a piezo hard bearing support showing that it is completely rigid in all
directions.

The piezoelectric pick up is a crystal cylinder diameter. 40-50 mm, thickness about 10 mm with a
central hole. An electric charge is generated on the external surfaces if they are subject to a
pressure.

Figure 12
Piezoelectric Crystal

(10) C = KF
where C = electro static charge on external surface (Coulomb)

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 F = force (Newton)Soft bearing machines were born first because of the simple principle of
operation and because of the high signal coming out of seismic pick-ups.
They have also the advantage of requiring reduced foundations.

Figure 13
Vibration amplitude in microns (peak) on a soft bearing machine versus rotor speed.

Above the critical speed the amplitude of vibration in microns is constant wile the vibration
velocity increases with the speed.

The principle of operation is simple and easy but some disadvantages appear, among them:

- Difficulty on balancing rotors with very high original unbalances (big support vibrations during
start-up or at standstill).

- Skillful operator required because of unbalance interference between planes (poor plane
separation on narrow balancing planes).

- Impossibility to balance dynamically a rotor with two balancing planes completely outboard.

- Ventilation problems. (Supports oscillate because of the air movement).

- Difficulty in balancing rotors with the center of mass outside the bearing supports (one upward
static force on one support).

With the development of electronics (operational preamplifiers and filters) the technology of
piezo pick-ups underwent a big success in the production field because all the above mentioned
problems were overcome and machine use became easier and quicker and less dependent to the
worker ability.

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The centrifugal force caused by the unbalance exerts an oscillating pressure over the piezo
transducers causing a sine output.

The output signal from piezo pick-up is preamplified and integrated before going to the
microprocessor measuring unit together with a reference pulse.
Knowing the force and rotor speed, the measuring unit calculates the unbalance.
(See formula 5).

The rotor runs on the balancing machine roller supports as it would under service conditions,
without undergoing any oscillation.

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5.0 Hard bearing balancing machine simple set up

For better understanding hard bearing machines behavior let us consider a beam on two supports
with a force F or an unbalance (vector) applied in one point.

Figure 14

with the simple laws of static, F1and F2 (Forces on supports 1 and 2) are calculated :

(11) F1 = Fx L - a F2 = F . a
L L
On a piezo hard bearing machine values of centrifugal forces F1 (U1) and F2 (U2) are directly
measured in one spin by using the piezoelectric transducer.
Now referring to chapter 1, it is evident that a hard bearing machine measures directly the
dynamic unbalance U1 (F1) U2 (F2), equivalent to rotor total unbalance, referred to the resting
journals.
The microprocessor, knowing the position of balancing planes, using formula (11) easily
calculate the unbalance referred to the balancing planes.

Figure 15

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 Hard Bearing Balancing Machine Set Up

A: Distance left support - left balancing plane

B: Distance between balancing planes
C: Distance right support - right balancing plane

The main advantage of hard bearing balancing machines is that they are permanently calibrated.
Just setting the A, B, C dimensions, and with one spin the dynamic unbalance is measured and
using formula (11) the relevant unbalance on planes 1 and 2 is calculated.
If also R1 and R2 are set up, the amount of unbalance in grams (ounces) is derived :

(12) U (grams) = U (grams x mm) / R (mm)

where U (grams) = unbalance on the correction radius in grams
R = correction radius in mm
U (grams x mm) = unbalance

Since a hard bearing machine directly measures the centrifugal force caused by the unbalance on
machine supports it is essential that there is no movement of the supports or base plate.
Necessary condition for good results and good plane separation is that the machine base plate is
rigidly connected to a solid ground.
Normally the working range of a hard bearing machine is given, depending on machine capacity;
within this range the machine is permanently calibrated.
Today CEMB machines can be used outside the normal range by using a special calibration
procedure.

Z1000

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 Figure 16
Normal working range (calibrated domain) of a hard bearing machine with maximum
capacity up to 1500 Kg.

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Practical advantages of hard bearing technology are :

• easy simple and quicker machine operation

(just setting up A,B,C,R1,R2) the dynamic unbalance on two planes is measured in one spin
• good plane separation independent of rotor center of mass position
• possibility to balance a rotor outside boards with an up-wards vertical force on a support
• no problem for high original unbalance
• low balancing speed without any noise caused by ventilation
• possibility to measure with good accuracy the dynamic unbalance of a rotor mounted on a
vertical axis balancing machine
• suitable to work in dirty environments
(no oscillating parts, sealed pickup)
• proper measuring of static unbalance on a two supports machine

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 Figure 17
Set Up For Horizontal-Vertical Axis Hard Bearing Dynamic Balancing Machines

Figure 18
Unbalance Display For Planes 1 And 2 In Polar Coordinates

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6.0 MARKET OVERVIEW FOR INDUSTRIAL BALANCING
MACHINES

Figure 19

Figure 19 refers to CEMB selling distribution on 1995 according to different market segments.
It clearly points out that :

1. There is a big market concentrated on production industry

2. Only a small percentage in value is concentrated in repairing/maintenance

Figure 20 points out that the market (mostly for production machines) requires a big percentage
of vertical axis balancing machines.

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 Figure 20
Horizontal-Vertical Axis Turn-Over (Cemb Selling 1995)

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7.0 VERTICAL AXIS HARD BEARING BALANCING MACHINES : A
RESPONSE TO PRODUCTION REQUIREMENTS.
A lot of work pieces, without a proper journal, such as pulleys, flying wheels, fans, pump impellers,
centrifuges, car wheels, brake discs, etc. are produced in big quantities.
Each one of these pieces is to be balanced because of increasing quality demands.
By accident, we point out that controlling and reducing the residual unbalance, it is possible to grant good
service condition eliminating all errors caused by bad machining or casting.
The balancing machine is considered a necessary production tool with following requirements :

• Easy to be used by an unskilled worker

• Reduced number of movements
• Sturdy and suitable to operate in bad environments
• Short cycle time
• Reduced maintenance
• Suitable for mass production (fully automatic)

Considering the type of work pieces to be balanced and their production requirements it is evident that a
vertical axis balancing machine is the most suitable solution.
Work pieces can be transported through roller or chain conveyors with their axis in vertical position, can be
loaded on a balancing and compensating station and then downloaded to an exit roller conveyor.
For reference see annexed layout Figure 21, which refers to a fully automatic station for car brake discs.

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 Figure 21
Section on lay-out for a fully automatic vertical axis balancing machine for car brake discs.

Discs are coming through a chain conveyor, loaded on the balancing machine by means of rotary table (one
piece is unloaded and loaded at the same time), and after the checking control discharged.
Balancing compensation is obtained by milling on the external surface according to annexed sketch.

Figure 22
Schematic Of Balancing Process

The example reported on Figure 21 refers to a fully automatic machine; in some case a semiautomatic
machine with an operator is recommended especially for balancing a reduced number of pieces with
different shapes.
See example Figure 23and Figure 24.

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 Figure 23
Semiautomatic Hard Bearing Horizontal Axis Balancing Machine Equipped With A Drilling Unit
Mounted On A Sturdy Horizontal Frame Suitable To Balance Crankshafts Only Loading/Unloading
Is Done By Hand.
(Under operation in Ferrari Maranello).

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 Figure 24
Vertical Axis Balancing Machine Equipped With An In Built Drilling Milling Unit And A Rotary Table.
Suitable To Balance By Removing Material Work pieces Such As Pulleys, Impellers, Centrifuges, Etc.

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