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RM 1016 US-e
HM-series modular balancing machines
Precision accuracy and maximum flexibility for universal applications
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C O N T E N T S
Introduction
The practice
The various modules Overview Mechanical equipment Drive Measuring instrumentationSafety equipment
Correcting
Ergonomics
Technical details
Fax questionnaire
Instruction sheet
Balancing creates quality
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Increasing demands
More sophisticated technical developments have lead to constantly
increasing requirements with regard to balancing quality. Higher
performance for applications such as high-speed tool spindles,
electric motors, turbines, fans, universal joint shafts or paper rolls
simply mean higher speed. The trend is clear, and in order to meet
these requirements precision balancing is essential. Accurately
balanced rotors allow us to safely reach higher speeds and deliver
considerably higher performance.
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Balancing enhances quality
Unless it is corrected, the effect of unbalance will often only
become noticeable in the finished product. If rotors are not
balanced, they can cause undesired or even dangerous vibrations.
They can also diminish the practical value of a machine, cause
damage to the bearing, or fractures to the casing, suspension or
foundation. Excessive noise and vibration may also irritate or
annoy the user and lead them to conclude that the product is of
poor quality. Thus, a product that is free from noise and vibration
is always a sign of quality, precision and craftsmanship.
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Belt drives for precision
Rotors with high operating speeds such
as this separator must be balanced
very accurately. The ideal solution for
such rotors is an underslung belt drive.
It prevents inaccuracies of mechanical
drive elements from affecting the rotor
unbalance readout.
Additional modules for versatility
The range of applications for the modular
universal balancing machine can easily
be increased by the use of additional
modules. This enables you to balance,
not only small electric motor armatures,
spindles, etc., but also tools and
toolholders quickly and accurately.
(For the exclusive balancing of
toolholders, we offer special balancing
machines.)
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The practice is the yardstick
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Overslung belt drives for convenience
For balancing small and medium size
lots, the overslung belt drive is the perfect
solution because it enables quick and
uncomplicated loading and unloading of
the rotors.
End drives for large inertia masses
Rotors with large flywheels require
high drive torques. The end drive is best
suited for these conditions. A split bed
makes it possible to mount workpieces
of a very large diameter. The possibility
of moving the drive in axial direction
enables easy and ergonomic working,
even with such rotors.
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Safety devices for any application
These electric motor armatures of up to
40,000 lbs. are balanced by applying
weights. The safety enclosure of the
protection class C according to ISO 7475
protects the surroundings against parts
that might fly off the rotor. The safety
enclosure is operated via a motor and
provides full access to the machine
when open.
Flexible rotors on hard-bearing balancing
machines
Rolls for paper or foil producing machines
often show an elastic behavior and must
be balanced in two or more correction
planes at high speed. On the hard-bearing
balancing machine you can bring the
rotors up to operating speed in order to
determine deflection and resonance during
acceleration. This data is used as the basis
for calculating the appropriate correction
weights.
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for measuring the efficiency of our HM machines
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Balancing at low and high speeds
Rotors of textile machines are balanced at
low and at high speeds. Consequently the
machine must meet very high dynamic
requirements. It must be suited for very exact
2-plane measurement of rigid rotors at low
speed as well as for testing flexible rotors up
to the maximum operating speed.
top right:
Spindle-bearing support for balancing
universal joint shafts
Universal joint shafts are accommodated
between spindles for balancing. A bear-
ing support and catching device that can
be moved by means of a motor facilitate
re-setting for another type of universal
joint shaft.
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Combine these five components for precision balancing results
A modular design for safety andflexibilityThe concept of the HM-series givesyou flexibility with the importantmachine modules. These fivemodules consist of the mechanicalequipment, drive, measuring unit,safety device and correction unitwhich can be perfectly adapted toyour balancing requirements.The best combination of compo-nents depends on many details: Are there many different rotor
sizes as in a repair shop, or do you
balance only one or two rotortypes in a production application?
What are the dimensions andweights of the rotors?
How are they loaded? What accuracy is required? Is it a rigid or a flexible rotor?Nothing is impossible with HMSeries balancing machines, or better,nearly everything is possible fromstandard universal machines up tocompletely integrated and customized
solutions.The flexibility of these machines isendless. If the requirements changewith your rotor program, the existingbalancing machine can generally beupgraded at low cost and with littleeffort.Simply complete the questionnaireattached to this brochure and tell usyour balancing requirements. Wewill then send you a proposal that isperfectly tailored to your application.
Versatile mechanical modules allowyou to balance a large range of
workpieces quickly and precisely.All modules can easily be adjustedto your rotor program at littleexpense.Based on standard lengths, themachine beds can be specified tomeet your individual requirements.The type of rotor support in thebalancing machine is chosen byyou according to your rotor design: roller carriages for rotors with
their own journals inclined roller bearings for rotors
to be balanced together withmounted bearings
bearing supports with sleevebearings for heavy rotors whichcannot be supported by rollerbearings, and
custom engineered designs forbalancing complete assemblies oruniversal joint shafts
See page 10 for further details
Mechanical equipment Drive
Our modular design offers the propersolution for any rotor or balancing
process. the underslung belt drive is an
economic solution that is appropriatefor rotors with a smooth outersurface
the overslung belt drive is the bestsolution if you have to balance alarge number of rotors and want theadvantages of a belt drive for thispurpose
the end drive is used if the surfaceof the rotor does not allow for a beltdrive or if the required drive poweris too large
you may also have a combinationof belt and end drive on the samemachine
See page 12 for further details
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Measuring instrumentation Safety equipment Correction unit
You can choose between threemeasuring units depending on your
requirements:CAB 700 the compact basic devicefor all standard balancing tasks:Simple operation via the menu, cleardisplays and a high degree of accuracyenable even less experienced opera-tors to balance a rotor perfectly.CAB 800 the comfortable andversatile measuring unit withWindows NT operating system. Itoffers all the functions of CAB 700plus a vector readout, algorithms forcomplex unbalance corrections, aswell as various types of result display,recording and documentation.CAB 690 perfectly suited for thebalancing of either rigid workpiecesor flexible rotors. Balancing atoperating speed, recording of therotor behavior during acceleration,measurement of vibration velocity,measurement of concentricity andeccentricity at a very high level of
signal processing are some of itsmany outstanding features.
See page 14 for further details
Schenck offers a complete line ofsafety enclosures that meet or
exceed industry regulations for theprotection of operator and machine.User-friendly protective devicesconforming to EC regulations ensurethat the machine is entitled to aCE/ISO 7475 certification.
See page 16 for further details
The modular components of themass correction system (MAK)
enable directly unbalance correctionon the balancing machine by meansof the removal or addition of material.The units can be attached axially fora correction on the face, and radiallyfor a correction at the outer diameter.For angular drilling, the correctionunit can be tilted.
See page 18 for further details
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MECHANICAL
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Mechanical equipment Experience and innovation
A precision balancing system is the
combination of mechanical equip-ment, measuring and control systemand software.With Schencks HM-series balancingmachines you can measure rotorunbalances equivalent to less thanone micrometer (m) eccentricity ofthe center of gravity. In other words, ifyou attached a label of the size of astamp to a 400 lb. rotor on a radius ofapproximately 8 inches, the balancingmachine would be able to identify the
position and the mass of this label this corresponds to a 3 millionth partof the rotor mass!
The stable bearing pedestalsare the interface betweenyour rotor and the balancingmachine. For this reason,they are appropriatelydesigned for good balancingquality and for everydayuse. Overall stiffness, maxi-mum linearity and minimumdamping characterize thismechanical unit.For the HM bearingpedestals we apply the
Schenck force-measuringprinciple. This means thatthe center part of thebearing pedestal is designedas a robust dynamometer.The pickups are situatedoutside the force flow andare not affected by impacts a definite advantage in arough industrial environ-ment.Another even more impor-
tant aspect is the perma-nent calibration of theentire system. Even in thefirst measuring run, theamount of unbalance andits angular position aredetermined for both balanc-ing planes and time con-suming calibration runs arenot necessary. The steelbearing pedestals even
The bearing pedestals sturdy and preciseabsorb heavy impacts thatmay occur when loading arotor without any problemsand without losing theirmeasuring accuracy. Themeasuring system alsomasters large initial unbal-ances.A small but quite importantdetail is the very narrowdesign of the bearingpedestals in direction of therotor axis. This provides
optimum conditions foreasy loading even in case ofshort rotor journals andexcessive cantilever lengthwithout requiring expensivespecial designs.Thus, the bearing pedestalsof our HM-series machinesare the basis for precisionbalancing at low operatingand service costs.
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The rotor support versatile and safe
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Inclined roller bearings safely support rotorsequipped with their ownanti-friction bearing. Thisheight adjustable bearingholds the rotor to bebalanced free from restor-ing forces about the rotorstransverse axis. Thus,
geometric inaccuracies ofthe anti-friction bearingscannot affect the unbalancereadout.
Sleeve bearings make balancing large,heavy rotors with journals,which are not suitable forroller carriages, possible.To avoid alignment errors,the bearings are sphericallyadjustable.
Special designsSpecial customized designsare also available for otherapplications such as forpedestal bearings or forcomplete assemblies.
Roller carriages are the solution forsupporting a large rangeof different rotors. Theycan be easily adjusted tothe journal diameter ofyour rotor without anytools. Their smooth surfaceavoids edge pressure and
excessive stress on rotorjournals. A sturdy radialhold-down bearing, eitherwith sliding block or withroller, increases operationalsafety. For specific applica-tions, such as flexiblerotors, we can also supplypatented damped rollercarriages.
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DRIVE The drives dynamic and flexible
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Belt drives are the right choice forrotors with a smoothsurface. They can be usedquickly, immediately and
without any special prepa-rations. The drives con-struction ensures accuratebelt guidance. In thespecified diameter range,the belt can be adjusted insuch a way that the beltruns vertically from therotor. This is the only wayto guarantee that the tensileforce of the belt does notaffect the measuringresult. Another advantage
The construction of the rotor also
determines the choice of the drive.You are particularly flexible withregard to any balancing tasks if youchoose a combined belt-and-end-drivefor your machine. With such a solutionyou will always have the appropriatedrive, even with frequently changingrotor programs. With the belt driveyou could balance an electric motorarmature, and then change to the enddrive to balance a fan which needsstrong drive power because of its
high air resistance all on one machineand with only a short set-up time.
The different drive systems
of this type of belt guidanceis that only two differentbelt lengths are required toutilize the entire performance
range of the machine.Stepped motor belt pulleysmake it possible to adjustthe drive power and speedto the body to be balanced.A fastening device securelyfixes the workpiece at thecircumference in balancingposition (optional).
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Squirrel-cage motors areused for small and mediumdrive power requirements,and DC motors are available
for larger controllablepower requirements. Freespeed selection, shortacceleration and shortbraking times enable aquick and dependable wayof working. Smooth accel-eration and brakingprocesses treat the univer-sal joint shafts, belts andother drive elements withcare. This also leads tohigh operational safety andreliable availability of thebalancing machine.
The performance adjusted to the taskEnd drives
are used for balancingvery heavy rotors with alarge moment of inertia, alarge air resistance, or for
rotors with a configurationthat makes using a beltdrive impossible.Gearboxes with motorizedpushbutton gear selectionprovide optimum adjust-ment of the electrical driveto the speed and torquerequirements. The flange ofthe universal drive shaft isaxially movable so that therotor can easily be connect-ed without having to moveit in the supports. A holdingdevice fixes the rotor atthe circumference in orderto ensure safe correction(optional).
There are two belt drivesavailable:The underslung belt drive ,proven and universal with
a large range of adjustment,is well suited for a rangeof diameters and transmitshigh drive power. The stan-dard pneumatic tensioningdevice provides for aconstant belt tension andfor reproducible measuringconditions.
The overslung belt drive is the appropriate solutionif high productivity isrequired. With this drive,the rotor loading andunloading procedure isvery quick and extremelysimple.
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MEASURING
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Once you have workedwith the powerful softwarein this precision measuringinstrument, you will findit is easily operated andperfect for universal appli-cations. With its compactdesign it meets the require-ments that really count
with universal balancingmachines. The CAB 700 isoperated by using a
combination of cursorkeys, a numerical keyboardand pre-defined functionkeys. It needs only very fewsteps to reach your aim.The well-arranged displaygives clear text informationin a variety of languages.Words, numbers, measuring
units and clear symbols indifferent colors facilitatea quick and safe readout.The instrument digitallyprocesses measuringsignals over a large unbal-ance range with highresolution and efficientnoise suppression.
The measuring devices simple and precise
The aim is a perfectly balanced
rotor and to reach this target weoffer an appropriate measuringdevice for every balancingrequirement. All devices functionaccording to a uniform operatingphilosophy provide precisionmeasurement processing and havea clear, easy-to-read display. Allof our measuring devices accuratelyprocess the measured signals andimmediately indicate the amountand angular position of the
unbalance. Functions such asstoring of measured values, index-ing displays, or instructions forcorrection, support the operatorquickly and efficiently whilebalancing the workpiece.
CAB 700 universal and cost-efficient
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The CAB 800 works withthe Windows NT operatingsystem. It offers all thefunctions of our CAB 700and provides a vectordisplay of the unbalancemeasurement at a glance.Thanks to its extendedcapacity, the CAB 800 can
also support complicatedbalancing processes.
Furthermore, it can easilybe coupled with other pro-gram systems or supersetcomputers.
Our CAB 690 is a high-performance measuringinstrument that has beenproven for both rigid andflexible rotors. It offers abroad application rangeand extraordinary accuracywith regard to signal pro-cessing and measurement.
It is the ideal instrumentfor balancing at operatingspeed and recordingmeasured values in orderto assess the rotor behaviorduring acceleration. It is
also perfectly suited formeasuring the vibrationvelocity, deviations inshape and eccentricityvalues. In addition, thismeasuring system issupplemented by powerfuland comprehensivecorrection software.
CAB 800 high-performance unit easy to integrate CAB 690 most accurate and versatile
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SAFETY
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Safety enclosures Its better to be on the safe side
Safety devices for balancing machines
help to avoid accidents and are evenprescribed by law for many applications.Schenck offers a complete line ofsafety barriers and enclosures thatmeet all regulations and applicablestandards for all machine sizes.
One decisive factor for thechoice of the appropriate
safety device is the hazardcaused by the rotor beingbalanced. This hazardpotential is determined bythe balancing speed, thebalancing method, and theshape and quality of theparts that may fly off therotor. Usually class B or Csafety enclosures are usedwith HM-series machines.
Protection class B is applic-able if parts flying off therotor are not a concern, butcontact with the rotor is(such as with fans, bladedrotors or metal-cuttingtools). This class requiresprotection around the rotor
or a barrier around theentire machine. The latter
offers optimum accessibilityfor loading and unloading,as well as during rotorcorrection and provides foreasy adjustment to anylocal conditions. Largesliding doors in the protec-tive enclosure ensure betteraccess to the balancingmachine. The enclosure isdesigned with safety inter-locks so it cannot beopened when the drive isactive and there is no riskof injury.
First-class safety
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All safety devices for HM-series machines meet the
requirements of DIN 45 690or ISO 7475. Balancingmachines equipped thisway are in line with theapplicable safety regula-tions of the EC (EuropeanStandard).
But that is not all protec-tion in accordance with theprotection classes B or C isonly one part of our safetyconcept. Comprehensivehazard analyses round offthe safety equipment ofSchenck RoTecs balancingmachines and make themperfect. an ergonomic design
avoids improper opera-tion
pinching points areeliminated
drives are equippedwith safety circuits at thebearing pedestals
radial hold-down bearingsavoid breaking out, and
axial hold-down bracketsensure that the rotorsdont move
AdviceAdvice in the field of protec-tive equipment is anotherelement of our safetyconcept. You can feel saferelying on our many yearsof experience and ourknowledge in this field!
Protection class C isapplicable if the possibility
of parts flying off the rotoris a concern. The protectivedevice is designed to bepuncture-proof so that theoperator and surroundingsare protected. When thedrive is active, the protectivedevice is electro-magnet-ically locked and cannot beopened accidentally. Allprotective enclosures areergonomically designed sothe rotors can be accessedquickly, without impedingthe operator.
Safety as a conceptNote! If your balancingapplication changes,
remember to check thatthe enclosure will meetthe new requirements!
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CORRECTING
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MAK Save time and cost
Measurement and correction without
re-clampingMAK Mass correction systemmakes it possible to measure andmake corrections in the balancingmachine. It is not necessary to movethe workpiece from the balancingmachine where the unbalance ismeasured to a separate machine toolfor correcting the unbalance as is stillcommon practice. Due to its design,MAK offers many advantages incomparison with the conventional
method. Since the rotor remains inthe machine during correction, timeis saved and balancing quality isimproved.Depending on the previously appliedbalancing method, number, and typeof rotor, the required time and costcan be reduced by 30 % to 50% !
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The rotor is loaded in themachine only once, thenthe measuring run isstarted and is immediately
followed by the correction.After checking the residualunbalance, the rotorbalancing is complete.Complicated handling ofthe rotors for correction isno longer necessary. SoMAK saves time exactlyat the point where youhave to invest most of it during the correctionprocess. Your rotor istransported less, so it istreated more carefully,and less material is re-moved which can provideadditional time and costsavings.
Load the rotor and thats it!In addition to the time sav-ings, there are also strongtechnical arguments infavor of the MAK system.
A correction in a separatemachine often leads toinaccuracies which thenrequires an additional cor-rection run. With MAK, therotor is indexed in thecorrect angular position inthe correction unit and thedrilling is performed exactlyat the required depth. As aresult, the ratio betweeninitial and residual unbal-ance improves. So addi-tional correction steps areavoided and the rotor is notruined by unnecessarydrillings.
Accurate correctionSuitable modules makeit possible to integrate theMAK system into yourbalancing machine at
nearly any point. With thissystem, correction can becarried out axially, radially,or on an angle. Variousmethods of metal cutting(removal of material) or ofattaching correction weights(addition of material) arepossible. MAK can be usedfor most types of rotors.Due to its modular design,it can be extended later orbuilt into existing balanc-ing machines.
Modular integration
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ERGONOMICS Ergonomics Operator and Machine
All frequently used adjust-ing elements are operatedby means of clampinglevers and no tiresome
search for the appropriatetool is required. To ensurequick and precise adjust-ments, the roller carriagesand idlers are equippedwith scales. For all basicsettings that must bechanged only occasionallywill you need one tool.
The bearing pedestals areadjusted at the desiredbearing distance by meansof a manual travelling
mechanism with ratchet. Atravelling mechanism withelectric motor and spring-loaded clamping devicesare available as an option.With these means, the HMbalancing machine can beset up for another rotorquickly and easily.
Re-setting in the blink ofan eye
Whats the use of good ideas if they
fail because of the details. We havethoroughly analyzed the balancingprocess and eliminated the problem-atic areas!
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A damping element at thehold-down bearings effec-tively prevents them fromclosing accidentally. Thisreduces the hazard of
injury and avoids excessiveuse of the interlockingmechanism. In case oflarge hold-down bearings,gas pressure springs are anadditional means to facil-itate operation so heavyhold-down bearings can beopened and closed withlittle effort and no dangerof injury.
Safety hold-down bearingsErgonomics also mean thatthe bearing pedestals havethe correct operatingheight. The rotor is easilyaccessible for correction
and all operating elementscan be reached withoutdifficulty. Working at theHM balancing machine isconvenient since it isdesigned to meet all opera-tor requirements.The same applies to thesafety devices which neitherimpede accessibility to theworking area, nor theloading and unloading oflarge rotors. And to makethings complete, operationof the protective devicescan be automated in orderto achieve faster handling.
Ergonomic in heightStraight to the objectivewithout any complications,that is our philosophy foroperating our measuringdevices. Clear operator
instructions, a limitednumber of function keys,intelligible dialogues andeasy-to-read displays inyour own language willguide you to balance arotor perfectly, without anyproblems.The operation of allmachine instrumentationis easy to learn in a shortperiod of time and helpsto avoid operator faults.Even if you do not use thebalancing machine veryoften, balancing will not bedifficult for you. The wellarranged display indicatingonly the informationactually required caneasily be read even froma greater distance.
Additional optionalaccessories, such as asecond operators monitor,or motorized bearingpedestals, considerably
expand the applicationrange of the balancingmachine and make opera-tion even easier.
Easy operation
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Type Machine Data Rotor Data
Max. rotorweight on roller
carriages [lb] 1)
Max. rotor diameter over themachine bed [in]
Standard Optional
Journal diameter rangeon roller carriages [in]
Max. sensitivityper plane
[gin] 2)
HM 1HM 10
HM 2HM 20
HM 3
HM 30
HM 4HM 40
HM 5HM 50
HM 6HM 60
HM 7
HM 70
HM 8HM 80
2236
100250
650
1500
3,3006,500
12,00017,500
27,50040,000
70,000
100,000
275,000550,000
1414
3131
49
49
6363
6363
8282
110
110
140140
4949
7676
8282
118118
140
140
196196
0.0020.004
0.0200.030
0.040
0.060
0.1000.150
0.3000.400
0.6000.800
1.250
1.500
3.0005.000
0.20 2.000.24 2.75
0.31 4.000.35 5.50
0.35 5.50
0.40 6.30
0.50 8.000.60 9.50
0.70 11.001.00 15.00
1.60 12.502.00 15.75
2.30 20.00
2.75 24.00
Different machine bed lengths are available,
depending on the type; this makes optimum
adaptation to the required maximum distance
between bearings possible.
Drive system standards are established on
each machine to accommodate typical
application requirements; however, drives
with higher hp ratings are also available.
1) For symmetrical loads.
Weight capacity is also deter-
mined by the available drive
power and balancing speed.
If machine is to be used
mainly in upper speed range,
choice of the next larger
machine model is recom-
mended to prevent excessive
wear. Maximum capacity on
rollers is also limited by
journal hardness (important
above 10,000 pound rotor
weight.)
2) This value is approximate
and depends on balancing
speed and type of measuring
unit. The minimum achiev-
able residual unbalance
depends on rotor, drive unit
and measuring instrument.
TECHNICAL DATAHM Specifications and Information
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Fax: 631-242-4147Please copy and send to Schenck Trebel
It is our aim to find an optimal solution for your balancing task. To prepare a quotation,please provide us with some information on your typical rotor types:
Name:
Phone:
Company:
Rotor type(s):
Rotor weight range [Ibs]:
Maximum diameter [inches]:
Maximum rotor length [inches]:
Journal diameter range [inches]:
Operating speed:
Balancing speed:
Balancing tolerance:
Number of correction planes:
Correction method:
Pieces per hour:
Sketch of rotor:
from
from
to
to
Address:
QUESTIONNAIRE From the rotor to the solution
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All advantages at a glance
Schencks HM-seriesbalancing machines aredesigned to meet mostbalancing requirementsin single unit or seriesproduction.
HM-series horizontal,hard-bearing balancingmachines solve any bal-ancing task.
Thanks to the modulardesign, the machines canbe fitted to each individ-ual application:
as a universal machine
that can be used ina repair shop withfrequently changingrotor sizes
runs. have a measuring
sequence with digitalmeasured value process-ing which makes themextremely accurate andstable in the long run,
enable perfect balancingof a large spectrum ofrotors with variable rotorsupport and adaptabledrive,
can be configuredindividually and adjustedto any balancing processby most versatile acces-
sories such as MAK mass correction withoutthe need to remove therotor from the machine,
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Balancing andDiagnostic Systems
Schenck Trebel Corporation535 Acorn StreetDeer Park, NY 11729Phone (631) 242-4010Fax (631) 242-4147eMail: [email protected]://www.schenck-usa.com
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The Group
Schenck RoTec Corporation2890 John R. RoadTroy, MI 48083Phone (248) 689-9000Fax (248) 689-8578eMail: [email protected]