HM-series modular balancing machines

Precision accuracy and maximum flexibility for universal applications

RM 1016 US-e

Balancing creates quality

Introduction The practice The various modules Overview Mechanical equipment Drive Measuring instrumentation Safety equipment Correcting Ergonomics Technical details Fax questionnaire Instruction sheet 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.

The practice is the yardstick

Belt drives for precision Rotors with high operating speeds such as this separator must be balanced 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.) 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.

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.

 for measuring the efficiency of our HM machines

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.

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.

top right: Spindle-bearing support for balancing universal joint shafts Universal joint shafts are accommodated between spindles for balancing. A bearing support and catching device that can be moved by means of a motor facilitate re-setting for another type of universal joint shaft. 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.

Combine these five components for precision balancing results

A modular design for safety and flexibility The concept of the HM-series gives you flexibility with the important machine modules. These five modules consist of the mechanical equipment, drive, measuring unit, safety device and correction unit which can be perfectly adapted to your balancing requirements. The best combination of components depends on many details: Are there many different rotor sizes as in a repair shop, or do you balance only one or two rotor types in a production application? What are the dimensions and weights of the rotors? How are they loaded? What accuracy is required? Is it a rigid or a flexible rotor? Nothing is impossible with HM Series balancing machines, or better, nearly everything is possible from standard universal machines up to completely integrated and customized solutions. The flexibility of these machines is endless. If the requirements change with your rotor program, the existing balancing machine can generally be upgraded at low cost and with little effort. Simply complete the questionnaire attached to this brochure and tell us your balancing requirements. We will then send you a proposal that is perfectly tailored to your application.

Mechanical equipment

Drive

Versatile mechanical modules allow you to balance a large range of workpieces quickly and precisely. All modules can easily be adjusted to your rotor program at little expense. Based on standard lengths, the machine beds can be specified to meet your individual requirements. The type of rotor support in the balancing machine is chosen by you according to your rotor design: roller carriages for rotors with their own journals inclined roller bearings for rotors to be balanced together with mounted bearings bearing supports with sleeve bearings for heavy rotors which cannot be supported by roller bearings, and custom engineered designs for balancing complete assemblies or universal joint shafts See page 10 for further details

Our modular design offers the proper solution for any rotor or balancing process. the underslung belt drive is an economic solution that is appropriate for rotors with a smooth outer surface the overslung belt drive is the best solution if you have to balance a large number of rotors and want the advantages of a belt drive for this purpose the end drive is used if the surface of the rotor does not allow for a belt drive or if the required drive power is too large you may also have a combination of belt and end drive on the same machine See page 12 for further details

Measuring instrumentation

Safety equipment

Correction unit

You can choose between three measuring units depending on your requirements: CAB 700 the compact basic device for all standard balancing tasks: Simple operation via the menu, clear displays and a high degree of accuracy enable even less experienced operators to balance a rotor perfectly. CAB 800 the comfortable and versatile measuring unit with Windows NT operating system. It offers all the functions of CAB 700 plus a vector readout, algorithms for complex unbalance corrections, as well as various types of result display, recording and documentation. CAB 690 perfectly suited for the balancing of either rigid workpieces or flexible rotors. Balancing at operating speed, recording of the rotor behavior during acceleration, measurement of vibration velocity, measurement of concentricity and eccentricity at a very high level of signal processing are some of its many outstanding features. See page 14 for further details

Schenck offers a complete line of safety enclosures that meet or exceed industry regulations for the protection of operator and machine. User-friendly protective devices conforming to EC regulations ensure that the machine is entitled to a CE/ISO 7475 certification. See page 16 for further details

The modular components of the mass correction system (MAK) enable directly unbalance correction on the balancing machine by means of the removal or addition of material. The units can be attached axially for a correction on the face, and radially for a correction at the outer diameter. For angular drilling, the correction unit can be tilted. See page 18 for further details

Mechanical equipment Experience and innovation

MECHANICAL
The bearing pedestals sturdy and precise The stable bearing pedestals absorb heavy impacts that may occur when loading a are the interface between your rotor and the balancing rotor without any problems and without losing their machine. For this reason, measuring accuracy. The they are appropriately designed for good balancing measuring system also masters large initial unbalquality and for everyday use. Overall stiffness, maxi- ances. mum linearity and minimum A small but quite important detail is the very narrow damping characterize this design of the bearing mechanical unit. pedestals in direction of the For the HM bearing rotor axis. This provides pedestals we apply the optimum conditions for Schenck force-measuring easy loading even in case of principle. This means that short rotor journals and the center part of the bearing pedestal is designed excessive cantilever length without requiring expensive as a robust dynamometer. special designs. The pickups are situated Thus, the bearing pedestals outside the force flow and of our HM-series machines are not affected by impacts are the basis for precision a definite advantage in a balancing at low operating rough industrial environand service costs. ment. Another even more important aspect is the permanent calibration of the entire system. Even in the first measuring run, the amount of unbalance and its angular position are determined for both balancing planes and time consuming calibration runs are not necessary. The steel bearing pedestals even

A precision balancing system is the combination of mechanical equipment, measuring and control system and software. With Schencks HM-series balancing machines you can measure rotor unbalances equivalent to less than one micrometer (m) eccentricity of the center of gravity. In other words, if you attached a label of the size of a stamp to a 400 lb. rotor on a radius of approximately 8 inches, the balancing machine would be able to identify the position and the mass of this label this corresponds to a 3 millionth part of the rotor mass!

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The rotor support versatile and safe Roller carriages Inclined roller bearings are the solution for safely support rotors supporting a large range equipped with their own of different rotors. They anti-friction bearing. This can be easily adjusted to height adjustable bearing the journal diameter of holds the rotor to be your rotor without any balanced free from restortools. Their smooth surface ing forces about the rotors avoids edge pressure and transverse axis. Thus, excessive stress on rotor geometric inaccuracies of journals. A sturdy radial the anti-friction bearings hold-down bearing, either cannot affect the unbalance with sliding block or with readout. roller, increases operational safety. For specific applications, such as flexible rotors, we can also supply patented damped roller carriages.

Sleeve bearings make balancing large, heavy rotors with journals, which are not suitable for roller carriages, possible. To avoid alignment errors, the bearings are spherically adjustable.

Special designs Special customized designs are also available for other applications such as for pedestal bearings or for complete assemblies.

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The drives dynamic and flexible

DRIVE

The construction of the rotor also determines the choice of the drive. You are particularly flexible with regard to any balancing tasks if you choose a combined belt-and-end-drive for your machine. With such a solution you will always have the appropriate drive, even with frequently changing rotor programs. With the belt drive you could balance an electric motor armature, and then change to the end drive to balance a fan which needs strong drive power because of its high air resistance all on one machine and with only a short set-up time.

The different drive systems Belt drives are the right choice for rotors with a smooth surface. They can be used quickly, immediately and without any special preparations. The drives construction ensures accurate belt guidance. In the specified diameter range, the belt can be adjusted in such a way that the belt runs vertically from the rotor. This is the only way to guarantee that the tensile force of the belt does not affect the measuring result. Another advantage

of this type of belt guidance is that only two different belt lengths are required to utilize the entire performance range of the machine. Stepped motor belt pulleys make it possible to adjust the drive power and speed to the body to be balanced. A fastening device securely fixes the workpiece at the circumference in balancing position (optional).

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There are two belt drives available: The underslung belt drive, proven and universal with a large range of adjustment, is well suited for a range of diameters and transmits high drive power. The standard pneumatic tensioning device provides for a constant belt tension and for reproducible measuring conditions. The overslung belt drive is the appropriate solution if high productivity is required. With this drive, the rotor loading and unloading procedure is very quick and extremely simple.

End drives are used for balancing very heavy rotors with a large moment of inertia, a large air resistance, or for rotors with a configuration that makes using a belt drive impossible. Gearboxes with motorized pushbutton gear selection provide optimum adjustment of the electrical drive to the speed and torque requirements. The flange of the universal drive shaft is axially movable so that the rotor can easily be connected without having to move it in the supports. A holding device fixes the rotor at the circumference in order to ensure safe correction (optional).

The performance adjusted to the task Squirrel-cage motors are used for small and medium drive power requirements, and DC motors are available for larger controllable power requirements. Free speed selection, short acceleration and short braking times enable a quick and dependable way of working. Smooth acceleration and braking processes treat the universal joint shafts, belts and other drive elements with care. This also leads to high operational safety and reliable availability of the balancing machine.

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The measuring devices simple and precise

MEASURING

The aim is a perfectly balanced rotor and to reach this target we offer an appropriate measuring device for every balancing requirement. All devices function according to a uniform operating philosophy provide precision measurement processing and have a clear, easy-to-read display. All of our measuring devices accurately process the measured signals and immediately indicate the amount and angular position of the unbalance. Functions such as storing of measured values, indexing displays, or instructions for correction, support the operator quickly and efficiently while balancing the workpiece.

CAB 700 universal and cost-efficient combination of cursor Once you have worked keys, a numerical keyboard with the powerful software and pre-defined function in this precision measuring keys. It needs only very few instrument, you will find steps to reach your aim. it is easily operated and The well-arranged display perfect for universal appligives clear text information cations. With its compact design it meets the require- in a variety of languages. Words, numbers, measuring ments that really count units and clear symbols in with universal balancing different colors facilitate machines. The CAB 700 is a quick and safe readout. operated by using a The instrument digitally processes measuring signals over a large unbalance range with high resolution and efficient noise suppression.

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CAB 800 high-performance unit easy to integrate Furthermore, it can easily The CAB 800 works with the Windows NT operating be coupled with other program systems or superset system. It offers all the computers. functions of our CAB 700 and provides a vector display of the unbalance measurement at a glance. Thanks to its extended capacity, the CAB 800 can also support complicated balancing processes.

CAB 690 most accurate and versatile also perfectly suited for Our CAB 690 is a highmeasuring the vibration performance measuring velocity, deviations in instrument that has been shape and eccentricity proven for both rigid and values. In addition, this flexible rotors. It offers a measuring system is broad application range supplemented by powerful and extraordinary accuracy and comprehensive with regard to signal procorrection software. cessing and measurement. It is the ideal instrument for balancing at operating speed and recording measured values in order to assess the rotor behavior during acceleration. It is

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Safety enclosures Its better to be on the safe side

SAFETY

Safety devices for balancing machines help to avoid accidents and are even prescribed by law for many applications. Schenck offers a complete line of safety barriers and enclosures that meet all regulations and applicable standards for all machine sizes.

First-class safety One decisive factor for the choice of the appropriate safety device is the hazard caused by the rotor being balanced. This hazard potential is determined by the balancing speed, the balancing method, and the shape and quality of the parts that may fly off the rotor. Usually class B or C safety enclosures are used with HM-series machines. Protection class B is applicable if parts flying off the rotor are not a concern, but contact with the rotor is (such as with fans, bladed rotors or metal-cutting tools). This class requires protection around the rotor

or a barrier around the entire machine. The latter offers optimum accessibility for loading and unloading, as well as during rotor correction and provides for easy adjustment to any local conditions. Large sliding doors in the protective enclosure ensure better access to the balancing machine. The enclosure is designed with safety interlocks so it cannot be opened when the drive is active and there is no risk of injury.

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Protection class C is applicable if the possibility of parts flying off the rotor is a concern. The protective device is designed to be puncture-proof so that the operator and surroundings are protected. When the drive is active, the protective device is electro-magnetically locked and cannot be opened accidentally. All protective enclosures are ergonomically designed so the rotors can be accessed quickly, without impeding the operator.

Note! If your balancing application changes, remember to check that the enclosure will meet the new requirements!

Safety as a concept All safety devices for HMseries machines meet the requirements of DIN 45 690 or ISO 7475. Balancing machines equipped this way are in line with the applicable safety regulations of the EC (European Standard). But that is not all protection in accordance with the protection classes B or C is only one part of our safety concept. Comprehensive hazard analyses round off the safety equipment of Schenck RoTecs balancing machines and make them perfect. an ergonomic design avoids improper operation pinching points are eliminated drives are equipped with safety circuits at the bearing pedestals

radial hold-down bearings avoid breaking out, and axial hold-down brackets ensure that the rotors dont move

Advice Advice in the field of protective equipment is another element of our safety concept. You can feel safe relying on our many years of experience and our knowledge in this field!

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MAK Save time and cost

CORRECTING

Measurement and correction without re-clamping MAK Mass correction system makes it possible to measure and make corrections in the balancing machine. It is not necessary to move the workpiece from the balancing machine where the unbalance is measured to a separate machine tool for correcting the unbalance as is still common practice. Due to its design, MAK offers many advantages in comparison with the conventional method. Since the rotor remains in the machine during correction, time is saved and balancing quality is improved. Depending on the previously applied balancing method, number, and type of rotor, the required time and cost can be reduced by 30 % to 50 %!

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Load the rotor and thats it! The rotor is loaded in the machine only once, then the measuring run is started and is immediately followed by the correction. After checking the residual unbalance, the rotor balancing is complete. Complicated handling of the rotors for correction is no longer necessary. So MAK saves time exactly at the point where you have to invest most of it during the correction process. Your rotor is transported less, so it is treated more carefully, and less material is removed which can provide additional time and cost savings.

Accurate correction In addition to the time savings, there are also strong technical arguments in favor of the MAK system. A correction in a separate machine often leads to inaccuracies which then requires an additional correction run. With MAK, the rotor is indexed in the correct angular position in the correction unit and the drilling is performed exactly at the required depth. As a result, the ratio between initial and residual unbalance improves. So additional correction steps are avoided and the rotor is not ruined by unnecessary drillings.

Modular integration Suitable modules make it possible to integrate the MAK system into your balancing machine at nearly any point. With this system, correction can be carried out axially, radially, or on an angle. Various methods of metal cutting (removal of material) or of attaching correction weights (addition of material) are possible. MAK can be used for most types of rotors. Due to its modular design, it can be extended later or built into existing balancing machines.

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Ergonomics Operator and Machine

ERGONOMICS

Whats the use of good ideas if they fail because of the details. We have thoroughly analyzed the balancing process and eliminated the problematic areas!

Re-setting in the blink of an eye All frequently used adjusting elements are operated by means of clamping levers and no tiresome search for the appropriate tool is required. To ensure quick and precise adjustments, the roller carriages and idlers are equipped with scales. For all basic settings that must be changed only occasionally will you need one tool.

The bearing pedestals are adjusted at the desired bearing distance by means of a manual travelling mechanism with ratchet. A travelling mechanism with electric motor and springloaded clamping devices are available as an option. With these means, the HM balancing machine can be set up for another rotor quickly and easily.

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Safety hold-down bearings A damping element at the hold-down bearings effectively prevents them from closing accidentally. This reduces the hazard of injury and avoids excessive use of the interlocking mechanism. In case of large hold-down bearings, gas pressure springs are an additional means to facilitate operation so heavy hold-down bearings can be opened and closed with little effort and no danger of injury.

Ergonomic in height Ergonomics also mean that the bearing pedestals have the correct operating height. The rotor is easily accessible for correction and all operating elements can be reached without difficulty. Working at the HM balancing machine is convenient since it is designed to meet all operator requirements. The same applies to the safety devices which neither impede accessibility to the working area, nor the loading and unloading of large rotors. And to make things complete, operation of the protective devices can be automated in order to achieve faster handling.

Easy operation Straight to the objective without any complications, that is our philosophy for operating our measuring devices. Clear operator instructions, a limited number of function keys, intelligible dialogues and easy-to-read displays in your own language will guide you to balance a rotor perfectly, without any problems. The operation of all machine instrumentation is easy to learn in a short period of time and helps to avoid operator faults. Even if you do not use the balancing machine very often, balancing will not be difficult for you. The well arranged display indicating only the information actually required can easily be read even from a greater distance.

Additional optional accessories, such as a second operators monitor, or motorized bearing pedestals, considerably expand the application range of the balancing machine and make operation even easier.

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HM Specifications and Information

TECHNICAL DATA
Machine Data Max. rotor weight on roller carriages [lb] 1) Max. rotor diameter over the machine bed [in] Standard Optional 49 49 76 76 82 82 118 118 140 140 196 196 0.20 0.24 0.31 0.35 0.35 0.40 0.50 0.60 0.70 1.00 1.60 2.00 2.30 2.75 2.00 2.75 4.00 5.50 5.50 6.30 8.00 9.50 0.002 0.004 0.020 0.030 0.040 0.060 0.100 0.150 0.300 0.400 0.600 0.800 1.250 1.500 3.000 5.000 Rotor Data Journal diameter range on roller carriages [in] Max. sensitivity per plane [gin] 2)

Type

HM 1 HM 10 HM 2 HM 20 HM 3 HM 30 HM 4 HM 40 HM 5 HM 50 HM 6 HM 60 HM 7 HM 70 HM 8 HM 80

22 36 100 250 650 1500 3,300 6,500 12,000 17,500 27,500 40,000 70,000 100,000 275,000 550,000

14 14 31 31 49 49 63 63 63 63 82 82 110 110 140 140

11.00 15.00 12.50 15.75 20.00 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 determined 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 recommended to prevent excessive wear. Maximum capacity on rollers is also limited by journal hardness (important above 10,000 pound rotor weight.)

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This value is approximate and depends on balancing speed and type of measuring unit. The minimum achievable residual unbalance depends on rotor, drive unit and measuring instrument.

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From the rotor to the solution

Fax: 631- 242-4147

QUESTIONNAIRE
Please copy and send to Schenck Trebel
Name: Company:

Phone:

Address:

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:
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: from to from to

Sketch of rotor:

All advantages at a glance

Schencks HM-series balancing machines are designed to meet most balancing requirements in single unit or series production. HM-series horizontal, hard-bearing balancing machines solve any balancing task. Thanks to the modular design, the machines can be fitted to each individual application: as a universal machine that can be used in a repair shop with frequently changing rotor sizes or as an individual customized solution, if the machine is used in a production application for one type of rotor only.

runs. have a measuring sequence with digital measured value processing which makes them extremely accurate and stable in the long run, enable perfect balancing of a large spectrum of rotors with variable rotor support and adaptable drive, can be configured individually and adjusted to any balancing process by most versatile accessories such as MAK mass correction without the need to remove the rotor from the machine, offer a comprehensive safety package for protection classes B and C which will protect your operating personnel, are a safe solution for the future, since upgrading is usually possible with little effort and at low cost.

HM-series balancing machines

are well suited for the rough work in a repair shop due to their sturdy construction, are equipped with ergonomically designed operating elements for easy and safe handling, feature permanent calibration to make fast and accurate balancing possible without time consuming calibration

Count on our HM balancing machines for state-of-the-art results!

Balancing and Diagnostic Systems Schenck Trebel Corporation 535 Acorn Street Deer Park, NY 11729 Phone (631) 242-4010 Fax (631) 242-4147 eMail: sales@schenck-usa.com http://www.schenck-usa.com Schenck RoTec Corporation 2890 John R. Road Troy, MI 48083 Phone (248) 689-9000 Fax (248) 689-8578 eMail: rotecsales@schenck-usa.com

The

Group

RM 1016 us-e 10.0103 m/o All information without obligation. Subject to change without notice. Windows NT is a registered brand name of Microsoft Corp.