Balancing of MM 340 Balancing Machine

A task in the project was to perform the balancing of the balancing machine available in the
mechanics of machine lab. The built in vibration analysis system in the machine was provided by
the ESSOM company. The system was not working as the software interface was not showing the
data obtained from the vibration sensors as well as the revolution counter sensor. In order to find
the fault in the machine, each and every component of the machine was tested using the available
known methods. First of all, all the software of the machine was installed on another computer and
data was taken. But the same error persisted. The pocket on the software interface that should show
the data were greyed out same as before. Therefore, another approach was selected. For the purpose
LabVIEW software with NI Max. DAQ driver was installed in the computer. The purpose of this
activity was to check whether sensors are giving data or not. The procedure used was taken from
the operating manual of the machine. The machine operating manual dictates that the vibration
sensors as well as rpm sensors must give sinusoidal waves. But when observed in the LabVIEW,
the data was very random.

Figure 1: The comparison of the actual wave form and correct waveform of the rpm data obtained using NI DAQ Max Test
Panels

The correct data for the revolution per minute was on the right side of above figure. It is very
regular and periodic in the shape. The actual data from the laser rpm sensor is not periodic and
somewhat random as well.
The data coming from the vibration sensor 1 attached to the left plane of the machine was also
obtained from the machine using DAQ Max test panels. This data was compared with given
waveform in the manual of the machine for interpretation.

Figure 2:The comparison of the actual wave form and correct waveform of the vibration from sensor 1 with data obtained using
NI DAQ Max Test Panels

The comparison clearly shows that the actual data was very random. The actual data was close to
the periodic but maximum value of the vibration vary too much and unpredictably. The vibration
data for the second vibration sensor was found no different. This data was also very random. The
manufacturer of the machine dictates that this data must be periodic and clean from the noise. But
that is not the case with the actual data obtained.

There is another component between the sensors and the computer. This was integral part of the
machine electronics. This part was NI USB 6009 card. All the data from the sensors go to the card
and it process the data and feed it to the computer software. The computer software then interpreted
the data and calculate the amount of unbalance in the machine. As the data from the machine was
random, this could possibly be due to the reason that card was not working properly. Therefore,
the software of the machine was not getting data in the clean form that it can interpret. Possibly
the data filters in the card were not properly filtering the data. This conclusion was reached due to
the fact that the operating manual dictates that if the data obtained by the sensors is not periodic
and different from the above clean waveforms, then the system is not working properly.

Figure 3: The comparison of the actual wave form and correct waveform of the vibration from sensor 2 with data obtained using
NI DAQ Max Test Panels

Experimental Setup
As the original system of the machine was not working properly, therefore, data acquisition system
and software developed for the dummy Perspex apparatus was used to balance the MM 340
dynamic balancing machine. The data for the phase of vibration could not be obtained from the
sensors of the machine, therefore, a rotary encoder was ordered from the Hallroad.org website.
The rotary encoder used was 1000 pulse per revolution and 5 V encoder. The model was JXL-G8L
1000. This rotary encoder can be used for measuring the phase of the vibration by recording the
degree in a cycle at which maximum vibration reading of the encoder occur. The signals from the
encoder were also converted to the revolution per minute speed to check its accuracy with inverter
of the machine. The rpm reading from both inverter and rotary encoder were in perfect agreement
indicating that rotary encoder was working properly.
 Figure 4: Rotary encoder used in the MM 340 machine

In order to install the rotary encoder to the machine shaft, some modification in the machine were
made. These modifications were fabrication of an aluminum coupling and attachment for mounting
the rotary encoder.

Figure 5: Design Modification in the machine for attaching rotary encoder

The attachment consisted of a plate on which the rotary encoder were installed. This attachment
was then attached to the right plane of the machine using studs, washers and nuts. Two MPU 6050
accelerometers were attached at each plane on the left and right side of the disk. All the data was
fed to the Arduino Mega 2560 and Arduino codes obtain data from the sensor and show them on
the serial monitor. One Arduino code takes the data for the fast Fourier transform for validation of
the results after and before balancing. The second code gives the maximum vibration reading with
the phase angle at both left and right plane.

Results and Discussion

Static Balancing
The static balancing of lab apparatus was performed with the help of above mentioned
experimental setup. Two different imbalance masses of 200 gram and 500 gram were used as the
imbalance mass. The trial mass used for the experiment was 50 gram. The vector method, influence
coefficient method and counter weight method were used in the calculation of balancing masses
for the system. Following results were obtained in the experiments. Initially when only 500 gram
imbalance was present, the system was run at 300 rpm and data was obtained. The FFT of the data
was performed to get following result for subsequent comparison with post balancing results.

Figure 6: Data with 500 gram imbalance in frequency domain

With the unbalance mass of 500 gram and a trial mass of 100 gram at 240 degree, the calculated
balancing mass using vector method was found to be 70 gram at 106 degree angle. But the possible
angle close to 106 degree was 120 degree, therefore, the mass was attached at that angle and
following results were obtained.

Figure 7: Vibration data after balancing 500 gram mass with 70 gram at 120 degree in time domain

The fast Fourier transform was performed on the data after balancing the system. The results shows
that some imbalance in the system was still present but was less than original imbalance.
 Figure 8: Vibration data after balancing 500 gram mass with 70 gram at 120 degree in frequency domain

With the unbalance mass of 500 gram and a trial mass of 50 gram at 240 degree, the calculated
balancing mass using vector method was found to be 265 gram at 123 degree angle. But the
possible angle close to 123 degree was 120 degree, therefore, the mass was attached at that angle
and following results were obtained.
 Figure 9: Vibration data after balancing 500 gram mass with 265 gram at 120 degree in frequency domain

The fast Fourier transform was performed on the data after balancing the system. The results shows
that some imbalance in the system was still present 0.13 but was less than original imbalance
amplitude of 0.17.

With the unbalance mass of 500 gram and a trial mass of 100 gram at 240 degree, the calculated
balancing mass using influence coefficient method was found to be 128 gram at 156.6 degree
angle. But the possible angle close to 156 degree was 180 degree, therefore, the mass was attached
at that angle and following results were obtained.
 Figure 10: Vibration data after balancing 500 gram mass with 128 gram at 180 degree in frequency domain

The results shows that some imbalance in the system was still present 0.11 but was less than
original imbalance amplitude of 0.17.

At the end, third strategy of counter balancing was performed using the 500 gram balancing mass
attached at the same radius and 180 degree angle to the reference unbalance mass of 500 degree.

Figure 11: Vibration data after balancing 500 gram mass with 500 gram at 180 degree in time domain
The fast Fourier transform was performed on the data after balancing the system. The results shows
that negligible imbalance in the system was found 0.01 which was much less than original
imbalance amplitude of 0.17.

Figure 12: Vibration data after balancing 500 gram mass with 500 gram at 180 degree in frequency domain

Therefore, best strategy for static balancing in the MOM lab apparatus was found to be counter
balancing strategy.

Dynamic Balancing
In order to perform the dynamic balancing of the lab apparatus, first of all, another plane was
installed at the machine. Then an unbalance of 500 gram was attached at the left plane of the
machine and system was run at 300 rpm. The data was taken with the help of accelerometers and
rotary encoder to the Arduino program. The data for the FFT was obtained using the left plane
accelerometer. Three different trials of the experiment are discussed below with the pre-balancing
and post-balancing of the results.

In first trial, 500 gram mass was attached and vibration data was obtained in the time domain and
then in the frequency domain.
 Figure 13: Data of the 500 gram imbalance mass at left plane at 5 Hz or 300 rpm in the time domain

Following result of the FFT were obtained. The results shows that the unbalance amplitude was
found to be 0.38 at 5 Hz (1x) or 300 rpm. This reading was noted for the subsequent comparison
for validation of results.

Figure 14: Data of the 500 gram imbalance mass at left plane at 5 Hz or 300 rpm in the frequency domain

A trial mass of 200 gram was attached at 120 degree on the left plane and system was run again at
300 rpm. The vibration reading of -1.55 g at 44 degree on the left plane and 1.56 g at 194 degree
on the right plane. Then trial mass on the left plane was removed and attached to 200 degree on
the right plane with respect to reference. Again vibration was recorded. It was found to be -1.15 g
at 243 degree on left plane and 1.17 at 36 degree on the right plane. All the data was put into the
dynamic balancing software and correction masses with the corresponding angles were calculated.

Figure 15: Calculation of balancing mass using the software for dynamic balancing

After calculation of the balancing mass, a mass of 100 gram instead of 88 gram was attached at
120 degree instead of 131 degree on the left plane based on the limitations. Similarly, a mass of
115 gram was attached at 200 degree instead of 190.64 degree on the right plane. After balancing
the system, the machine was again turned on at 300 rpm and vibration data was obtained in the
time domain as follows.
 Figure 16: Vibration Data in time domain after balancing

The FFT of the above data was performed using the Matlab code and compared with the previous
data in frequency and time domain.

Figure 17: Vibration data after balancing in frequency domain

The results of the dynamic balancing shows that the vibration amplitude of the system had been
reduced by more than 50 %, both in time domain signal and frequency domain signal.

In the second trial, same procedure was repeated and a different combination of balancing masses
was calculated as there can be infinite combinations for the dynamic balancing.

A trial mass of 200 gram was attached at 120 degree on the left plane and system was run again at
300 rpm. The vibration reading of 3.6 g at 294 degree on the left plane and 2.08 g at 294 degree
on the right plane. Then trial mass on the left plane was removed and attached to 200 degree on
the right plane with respect to reference. Again vibration was recorded. It was found to be -3.21 g
at 251 degree on left plane and -1.18 at 258 degree on the right plane. All the data was put into the
dynamic balancing software and correction masses with the corresponding angles were calculated.

Figure 18: Calculation of balancing mass using the software for dynamic balancing
As a result a mass of 90 gram was attached at 120 degree on left plane and a mass of 115 gram
was attached at 200 degree instead of 220 degree on right plane. After balancing the system,
following results were obtained.

Figure 19: Vibration data after balancing in frequency domain

The vibration amplitude at 5 Hz has decreased from 0.24 to 0.12 g indicating successful dynamic
balancing of the system.

In the third trial experiment, a trial mass of 200 gram was attached at 120 degree on the left plane
and system was run again at 300 rpm. Then trial mass on the left plane was removed and attached
to 200 degree on the right plane with respect to reference. Again vibration was recorded. All the
data was put into the dynamic balancing software and correction masses with the corresponding
angles were calculated. The results showed that a balancing mass of 197 gram at 180 degree on
the left plane and 116 gram on 107 degree at the right plane needs to be attached. After balancing
the system by using 200 gram at 180 degree and 116 gram on 140 degree instead of 107 degree,
following results were obtained.
 Figure 20: Vibration Data in time domain after balancing

The FFT of the above data was performed using the Matlab code and compared with the previous
data in frequency and time domain.

Figure 21: Vibration data after balancing in frequency domain

The results shows that the vibration amplitude decreased from 0.28 g to 0.12 g with the help of
dynamic balancing.

Conclusion
The above project focuses on the rotary machinery problem such as rotary imbalance. The rotary
imbalance causes excessive vibration of the machines and reduce their life. The project started by
development of a data acquisition system for detection and correction of rotary imbalance of
machines using condition monitoring. The data acquisition system includes the accelerometers and
rotary encoder attached with Arduino Mega 2560 board. An algorithm was developed using
Matlab software for calculation of correction masses in order to save time. The software uses
vector method of balancing. The system was first tested on a dummy apparatus made of Perspex
to evaluate the technique and data acquisition system. In the second phase of the project, an
investigative had been performed on the Dynamic balancing machine MM 340 in the mechanics
of machine lab. The investigation showed that the data filters in the machine were not working
properly and software could not interpret the coming data. Therefore, in order to reuse the machine
a set of experiments were performed on the machine using the already developed electronics and
software. For the purpose, some modifications in the machine were also performed. Initially, the
results were not satisfactory. But the FFT of the vibration data of the machine showed that
amplitude of vibration by the unbalance was much less than the vibration noise by other faults in
the machine like looseness and misalignment etc. Therefore, it was found that when a mass of 500
gram was attached as unbalance mass, machine produced periodic vibrations. This vibration data
was then used to perform the static and dynamic balancing of the machine.