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Balancing single/dual plane (view source)
Revision as of 10:52, 26 November 2024
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=Single / Dual PLANE Balancing: User<nowiki>'</nowiki>s Manual= | =Single / Dual PLANE Balancing: User<nowiki>'</nowiki>s Manual= | ||
==Introduction== | ==Introduction== | ||
A rotor is a shaft rotating around its axis during service. In general such a rotor consists of a shaft with one or more discs fitted to the axle. Such discs can be fly wheels, grinding wheels, turbine wheels, etc. The shaft is usually running in bearings allowing the rotation of the body. Depending on their rotational speed, two basic categories can be defined to classify rotors: <u>rotors with rigid shaft</u>, and <u>rotors with flexible shaft</u>. <br> | A rotor is a shaft rotating around its axis during service. In general, such a rotor consists of a shaft with one or more discs fitted to the axle. Such discs can be fly wheels, grinding wheels, turbine wheels, etc. The shaft is usually running in bearings allowing the rotation of the body. Depending on their rotational speed, two basic categories can be defined to classify rotors: <u>rotors with rigid shaft</u>, and <u>rotors with flexible shaft</u>. <br> | ||
<br> | <br> | ||
If the operating speed remains below half of the first critical bending speed, the shaft does not deflect : it may be considered as a rotor with a rigid shaft. At such operational speeds and due to the non circular cross section of the rotor, the axis of rotation (Z) and the inertial axis (Δ) does not coincide (e.g. the mass is not evenly dispatched in a section of the shaft). This may results in a tumbling movement of the structure, | If the operating speed remains below half of the first critical bending speed, the shaft does not deflect : it may be considered as a rotor with a rigid shaft. At such operational speeds and due to the non circular cross section of the rotor, the axis of rotation (Z) and the inertial axis (Δ) does not coincide (e.g. the mass is not evenly dispatched in a section of the shaft). This may results in a tumbling movement of the structure, this amplitude depends on the bearing clearance and stiffness. In any case, the bearings are subjected to unnecessary or even not allowed loads. | ||
[[Image:Unbalanced_shaft_schem.png|framed|center|''Unbalance : | [[Image:Unbalanced_shaft_schem.png|framed|center|''Unbalance : Inertial axis does not coincide with rotational axis.<br> The unevenly mass distribution is represented by "m"'']]<br> | ||
At higher speeds the shaft will deflect, due to is own stiffness. In that case, it might be considered as a rotor with flexible shaft. Depending on the position of the discs on the shaft they can even be inclined and thus create an oil whirl. In that case, the Multiplane Balancing solution must be used.<br> | At higher speeds the shaft will deflect, due to is own stiffness. In that case, it might be considered as a rotor with flexible shaft. Depending on the position of the discs on the shaft they can even be inclined and thus create an oil whirl. In that case, the Multiplane Balancing solution must be used.<br> | ||
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'''Accelerometer''' | '''Accelerometer''' | ||
The measurement direction of the accelerometer must be referred to the tach sensor position. This can be done by the "Angular correction" in the analyzer setup. In our example in '''Sketch 1,''' the '''angular correction''' </font>is '''90°''' and the <font color="#339966">'''offset''' </font>is -'''15 °'''. | The measurement direction of the accelerometer must be referred to the tach sensor position. This can be done by the "Angular correction" in the analyzer setup. In our example, in '''Sketch 1,''' the '''angular correction''' </font>is '''90°''' and the <font color="#339966">'''offset''' </font>is -'''15 °'''. | ||
'''Tip''' | '''Tip''' | ||
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===Physical Background=== | ===Physical Background=== | ||
The <u>initial run</u> | The <u>initial run</u> analyzes the behavior of the rotor due to its initial unbalance. | ||
During the <u>test run</u>, the applied test masses modify the position of the unbalance. This yields the sensitivity of the rotor. Thus with the knowledge of the reaction of the rotor to added masses, suitable masses can be calculated to compensate the initial unbalance. | During the <u>test run</u>, the applied test masses modify the position of the unbalance. This yields the sensitivity of the rotor. Thus with the knowledge of the reaction of the rotor to added masses, suitable masses can be calculated to compensate the initial unbalance. | ||
For <u>balancing in one plane</u>, just one test mass and one test run is necessary. It is important that the angular position of the initial unbalance is changed | For <u>balancing in one plane</u>, just one test mass and one test run is necessary. It is important that the angular position of the initial unbalance is changed significantly by the test mass. Take this into account when choosing test weight and position. | ||
When <u>balancing in two planes</u>, two test runs are necessary. For each run only one test mass is necessary positioned in one of both planes respectively. Again in both test runs the position of the unbalance must be changed by the test masses. | When <u>balancing in two planes</u>, two test runs are necessary. For each run only one test mass is necessary to be positioned in one of both planes respectively. Again, in both test runs the position of the unbalance must be changed by the test masses. | ||
'''Assumptions''' | '''Assumptions''' | ||
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'''Example''' | '''Example''' | ||
Imagine a rotating machine to be balanced when standing untightened on the floor. After the test mass is mounted the increased unbalance | Imagine a rotating machine to be balanced when standing untightened on the floor. After the test mass is mounted the increased unbalance causes the machine to move. Holding or fixing the machine during the test run will cause wrong balancing results. To overcome this you must choose a lower test mass or position to reduce the unbalance. If this doesn<nowiki>'</nowiki>t work you could fix the machine during the <u>complete</u> balancing procedure. After this basic balancing, execute a second complete balancing procedure with the machine unfixed (in normal operating conditions). | ||
'''General advice''' | '''General advice''' | ||
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====Setting the tachometer==== | ====Setting the tachometer==== | ||
To set the tachometer, you need to go into the "Speed" tab : | |||
[[Image:Bal_Tacho.png|framed|none]] | [[Image:Bal_Tacho.png|framed|none]] | ||
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====Set a phase adjustment==== | ====Set a phase adjustment==== | ||
To set a phase | To set a phase adjustment, you can specify the position of the sensors. To enter the menu, click on "Position": | ||
[[Image:Bal_Position.png|framed|none]]<br> | [[Image:Bal_Position.png|framed|none]]<br> | ||
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For a new Project with these Settings: Load Reference Project. | For a new Project with these Settings: Load Reference Project. | ||
This is now the last project that has been used | This is now the last project that has been used: | ||
* Create New Project: It has the settings of the Reference Project. | * Create New Project: It has the settings of the Reference Project. | ||
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''Rotor geometry and balancing quality'' | ''Rotor geometry and balancing quality'' | ||
In this window, the test runs and plane are positioned as follow : | |||
[[Image:Bal_2_Test_Prep.png|framed|none]]<br> | |||
You can export and reload a configuration with the "Export" and "Load" buttons. | You can export and reload a configuration with the "Export" and "Load" buttons. | ||
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If you use accelerometers for your measurement the signal can be integrated to show vibration velocity. | If you use accelerometers for your measurement the signal can be integrated to show vibration velocity. | ||
'''The analyzer is now ready for measurement.''' | The '''Rotor''' window is automatically displayed. You can now prepare your test run or close this window to set it up later: | ||
Your settings are shown by a red point in the polar graph. | |||
There are three methods: | |||
* '''Remove test masses ''' : The test mass will be removed after test for example bolts etc. | |||
* '''Keep test masses ''' : The test mass cannot be removed after the test (for example for welding or drilling etc…) | |||
* '''Displace two masses per plane '''for machines with slidable balancing weights. | |||
The figure below shows an example where test mass is to be removed. The test mass of 4.2 grams is set at position 4 (105°; radius 100 mm). | |||
The settings are saved automatically when closing the window. To use these settings in another project, click on export '''(1)''' </font>and save it in the sub directory of the other project. Proper settings can be loaded from another project '''(2)'''</font>. | |||
[[Image:Bal_1_Test_Prep.png|framed|none]] | |||
Click on OK to come back on the measurment window.<br> | |||
'''The analyzer is now ready for measurement.'''<br> | |||
To start the analyzer click '''(1)''' or <nowiki>[</nowiki>F2<nowiki>]</nowiki> and the Measurement is displayed. | To start the analyzer click '''(1)''' or <nowiki>[</nowiki>F2<nowiki>]</nowiki> and the Measurement is displayed. | ||
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* ''Measurement display - start analyzer'' | * ''Measurement display - start analyzer'' | ||
====Measurement monitor settings==== | |||
[[Image:Bal_MonitorSetting.png|framed|none]] | |||
<br>''Display settings - Diagram 2 - Plane 2'' | |||
'''Notice: The balancing module''' always starts with the monitor that has been used last. | |||
All Settings can be modified: | |||
* Set the number of graphs, the type and the order in which you want to see them. | |||
Graphs with frames can be treated like windows in Windows®. | |||
* Chose the scaling of the axis or use auto scaling (Y-axis only). | |||
* Colors and graph names can be arranged. | |||
* <u>Click "Set" to create your new monitor.</u> | |||
* Use "Save" at the bottom to save your new monitor. | |||
If you want to use several monitors with different layouts put existing monitors into the monitor table (double click a field in the table). | |||
You can save and reload this selection of layouts. | |||
Continue with "Close" | |||
===Initial run=== | ===Initial run=== | ||
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Polar graph: The blue point represents the magnitude and phase of the first order of averaged order spectrum (10 averages). Click "Initial run" '''(1)''' </font>and save the initial measurement '''(2)'''</font>. | Polar graph: The blue point represents the magnitude and phase of the first order of averaged order spectrum (10 averages). Click "Initial run" '''(1)''' </font>and save the initial measurement '''(2)'''</font>. | ||
[[Image: | [[Image:Bal_1_Stopped.png|framed|none]] | ||
''Initial run'' | ''Initial run'' | ||
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After saving the initial run the results are displayed as shown in '''the figure below.''' | After saving the initial run the results are displayed as shown in '''the figure below.''' | ||
[[Image: | [[Image:Bal_1_Init_Result.png|framed|none]] | ||
''Results of Initial run'' | ''Results of Initial run'' | ||
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On this figure, the blue circle, representing the allowed residual unbalance, shows directly after the initial run if the machine meets the required balancing quality or not. | On this figure, the blue circle, representing the allowed residual unbalance, shows directly after the initial run if the machine meets the required balancing quality or not. | ||
''' | '''Note: '''At this point the tables only show amplitude and phase. The unbalance in <nowiki>[</nowiki>g mm<nowiki>]</nowiki> or in <nowiki>[</nowiki>oz in<nowiki>]</nowiki> can only be calculated after the rotor sensitivity is measured in the test run. Click OK to proceed to the test run. | ||
===Test run=== | ===Test run=== | ||
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* Fix a test mass to the rotor. | * Fix a test mass to the rotor. | ||
* Mass, value and position must be set in the rotor geometry table. | * Mass, value and position must be as set in the rotor geometry table.<br> | ||
[[Image: | To see the position and mass, click "Rotor" in the Measurement monitor to open the rotor geometry window'''.''' | ||
[[Image:Bal_1_Test_Prep.png|framed|none]]<br> | |||
' | Your settings are shown by a red point in the polar graph. If you haven't set the test mass previously, you can do it now. | ||
Click "Test run" '''(1)''' </font>and save the measurement '''(2)'''</font>. | Click on OK to go back in the Measurement window. Click "Test run" '''(1)''' </font>and save the measurement '''(2)'''</font>. | ||
After every test run, don<nowiki>'</nowiki>t forget to remove the test mass '''(3)'''. | After every test run, don<nowiki>'</nowiki>t forget to remove the test mass '''(3)'''. | ||
[[Image: | [[Image:Bal_1_TestRun_Save.png|framed|none]] | ||
''Test run'' | ''Test run'' | ||
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The amplitude scaling of the polar graph is now displayed in unbalance unit <nowiki>[</nowiki>g mm<nowiki>]</nowiki> (blue axis). | The amplitude scaling of the polar graph is now displayed in unbalance unit <nowiki>[</nowiki>g mm<nowiki>]</nowiki> (blue axis). | ||
The blue circle now represents the allowed residual unbalance in <nowiki>[</nowiki>g mm<nowiki>]</nowiki>. | The blue circle now represents the allowed residual unbalance in <nowiki>[</nowiki>g mm<nowiki>]</nowiki> according to the specified class (ISO1940/1). | ||
The result table now shows the results for initial run and test run. | The result table now shows the results for initial run and test run. | ||
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<u>Example</u> | <u>Example</u> | ||
'''(1 | '''(1)''' Click to start the calculation | ||
[[Image: | [[Image:Bal_1_test_Result.png|framed|none]] | ||
''Test run results'' | ''Test run results'' | ||
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'''Orange point '''unbalance with test weight | '''Orange point '''unbalance with test weight | ||
---- | ---- | ||
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{|border="2" cellspacing="0" cellpadding="4" width="100%" | {|border="2" cellspacing="0" cellpadding="4" width="100%" | ||
|'''(1)''' </font>Select Init run <nowiki>+</nowiki> Test run<br>'''(2)''' Click OK to start the calculation<br>'''(3)''' Result - Unbalance and Phase | |'''(1)''' </font>Select Init run <nowiki>+</nowiki> Test run<br>'''(2)''' Click OK to start the calculation<br>'''(3)''' Result - Unbalance and Phase | ||
|'''(4)''' Result - proposal mass and position<br>'''(5)''' Proposal position | |'''(4)''' Result - proposal mass and position : You need to enter the real mass you will add/remove<br>'''(5)''' Proposal position | ||
|} | |} | ||
[[Image: | [[Image:Bal_1_imb_calc.png|framed|none]] | ||
''Calculation of balancing weights'' | ''Calculation of balancing weights'' | ||
If the prognostic is in the blue circle, the imbalanced of the rotor will be within the class after the mass correction. | |||
====Balancing prognosis==== | ====Balancing prognosis==== | ||
The effect of balancing weights can now be predicted by the mathematical calculations of the balancing prognosis. | The effect of balancing weights can now be predicted by the mathematical calculations of the balancing prognosis. | ||
Set mass and position of the mass you want to use in column "Mounted Mass". | Set mass and position of the mass you want to use in column "Mounted Mass". The software automatically calculates the expected residual unbalance (green point in polar graph). | ||
In this example, we only had a mass of 5 grams available instead of the calculated 4.685g mass to add at the 7th position. The prognosis shows that the residual unbalance (blue point in polar graph) moves to the green point inside the blue circle. | |||
{|border="2" cellspacing="0" cellpadding="4" width="100%" | {|border="2" cellspacing="0" cellpadding="4" width="100%" | ||
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<br>Prognosis<br> | <br>Prognosis<br> | ||
| | |} | ||
====Balancing Run==== | |||
Once you have mounted the test mass as indicated by the software, you can perform a Balancing run, to ensure the rotor is now properly balanced. | |||
* Click | |||
To do so, Go back in the measurement window and press start. | |||
*'''(1)''' Click on average | |||
*'''(2)''' Select "Balancing Run1" | |||
*'''(3)''' Save the measurement | |||
| | [[Image:Bal_1_BalRun.png|framed|none]] | ||
These points only appear if they are marked "active" in the result window. Then, save the balancing result. At any stage saved results can be reloaded using the "Load Measurement" buttons. They also can be overwritten. | The orange and green point represent the initial and resulting imbalance. These points only appear if they are marked "active" in the result window. Then, save the balancing result. At any stage saved results can be reloaded using the "Load Measurement" buttons. They also can be overwritten. | ||
<u>Example</u> | <u>Example</u> | ||
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'''(2)''' Click to start the calculation | '''(2)''' Click to start the calculation | ||
[[Image: | [[Image:Bal_1_BalRun_Resut.png|framed|none]] | ||
''Balancing run results'' | ''Balancing run results'' | ||
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====Balancing report==== | ====Balancing report==== | ||
[[Image: | [[Image:Bal_1_Overview.png|framed|none]] | ||
''Balancing results overview'' | ''Balancing results overview''<br> | ||
The overview in the following figure now shows the chronological mass predictions and settings as well as the final result ("End"). | The overview in the following figure now shows the chronological mass predictions and settings as well as the final result ("End"). | ||
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This overview can be exported into a Microsoft® Editor file (*.txt)''' '''by clicking "Report". | This overview can be exported into a Microsoft® Editor file (*.txt)''' '''by clicking "Report". | ||
[[Image: | [[Image:Bal_1_Report.png|framed|none]] | ||
''Balancing Report'' | ''Balancing Report'' | ||
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===Measurements, display, storage=== | ===Measurements, display, storage=== | ||
After setting up the acquisition channel and the machine type, you may setup the test run in the "Rotor" window. For two plane balancing, you will need to perform two test run, and set a mass on each plane. By example, here, we are putting a 5g mass at pos. 3 on the first plane for the test run1 and 5g mass at pos. 8 on the second plane for the test run2. We are not putting mass on the second plane for test run1 and no mass on the first plane for test run2 : | |||
[[Image:Bal_2_TestPrep_real.png|framed|none]]<br> | |||
*'''Note :''' You may '''not''' mount the masses at this stage. <br> | |||
Then Press '''Ok''' to reach the measurement window. '''The analyser in now ready for measurement.''' | |||
'''(1)''' </font>Click "Start" start or F2. Measurement is displayed. | '''(1)''' </font>Click "Start" start or F2. Measurement is displayed. | ||
[[Image: | [[Image:Bal_2_Init.png|framed|none]] | ||
''Measurement Display'' | ''Measurement Display'' | ||
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'''(1)''' </font>Click "Average" when rotor is at stable speed (Stationary state). | '''(1)''' </font>Click "Average" when rotor is at stable speed (Stationary state). | ||
[[Image: | [[Image:Bal_2_Init2.png|framed|none]] | ||
''Measurement Display'' | ''Measurement Display'' | ||
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'''(2)''' Save your initial measurement | '''(2)''' Save your initial measurement | ||
[[Image: | [[Image:Bal_2_Init3.png|framed|none]] | ||
''Initial run'' | ''Initial run'' | ||
[[Image: | [[Image:Bal_2_Init_Result.png|framed|none]] | ||
''Results of Initial run'' | ''Results of Initial run'' | ||
===Test run 1 | ===Test run 1=== | ||
<u>Preparation</u> | <u>Preparation</u> | ||
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* '''Keep test masses '''after test for example welding or drilling etc. | * '''Keep test masses '''after test for example welding or drilling etc. | ||
* '''Displace two masses per plane '''for machines with slidable balancing weights. | * '''Displace two masses per plane '''for machines with slidable balancing weights. | ||
It shows an example where test mass is to be removed. The test mass of | It shows an example where test mass is to be removed. The test mass of 5 grams is set at position 3 '''(1)''' </font>(75°; radius 100 mm) '''(2)''' </font> | ||
The settings are saved automatically when closing the window. | The settings are saved automatically when closing the window. | ||
[[Image: | [[Image:Bal_2_Test_PrepRun1.png|framed|none]] | ||
''Test mass positioning for two planes - Test run 1 - Test mass 1 - Plane 1'' | ''Test mass positioning for two planes - Test run 1 - Test mass 1 - Plane 1'' | ||
[[Image: | [[Image:Bal_2_TestRun1.png|framed|none]] | ||
''Test run 1'' | ''Test run 1'' | ||
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After every test run, don<nowiki>'</nowiki>t forget to remove the test mass '''(3)'''. | After every test run, don<nowiki>'</nowiki>t forget to remove the test mass '''(3)'''. | ||
[[Image: | [[Image:Bal_2_TestRun1Fin.png|framed|none]] | ||
''Remove Test mass 1'' | ''Remove Test mass 1'' | ||
[[Image: | [[Image:Bal_2_TestRun1_Result.png|framed|none]] | ||
''Test run 1 results'' | ''Test run 1 results'' | ||
===Test run 2=== | |||
<u>Preparation</u> | <u>Preparation</u> | ||
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* '''Keep test masses '''after test for example welding or drilling etc. | * '''Keep test masses '''after test for example welding or drilling etc. | ||
* '''Displace two masses per plane '''for machines with slidable balancing weights. | * '''Displace two masses per plane '''for machines with slidable balancing weights. | ||
An example is shown where test mass is to be removed. The test mass of 5 grams '''(4)''' </font>is set at position 8 (225°; radius 100 mm) '''(3)'''</font> | |||
The settings are saved automatically when closing the window. | The settings are saved automatically when closing the window. | ||
[[Image: | [[Image:Bal_2_Rotor_2.png|framed|none]] | ||
''Test mass 2 positioning for two planes - Test run 2 - Test mass 2 - Plane 2'' | ''Test mass 2 positioning for two planes - Test run 2 - Test mass 2 - Plane 2''<br> | ||
You can now perform the measurement of the second test run as previously ( click '''Start/F2''' and '''Average'''). Then, to save the measurement, set the Run number to 2 (1) </font>and save the measurement (2).</font> | |||
[[Image: | [[Image:Bal_2_testRun2_1.png|framed|none]] | ||
''Test run 2'' | ''Test run 2'' | ||
[[Image: | [[Image:Bal_2_TestRun2_Fin.png|framed|none]] | ||
''Remove Test mass 2'' | ''Remove Test mass 2'' | ||
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'''(1)''' </font>Results for Plane 1 and Plane 2 | '''(1)''' </font>Results for Plane 1 and Plane 2 | ||
'''(2)''' | '''(2)''' Click to start the calculation | ||
[[Image: | [[Image:Bal_2_TestRun2_Result2.png|framed|none]] | ||
''Test run 2 - Result, Save and Start Calculate'' | ''Test run 2 - Result, Save and Start Calculate'' | ||
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'''(2)''' Click OK to start the calculation | '''(2)''' Click OK to start the calculation | ||
[[Image: | [[Image:Bal_2_imbal_Calc.png|framed|none]] | ||
''Test run 2'' | ''Test run 2'' | ||
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'''(6)''' Proposal mass and position Plane 2 | '''(6)''' Proposal mass and position Plane 2 | ||
[[Image: | [[Image:Bal_2_imbal_Calc_2.png|framed|none]] | ||
''Test run results'' | ''Test run results'' | ||
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Click on "Prognosis" to get the calculation of the expected residual unbalance (green point in polar graph). | Click on "Prognosis" to get the calculation of the expected residual unbalance (green point in polar graph). | ||
Masses of 1 and 3.5 grams were available, and set to positions 5 and 6 on the first plane, and calculated masses are too small for the second plane. Therefore, we don't mount masses on the second plane as it is already balanced. <br> | |||
The prognosis shows that the residual unbalance (light green point in polar graph) moves inside the blue circle. | |||
[[Image: | [[Image:Bal_2_MountedMass.png|framed|none]] | ||
''Prognosis'' | ''Prognosis'' | ||
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<u>Execution:</u> | <u>Execution:</u> | ||
* Click "balancing | * Click "Online balancing" (bottom left) | ||
* Click "Start" start or F2. Measurement is displayed. | * Click "Start" start or F2. Measurement is displayed. | ||
* Click "Average", when rotor is at stable speed .(Stationary state) | * Click "Average", when rotor is at stable speed .(Stationary state) | ||
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(These points only appear if they are marked "active" in the result window) | (These points only appear if they are marked "active" in the result window) | ||
To save the balancing result, go back in the standard window by clicking on '''"Standard"''' and save as usual. | |||
[[Image:Bal_2_onlineBal.png|framed|none]] | |||
[[Image: | |||
''Balancing run'' | ''Balancing run'' | ||
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* Click "Report" in''' '''to''' '''export this table into a Microsoft® Editor file (*.txt). | * Click "Report" in''' '''to''' '''export this table into a Microsoft® Editor file (*.txt). | ||
[[Image: | [[Image:Bal_2_FinalResult.png|framed|none]] | ||
''Balancing run results'' | ''Balancing run results'' | ||
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====Balancing report==== | ====Balancing report==== | ||
[[Image: | [[Image:Bal_2_Overview.png|framed|none]] | ||
''Balancing results overview'' | ''Balancing results overview'' | ||
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This overview can be exported into a Microsoft® Editor file (*.txt) as a Balancing Report. | This overview can be exported into a Microsoft® Editor file (*.txt) as a Balancing Report. | ||
[[Image: | [[Image:Bal_2_Report.png|framed|none]] | ||
''Balancing Report'' | ''Balancing Report'' | ||
[[Image: | [[Image:Bal_2_Before_After.png|framed|none]] | ||
''Unbalance before [[Image:Balancing_61.png]] and after [[Image:Balancing_62.png]]balancing'' | ''Unbalance before [[Image:Balancing_61.png]] and after [[Image:Balancing_62.png]]balancing'' | ||
[[Image: | [[Image:Bal_2_Before_After_2.png|framed|none]] | ||
''Vibration measurement before [[Image:Balancing_64.png]]and after [[Image:Balancing_65.png]]balancing'' | ''Vibration measurement before [[Image:Balancing_64.png]]and after [[Image:Balancing_65.png]]balancing'' | ||