Vibrations Et Grandeurs Associees
Vibrations Et Grandeurs Associees
To cite this article: A. Ait Ben Ahmed , A. Touache , A. El Hakimi & A. Chamat (2020): A new
hybrid method for rigid and flexible rotor balancing without phase response measurements,
Australian Journal of Mechanical Engineering, DOI: 10.1080/14484846.2020.1842616
ARTICLE
A new hybrid method for rigid and flexible rotor balancing without phase
response measurements
a
A. Ait Ben Ahmed , A. Touachea, A. El Hakimia and A. Chamatb
a
, Laboratory of Mechanical Engineering, University of Sidi Mohamed Ben Abdellah, Fez, Morocco; b, Laboratory of Industrial Techniques,
University of Sidi Mohamed Ben Abdellah, Fez, Morocco
Moreover, it is very appropriate for rigid (Schneider method to estimate the overall corrective weight, as
2006c) and flexible (Schneider 2006d) rotors, while the shown in Figure 1. The performance of this hybrid
hypothesis of linearity is satisfied (Darlow 1989, 1987; method has been assessed by a comparative study
Gunter, Springer, and Humphris 1982). Generally, the described in (Barrett, Li, and Gunter 1978) based
IC method consists of measuring the amplitude of the only on the measurement of the vibration amplitude,
vibration and its phase angle to balance the rotor. An where the result of the balancing was reported graphi
accurate phase angle measurement is generally diffi cally. As well as, this comparative test has been cited in
cult because the phase of vibration is sensible to speed (Foiles and Allaire 2006) by Foiles to verify its meth
variations, and it is, therefore, difficult to maintain a odology. To more evaluate the hybrid method, two
constant speed under the same operating conditions. experimental cases were designed to assess its effi
Also, the phase response measurement requires very ciency. The first case involves a rigid rotor, which
high-quality instrumentation for accurate measure has a normal rotor balancing condition and perfectly
ment. Consequently, during the last of the 1980s, satisfies the linearity assumption. The second case
Euler and Speckhart (Euler and Speckhart 1985), and involves a flexible rotor, which has a significant degree
Everett (Everett 1987) have subsequently published an of flexibility that is critical for rotor balancing methods
influence coefficient procedure without the need for based on the linearity assumption of the rotor system.
phase response measurements, which are fundamen In both cases, the balancing measurement is carried
tally analytical and multi-plane extensions of the clas out in the vertical and horizontal direction of the
sical 4-runs balancing method. Al-Aboud (Al Abbood balancing plane. The results of the experiment prove
and New Mathematical 2019) has introduced a new the success of the proposed method followed by an
two-plane balancing procedure using vibration ampli
tude data only. The method requires eight trial runs
with two-plane balancing. This method is based on the
same concept as the 4-runs method for estimating the
corrective weight and its position. Whereas the 4-runs
method requires only 6 trial runs to perform the two-
plane balancing. Bhende (Bhende 2020) presented a
new rotor balancing method called Amplitude
Subtraction Method (ASM) where only the vibration
amplitudes are required. This method is similar to the
4-runs method which requires three trial runs and two
measuring points on the rotor bearings for single-
plane balancing. Foiles and Allaire (Foiles and Allaire
2006) present a methodology based on the 4-runs
method to overcome the use of test weights of the
same size. The authors provide a generalisation of
the 4-runs method using so-called relative influence
coefficients for single-plane and multi-plane balan
cing. The methods without phase measurement have
powerful performance in terms of correction position.
However, the correction weight may be affected by
certain biases in the amplitude measurement due to
the resolution of the sensors or critical operation clo
sest to the non-linearity zone of the system.
This paper presents a new hybrid method for rotor
balancing by combining the benefits of the 4-runs
method and the influence coefficient method, without
the need for phase response measurements. This
method requires only the measurement of the vibra
tion amplitudes using a vibrometer. In this case, a
smartphone was used as a vibrometer to acquire the
vibration data via its embedded accelerometer, as
described in Section 4.1. The hybrid method starts by
measuring the vibration amplitude of the initial run
and, sequentially, three trial runs with the same trial
weight at three different positions on the rotor.
Subsequently, applying the next steps of the hybrid Figure 1. Flowchart of the hybrid method.
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 3
extensive discussion concerning the results of the the reality of the unbalance defect before starting the
hybrid method. procedure, as shown in Figure 4. Then, a three trial
With the fast development of smartphones in runs shall be carried out the amplitude vibration of
recent years, it has become an essential part of our trial runsOT1;2;3 , with the same trial weight at three
lives, their quality and quantity have increased to different positions P1;2;3 . The amplitude value of the
reach powerful data processing and telecommunica vibration signal can be calculated using Equation (4).
tions capabilities. In addition, several types of high-
precision sensors are integrated into today’s smart Step 2: Find the unbalance position (φ)
phones. Due to the high capacity of smartphones, By applying the centroid concept on the vibration
they have been widely used in human health monitor amplitude of the three trial testsOT1;2;3 , using the same
ing (Lamonaca et al. 2015; Song et al. 2012; Natale et trial weight at different positions P1;2;3 , it is possible to
al. 2012), information on traffic and vehicle locations define exactly the position of the unbalance mass.
(Händel et al. 2014), educational practice works of Theoretically, if the rotor is perfectly balanced, the
physics experiments (Monteiro, Cabeza, and Martí amplitude of the vibrations of the three tests must be
2014; Ait Ben Ahmed et al. 2019a) and even structural equal, because the same weight is used at different
health monitoring (Feldbusch, Sadegh-Azar, and positions on the disc, since we only capture the vibra
Agne 2017). In rotating machinery monitoring, tions generated by the trial weight, where its centroid
paper (Ali et al. 2016) presents a system for rotating coincides with� the geometric centre of the disc, i.e.,
machinery vibration analysis using the smartphone’s point xc ; yc ¼ ð0; 0Þ. In the case of the unbalanced
acceleration sensor. In parallel, a test has also been rotor, the calculation of the centroid’s coordinate
�
carried out to investigate the possibility of using xc ; yc of the three values OT1;2;3 , using Equation
smartphone sensors to implement the balancing pro (1), accurately estimates the position of the imbalance
cedure using the influence coefficient method (Ait Ben massφ, using Equation (2).
Ahmed et al. 2019b). Experimental results of these � �
studies show that smartphones are stable and reliable xc 1
¼ P3
yc
to satisfy different engineering requirements. In this i¼1 OTi 8 9
context, this paper highlighted the feasibility of the >
> OT21 >
>
� �>> >
>
hybrid method using a modest instrument and < =
cosðP1 ÞcosðP2 ÞcosðP3 Þ 2
showed the opportunities behind smartphones, � OT2 (1)
sinðP1 Þ sinðP2 ÞsinðP3 Þ > > >
>
which can be a reliable instrument to perform profes >
> >
>
: ;
sional operations such as rotor balancing in the field. OT23
� � �
2. The methodology of the hybrid method φ ¼ Tan 1 yc (2)
xc
� �
Section 2.1 presents the hybrid method diagram,
Step 3: The phase angles of the trial runs βi¼1;2;3
which illustrates the combination of the advantages
of the 4-runs balancing method and the influence The phase angles βi¼1;2;3 of the trial runsOT1;2;3 can
coefficient balancing method to improve the corrective be calculated from the unbalance position φ and the
weight result without the need for phase measure trial weight positions P1;2;3 , as given in Equation (3).
ment. The methodology steps are explained in detail 8 � �
>
< Pi þ sin 1 sinðφ Pi Þ � OT O
; φ � Pi
in Section 2.2. i
βi ¼ � � (3)
>
: Pi sin 1 sinðPi φÞ � O ; Pi > φ
OTi
2.1. Flowchart of the hybrid method
Figure 2 illustrates the phase angle β1 of the trial run
Figure 1 shows the diagram of the hybrid method �!
proposed in this paper, which has five steps from the OT 1 of Case 1, in the direction of Y-axis, as presented
data acquisition step to the overall corrective weight in Section 5.1.
estimation. Each step of the diagram is further detailed
in the next section. Step 4: Influence coefficient method
~ and three trial
At this step, the initial vector O,
�! �! �!
vectors OT 1 ,OT 2 and OT 3 are completed to imple
2.2. Hybrid method steps
ment the influence coefficient method to estimate the
Step 1: Measure the amplitude of the vibration data correction weights, as illustrated in Figure 3.
At this step, we only need an instrument to acquire The three correction weights �!cw 1;2;3 was calculated
the vibration amplitude of an unbalanced rotor. using the IC method, as follow as:
Firstly, during the initial test, it must perform the
spectrum of the vibration signal to verify and confirm 1. Input synchronous vibration vectors:
4 A. AIT BEN AHMED ET AL.
Figure 2. Illustration of the phase angle of the first trial run for
Case 1, in Y-axis direction. Figure 4. Graphic illustration of the centroid shift of the three
weightscw1;2;3 .
After calculating the centroid magnitude of the three Table 3. Correction weights obtained by the IC method.
correction weights cwi¼1;2;3 which represents the shift Correction
�! weights according to
OT i¼1;2;3 (grams)
ing error (eÞ; as shown in Figure 4. As described in Correction weight
cw1 cw2 cw3 (grams at °)
Equation (10), we subtract the error value (eÞ from
0.495 0.544 0.548 0.496 at 137.56°
each value of cwi¼1;2;3 and calculate the root mean
square of the three results to minimise the errors and
to enhance the overall corrective weight result. in the paper (Barrett, Li, and Gunter 1978) by 6.65%.
With respect to the corrective position, it can be Hence, the hybrid method gives acceptable results
determined by adding or subtracting 180° from the compared to the graphical balancing performed in
unbalance position ðφ� Þ, as given in Equation (10). the comparative test.
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u
��! u 1 X 3
CW ¼ t � ðcwi eÞ2 at φ� þ 180� (10)
3 i¼1 4. Experimental setup
4.1. Description of data acquisition
Table 4 illustrates the characteristics of the embedded
3. Contrast test
smartphone’s accelerometer used in these experiments
3.1. Test process to acquire vibration data from the unbalanced rotors.
It is a MEMS (Micro Electro Mechanical Systems)
A comparative test was carried out to verify the hybrid
accelerometer with the following specifications listed
balancing method using data used in a previous
in the table below, and more details are included in its
research paper. LE Barrett, DF Li, and EJ Gunter
datasheet (BMC150 datasheet n.d.).
(Barrett, Li, and Gunter 1978) reported the following
The coordinate system of the accelerometer is
experience, as summarised in Table 1. The trial weight
defined according to the phone’s screen in its default
used in this experiment is 0.17 grams. Graphically, the
orientation. The axes directions are not interchanged
authors stated that the correction weight should be
when the orientation of the phone’s screen is changed.
equal to 0.53 grams at position 140 degrees.
The X-axis is horizontal, the Y-axis is vertical, and the
W. C. Foiles and P.E. Allaire cited these experimen
Z-axis is directed outward from the front of the screen,
tal data to verify their proposed analytical procedure
as illustrated in Figure 5.
in (Foiles and Allaire 2006) to solve the 4-runs balan
For data acquisition, there are many free mobile
cing method with different amounts of trial weights.
apps to listen to smartphone sensors. In this case, we
used an app developed by our team called ‘VibroTeak’
3.2. Test result
Table 2 lists the estimated synchronous vibration vec Table 4. Smartphone’s accelerometer characteristics.
Accelerometer Specifications Unit
tors calculated using the hybrid method obtained in
Reference Name BOSCH BMC150 -
Step 3. Amplitude Range ±2, ±4, ±8, ±16 g
Table 3 presents the calculated correction weights Output data rate (Fs) Up to 100 Hz
Maximum Sensitivity 1024 LSB/g
provided in Step 4. The overall correction weight and Nonlinearity ±0.5 % Fs
its position are obtained after applying Step 5. Resolution 0.0095 m/s2
As shown in Table 3, the result of the hybrid
method differs from the graphical solution reported
Figure 6. (a). Time domain, (b). Frequency domain of the vibration signal recorded by the smartphone in the Y-axis direction with
the imbalance mass installed on the rigid disc, at 1525 rpm.
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 7
different type of rotor system than the rigid rotor. Table 5. The input of Case 1.
More details about the flexible rotor components are Imbalance Trial
mass Weight
included in Appendix B.
Weight Position Weight Position
In the case of non-linear behaviour, as in Case 2, the (gram) (Degree) (gram) (Degree)
results of the influence coefficient method become more 11 75° 7 0°, 120°, 240°
inaccurate due to the distortion of the amplitude and
phase measurement. Case 2 was designed to assess the
hybrid method in critical conditions. However, the non- rigid rotor, which was precisely balanced. The selected
linearity of the rotor system still threatens the efficiency trial weight is 7 grams at three different locations on
of balancing methods based on the linearity assumption. the rigid disc.
Case 1 confirms that the hybrid method is more Table 9. The input of Case 2.
accurate in front of the 4-runs method and guarantees Trial
its reliability in balancing rigid rotors. Imbalance mass Weight
Weight Position Weight Position
(gram) (Degree) (gram) (Degree)
12 60 10 0°, 120°, 240°
5.2. Case 2: flexible rotor
Figure 10 illustrates the components of the flexible
rotor with the smartphone attached near the balancing locations on the rigid disc according to, respectively,
plane (rigid disc), which agrees with the YZ plane of each trial run.
the coordinate system of the smartphone.
5.2.2. Test result
Table 10 presents the test readings acquired via the
5.2.1. Test process smartphone’s accelerometer in the Y-axis and Z-axis
In Case 2, the rotor system has considerable flexibility directions.
due to the flexible shaft used in the test, as shown in Table 11 presents the calculated synchronous vibra
Figure 10. These new conditions were established to tion vectors, as indicated in Step 3, in the Y-axis and
assess the hybrid method for balancing this kind of Z-axis directions.
mechanical systems. To simulate the unbalance defect, Table 11 provides the necessary balancing para
an imbalance mass was artificially installed in a pre meters to apply three times the influence coefficient
determined position on the flexible rotor, which is method, as explained in Step 4. The next step requires
precisely balanced, as indicated in Table 9. The only the mass quantity of correction weights to imple
selected trial weight is 10 grams at three different ment Step 5, which consists of estimating the overall
corrective weight from the three correction weights
obtained by the IC method.
Table 12 lists the calculated correction
weightscwi¼1;2;3 with the overall corrective weight
compared to the results provided by the 4-runs balan
cing method in the Y-axis and Z-axis directions of the
rotor, as indicated in Figure 10.
Assuming that the rotor is perfectly balanced, the
oretically, the correction weight should be 12 grams at
the 240 degrees position. As shown in Table 12, the
calculated result in the horizontal direction (Z-axis) direction, which leads to reduce the effectiveness of
differs from the exact solution by 6.6%, which makes the method due to the resolution of the vibration
the hybrid method provide an acceptable result in this sensors, even though the rigid rotor satisfies the line
direction. Unlike the horizontal direction, the vertical arity assumption of the system, as stated in (Darlow
direction (Y-axis) has the furthest result, which differs 1989, 1987). Concerning the 4-runs method, the result
from the exact solution by 37.6%. obtained in the vertical direction is better than the
The 4-runs method provides farther results com horizontal direction, which confirms the inaccuracy
pared to the hybrid method in both directions. In the in this direction. But for both directions, there is an
Y-axis and Z-axis directions, the results differ, respec exaggeration in the quantity of corrective weight.
tively, with 55.2% and 20.5% to the exact result. With respect to the results of Case 2, which present
Case 2 confirms that the hybrid method is more a critical operating environment for rotor balancing
accurate in front of the 4-runs method and guarantees methods based on the linearity assumption (Gunter,
its reliability in balancing flexible rotors. Springer, and Humphris 1982; Everett 1987). The
hybrid method presents a good result in the horizontal
direction as compared to the result obtained in the
6. Discussion vertical direction. The rotor system is extremely flex
The vibration amplitude response in the vertical direc ible in this case, which leads to creating a non-linearity
tion (Y-axis) is more significant than the horizontal of the responses of vibration. The 4-runs method and
direction (Z-axis) for both cases, rigid and flexible the hybrid method are based entirely on the assump
rotor system, as listed in Tables 6 and 10. This differ tion of linearity of the system, which puts them in
ence indicates that the vibration energy at the bearing front of critical conditions for balancing the flexible
more attenuated in the horizontal direction, which rotor. In the horizontal direction, the results are
means that both rotor systems present a considerable acceptable for both methods. Despite there is always
stiffness against the vibration propagation in the Z- an exaggeration in the quantity of corrective weight
axis direction more than the Y-axis direction. for the 4-runs method. The good results in this direc
Consequently, this leads to a slightly elliptical orbit tion justified by the stiffness of the rotor system indi
of the normal vibration response of the bearing-shaft cated before in this direction, which helps the
system at the YZ plane. The unbalance defect induces mechanical system to satisfy the linearity assumption
the elliptical orbit to become more oval (Mogal and at the bearings in the horizontal direction. For that, it
Lalwani 2015). should take attention to the linearity of the flexible
With respect to the results of Case 1, the hybrid rotor system; for this reason, the measurement in both
method presents a good result in the vertical direction directions of the balancing plane helps to minimise the
compared to the result obtained in the horizontal repetition of the balancing procedure.
direction. As indicated in the previous paragraph, the The 4-runs method and the hybrid method have
rotor system shows considerable stiffness in this direc the same concept in the determination of the unba
tion, which leads to acquiring small responses of lance position. The use of three points to identify the
vibration. Due to the current resolution of the smart location of the unbalance fault is a powerful feature of
phone’s sensor 0.0095 m/s2, as presented in Table 4, these methods. As indicated in Step 2, the measure
the measurement of the vibration data becomes less ment error included in (xc) and (yc) is approximately
accurate than responses vibration in the vertical the same error for both values since it is calculated
10 A. AIT BEN AHMED ET AL.
from the same input data OTi=1,2,3. Equation (2) The position of unbalance is highly sensitive for the
ensures that this error will be eliminated when calcu hybrid method, where the correct determination of the
lating the unbalance position. Figure 11 shows a simu position of unbalance allows the IC method to esti
lation of the effect of the included error in the input mate the correct results of the correction weights
data OTi=1,2,3 (of Case 1 in the Y-axis direction) on the cwi¼1;2;3 , which means accurate overall weight. As
determination of the unbalance position. The upper indicated previously, Step 5 is based on the hypothesis
limit of the simulated error was taken at 20 m/s2, of the three results should be equal if the system is
which presents a huge error due to the poor resolution linear and at the same operating speed, where the trial
and sensitivity of the sensor. Where the error values weight should produce the same influence coefficient
were added to the input data, then calculating the for each trial run.
unbalance position from Equations (1) and (2). The In sum, the errors associated with the hybrid method
figure presents the variation of the unbalance position are related to the measurement instrument and the
according to a different amount of error to evaluate satisfaction of the linearity assumption of the system.
Step 2 of the hybrid method. The origin of the error These errors are associated with all existing balancing
may be due to the low resolution of the sensor, the methods. The Influence Coefficient (IC) method has
inconsistency of the rotor speed, and the improper two major limitations: Firstly, it is when there is no
mounting. As shown in Figure 11, the major error of accurate synchronisation measuring instruments avail
the unbalance position can reach a maximum of 5 able. In this case, phase measurements become inaccu
degrees as an upper limit for high errors. rate leading to incorrect results. Secondly, the wrong
For this reason, the three-point centroid guarantees choice of trial weight position. Where, in certain cases,
a perfect estimation of the unbalance position, as it impacts the results when the vector effect is too small
demonstrated in the two case studies. Foiles and (when the position of the trial weight is closer to the
Allaire presented the numerical solution of the 4- unbalance position). In this case, maintenance person
runs method, as reported in (Foiles and Allaire nel recommend changing the position of the trial
2006), which calculates a relative influence coefficient weight and repeating the balancing procedure. In addi
in the complex form for estimating the unbalance tion, it is not exempt from phase response measure
correction. The complex coefficient has the same con ments. The 4-runs method has one major limitation,
cept of the hybrid method, which ensures the elimina namely when the measuring instrument is not accurate
tion of the error during the determination of the and does not have a high sensitivity. In most cases, the
unbalance position. graphical plot of the 4-runs method is not accurate
The unbalance position is very sensitive for the when the intersection of the three circles does not
hybrid method, where the good determination of coincide at a single point. Also, due to the algorithm
unbalance position allows the IC method to estimate of the method of direct calculation of the corrective
good results of correction weights cwi=1,2,3, which weight from the three trial runs, this leads to obtaining
means accurate overall weight. As given in Step 5, an incorrect amount of corrective weight.
based on the theoretical hypothesis of equality of the The hybrid method combines the advantages of the
three results if all is perfectly carried out, Equation 4-runs method and the Influence Coefficient (IC)
(10) ensures the reduction of the errors by calculating method without requiring response phase measure
the root mean square of the values obtained by sub ments to estimate three correction weights in order
tracting the shift error of the centroid pointðCÞfrom to minimise rotor balancing errors. The hybrid
each correction weight cwi¼1;2;3 . method shows good results compared to the 4-runs
method because of the compensation of the three
results calculated by the IC method, and also, it pro
vides a lot of information about the rotor system and
overcomes the wrong choice of the position of the test
weight. Therefore, it exploits the strength of the 4-runs
method to determine the position of the unbalance
defect and the strength of the IC method to estimate
three correction weights based on the calculated phase
angles of the trial runs. In addition, the hybrid method
can be extended to multi-plane rotor balancing.
7. Conclusion
Figure 11. Position of unbalance according to the included In this paper, a hybrid method for rotor balancing
error into the input data, Case 1 in the Y-axis direction. is proposed without the need for the phase
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 11
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AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING 13
The body of revolution in the flexible rotor composed of: R = Radius of the trial weight (mm).
Rigid disc weight: 1.675 kg Honestly, Equation (13) calculate the threshold of the
Clamping kit: 0.162 kg trial weight. So, if the trial weight is smaller thanTwper , the
Shaft weight: 1.6934 kg rotor system will remain within its uncertainty zone. In
Imbalance mass: 12 g contrary, if the trial weight is too large thanTwper , the
behaviour of the rotor system may leave its linearity zone.
So, to ensure that trial weight must at least vary the ampli
Elastic shaft Bearings
tude of vibration by 20% or its phase by 20°, the value of trial
Shaft diameter: ø 10 mm Self-aligning ball bearings
weight can be taken as follow as:
Bearing housing diameter: ø 20 mm Type: 1204TV d = 20, D = 47,
The diameter of the shaft end: ø B = 14
14 mm Diameter of the pitch circle: 1 � Twper � Tw � 10 � Twper (14)
Length: 530 mm 33 mm
Shaft weight: 1.6934 kg Diameter of the balls: 6.35 mm In this work, the trial weight of Case 1 (rigid rotor) is 7
Material: Steel (1.4125) 56HRC Number of balls per series: 12 grams, and for the Case 2 (flexible rotor) is 10 grams to
Number of series: 2 achieve a significant excitation of the rotor.