Integrated Mill Head Automatically Corrects Unbalance

Universal Balancing introduces its V100S vertical axis balancing machine with automatic mill correction. Offering high accuracy and repeatability, it is capable of handling any component weighing up to 100kg that requires correction of unbalance by milling.

Self-contained, the V100S can be fully integrated into high speed automated production lines with the deployment of pick and place robots.

Workpiece loading/unloading and manual correction is avoided and machines can be added or removed from the line in order to meet changing production volumes – ensuring a continuous and streamlined operation.

An outstanding feature of this versatile machine is the very high unbalance reduction ratio it provides – 99.65% – probably the highest currently available on a vertical balancing machine.

The milling head which gives 300 Nm cutting torque, is able to accommodate axial through to radial positions and cuts arc angles of up to 180 degrees in the part on the rotary table. In addition, it can be adjusted to allow different cut angles for a range of components. The height and radii of the milling cut changes automatically for each part. High suction extraction vacuum removes virtually all metal chips produced by the mill cutting process.

A 10″ precision air chuck offers 2.5 micron repeatability with interchangeable jaws clamping on the inside or outside diameters of parts – even those incorporating a shaft (ie pump impeller). With a compact footprint of 2.2 x 2.4 x 1.3 metres (including extractor), the V100S is capable of balancing in 1 or 2 planes.

Further underlining the system’s speed and flexibility, the jaws can be changed in less than 2 minutes and milling cutter in less than 1 minute. The mill head position adjusts in a matter of seconds at the touch of a button, due to the use of servo motors.

The V100S is being used within a broad range of industries to balance components such as brake drums and discs; impellers; differential parts – or others with or without their own journals that require correction by milling.

Measuring system
The touchscreen operated measuring system for the V100S features simple intuitive displays available in imperial, metric and multiple unit options (ie gmm, gcm, ozinch); automated machine procedures for tooling compensation and calibration; and advanced proving routines.

Part/batch serial numbers can be recorded for quality and process control purposes. All information for individual jobs including setup, correction and calibration is stored permanently, allowing fast retrieval when required. Results can be logged to a file, SQL database, printer, network or serial port in an easy to edit format, while advanced diagnostics allow fault analysis to be carried out both on site and remotely through the internet. Furthermore, four-level password protection locks down functions within a module or for whole pages.

Technical specification:
Minimum part diameter – tooling dependent
Maximum part diameter – ~600mm
Minimum correction radius – 0 radial, 0 axial
Maximum correction radius – axial 600mm radial 600mm
Single plane repeatability MU – 1.8gmm
Reduction ratio single plane – URR 99.65%
Cycle time – less than 1 minute, depending on material and amount of initial unbalance

Universal Balancing provides industry with a full range of balancing equipment combined with an excellent service. Machines include manual horizontal and vertical to fully automated turnkey solutions. All machines have a track record of balancing millions of components per year and some of the first originally manufactured by Jackson & Bradwell in the 1950s are still in operation today. Universal Balancing can provide a total solution for all balancing requirements – by telephone, email, web, remote diagnostics and attendance on-site by one of the company’s global service engineers.

For More Info

3 Reasons the U.S. is Still On Top of Global Manufacturing

By Amanda Earing, News Editor, Manufacturing.Net – November 03, 2009

While U.S. manufacturing jobs have shrunk from 20 million in 1980 to about 12 million today, the U.S. has never been more important in global manufacturing. Manufacturing.net spoke with Dr. Chris Kuehl, Economic Analyst, Fabricators & Manufacturers Association, to learn what he believes the future holds for U.S. manufacturing.

How is it possible for U.S. manufacturers to compete against China when they hold a large portion of our debt and have fewer regulations imposed on their manufacturers?

Dr. Kuehl: There are three things that give U.S. manufacturers a bit of an edge even with China in the picture.

First — and on a more temporary level — the weakness of the dollar. With the dollar down at the level it currently is, we’re essentially discounting anything we sell internationally. But at some point, that advantage begins to go away.

Second, China is still a fairly rudimentary manufacturing culture. They do have a few sophisticated sectors, but China’s specialty is the labor-intensive, mass-production items for WalMart. The U.S. continues to be a more high-value manufacturer and our biggest competitor would be Europe more than it would be Asia. Again, that will change over time. We certainly have some Chinese companies that are becoming more competitive but they are still few and far between.

Third — the single biggest advantage and the one that would be the most consistent — is simply that US manufacturers are closer to their markets. Being closer hasn’t been a huge issue in the last 10 or 15 years, but if you track what is happening with the energy crisis, it becomes more expensive to bring things from various distant and drawn out supply chains. So you began to see, particularly if oil prices come back up, more incentive to produce closer to the consumer. You now have much more customized, specialized manufacturing and smaller lots. Consumers are no longer content with mass production and that makes it even more important to be closer to your ultimate destination.

Those are the three biggest factors. And certain U.S. companies will have other advantages as well because of their patents and process and the work forces they have.

Reco

On the Knife’s Edge

‘Static balancing’ dates back to the days when rotors were placed on knife edges (on a mandrel if required) and the unbalance would cause the heavy spot of a rotor (unbalance) to fall to the bottom through the force of gravity. The unbalance could therefore be identified without the need to drive the rotor, or in other words ‘static’.

When the heavy spot had fallen to the bottom, weight would be added at the top or removed at the bottom and the rotor would be rotated, and where required, the process would be repeated until the rotor remained stationary at any angle it was positioned at (balanced).

Balancing on knife edges still takes place, although typically when there are very low production volumes and where the rotor requires only a rough balance. Advances in technology allow for the same theory of balancing taking place through non-rotating balancing machines where the rotor is mounted in a vertical axis on what is effectively a set of polar scales.

The benefit of this over using knife edges is, as a result of stored calibration procedures on the machine, the exact amount and angle of unbalance can be established rapidly meaning parts can be balanced faster. Not all static balancing machines measure without rotation – this is also a common misconception. If greater degrees of accuracy are required, and/or if production levels dictate that on-station unbalance correction facilities are required, then a rotating vertical balancing machine will be the better choice.

There are three types of unbalance, static, couple and dynamic. Static unbalance can also exist in rotors that are typically balanced dynamically. Static unbalance is also referred to as single or one plane balancing, meaning unbalance is removed or countered in a single plane of correction.

In summary, if you refer to the term ‘static balancing’ as correcting unbalance in a single plane of correction and pay less attention to whether the unbalance is measured while the rotor is driven or not.

Joint Venture Brings Balance to Michigan

Universal Balancing strengthened its presence in North America with the establishment of Reco-Unibal, a joint venture sales and service operation in Michigan.

This joint venture combines the strength of Universal Balancing’s advanced component balancing technology with the extensive industry sector experience of the Reco Unibal team.

Through the collaboration, Reco-Unibal will be responsible for sales and service support across USA and Canada for the complete range of Unibal component balancing systems.

“That includes everything from simple vertical axis machines, through hard and soft bearing horizontal axis equipment, to sophisticated special-purpose units, complete with automatic work handling and balance correction modules for integration into high volume production facilities”, says Bob Edwards.

“This vast range of equipment – along with associated software and controls technology – were the reasons we were so keen to collaborate with Universal Balancing.

“Reco-Unibal enables us to harness the potential of the North American market by offering a combination of top quality balancing equipment, backed by the highest levels of after-sales service and support”.

Universal Balancing’s Managing Director, Steve Fowler is equally optimistic about the launch of the new company. “We have a definite technology advantage in several key areas. In particular, the accuracy, cost and time cycle savings offered by our new prop-shaft balancing systems make them particularly attractive to automotive industry OEMs and Tier 1 suppliers.

Location of our new US operations in Michigan puts it in exactly the right place to capitalize on the requirements of this important market sector”.