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Analysis to maintain rotating machinery

Rotating machinery will always vibrate to some extent, but as equipment gets older the internal components and bearings begin to suffer from the effects of wear and tear. This means they will inevitably begin to vibrate more dramatically. The aim of analysis is to detect mechanical fatigue and the potential for breakdown at the earliest possible point. By opting for ongoing inspection of your plant equipment and machinery, you can identify any sign of damage and issue before it has the chance to escalate into a costly issue. Continue reading

Providing industrial fan balancing

Forced Draft (FD) fans are designed to produce positive pressure within a system by sucking air into it. They are most commonly used on industrial boilers to provide combustion air and help to boost the efficiency of the system. This kind of fan can help a smaller boiler produce much more heat by boosting the transfer rate. This has the potential to reduce the operating costs. Continue reading

Optimising our work with our iPad vibration analyser

Though they may not seem important, vibrations can have a hugely detrimental effect on machinery over time, affecting the balance. This leads to troubles in operation, poor quality work and damage to the machinery itself. This can lead to expensive repairs or replacements being required and can put the machine operators at incredible risk, particularly in high speed vehicles where this damage can result in catastrophic failures of the relevant equipment.

For these reasons, dynamic balancing is essential, and that means measuring the vibrations in order to find out how you can minimise them. We have developed an extensive predictive maintenance system based around the iPad to assist with this task.

Our iPad vibration analyser system contains everything you need to transform an iPad into a vibration analyser and balancer. In terms of hardware, we supply the iPad mini or iPad Air to you, alongside a custom 2-channel DAQ box, assembled by qualified technicians and calibrated to the iPad and a supplied accelerometer. The accelerometer comes with a magnetic base to ensure that there is minimal interference with the vibration data, allowing you to receive extremely accurate results. A custom tachometer is also included with a two plane balancing system to allow optimised readings.

This hardware is designed to work with the software we have available for our customers in the form of apps, freely available for download on the iTunes App Store. These include VibePro, a vibration analyser which can be connected to a microphone or other industrial sound detector to acquire audio signals and which works well alongside the accelerometer and DAQ box supplied. VibeTrend allows for the monitoring of RMS vibration amplitude levels, whilst iRotorBalancer is used for balancing rotating machinery in single plane and two planes.

Other apps include VibeRMS, a vibration RMS meter; BalanceVision, used for machine rotor balancing using the camera feature to allow for the location of the angular location where the trial and correction weights need to be mounted in the rotor; VibeSpectra, a reference guide for maintenance of rotating machinery and iAlignCalc for calculating machine shaft alignment corrections accurately. There are many other apps available, all designed to optimise balancing and reduce vibrations in machinery.

Through the minimisation of vibrations and correctly balancing your equipment, the overall reliability, safety and performance of the machinery or vehicle can be significantly improved. We can supply this iPad vibration analyser to a number of industries, from machine tooling to motorsports, ensuring that all vibrations are minimised as much as possible. If you require further information, contact our team today and we will advise you on how our vibration analyser can help.

Precision balancing for rotary machinery

High speed electric motors rotate at an amazing rate, with the fastest products on the market hitting an incredible 1 million RPM. They are used in all kinds of vehicles and machinery. Rotating parts have two major obstacles to overcome; controlling the centrifugal force and accounting for rotordynamic vibrations. Both of these things can lead to higher wear on the device as well as increased background noise and heat.

The leading cause of these problems is weight imbalance. When there is more weight on one side of the rotor it causes an asymmetrical rotation, resulting in vibrations and excess wear. Treating the problem is challenging as every part in the device will need to be properly balanced. To do this they could require weight be added or removed to improve the distribution.

The best way to control centrifugal force and rotordynamic vibrations is to manufacture all of the parts precisely before assembling them. At all times balance and weight distribution should be accounted for. This means that the rotor will be properly balanced to begin with. Even with this imbalances can develop over time due to wear on parts. To avoid this becoming problematic you should have a full maintenance plan in place to monitor the performance of the motor. Worn parts should be replaced sooner rather than later to prevent other aspects of the device getting damaged.

At Vibration Free we have worked on all kinds of high speed electric rotors, handling machinery up to 3000kg in weight at our facility and even larger ones at our customer’s sites. Our experienced team provide analysis and dynamic balancing, ensuring all rotary equipment is properly checked, balanced and ready to perform smoothly and accurately.

The most difficult aspect of balancing a rotor is adding or removing weight without affecting the function of device. Both need to be done with absolute precision, especially if the part is being remanufactured. We are skilled at all aspects of dynamic balancing and will ensure it is done to the highest standard.

Improving engine performance and efficiency

Properly balanced engines will function more efficiently than those that are not. Imbalances can occur for several reasons including mechanical, rotational, fluid and drag problems. It can be difficult to diagnose the issue and resolve it. A full range of diagnostics and analyses will usually be needed to gain a clear picture. These should be done by an experienced specialist who knows what to look for. Any balancing should also be carried out by professionals to avoid damaging the engine.

Dynamic balancing is commonly used on engines to help ensure that rotational parts can move efficiently without causing excessive levels of vibration. The vibrations can cause many issues for engines, including causing high levels of wear, generating more heat and producing more noise. They are also wasted energy that could be better used in other areas. The balancing helps to protect parts from wear and improves the performance of the engine too.

We offer a flexible service to analyse and balance parts in all kinds of engines, from small to large scale ones. We have an experienced team and strive to resolve all kinds of imbalances, regardless of their cause. It is our goal to leave engines finely balanced, increasing the tolerance so rotating and reciprocal parts produce as few vibrations as possible.

Our team are able to examine engines for all kinds of problems including the alignment of moving parts, electrical sources of vibrations, loose parts and belt failure. We will also examine bearings and lubricant to make sure everything is correct. After assessing the engine we can determine what course of action to take and how to improve the efficiency, performance and the longevity of the engine too.

If you have noticed any issues with the performance of an engine or detect higher noise levels, you should get it examined to determine the cause of the problem. The longer you leave it the more potential there is for an issue that could result in extensive damages. Contact Vibration Free today to arrange analysis and dynamic balancing services.

Essential balancing for efficient machinery

Dynamic balancing is essential for the resolution of alignment issues in machinery, and for removing vibrations that can reduce the lifespan of equipment. Balancing can be a complex process, but it is important if you want to maintain accuracy and performance levels. If you need your machinery and equipment balancing, it is best to ensure each device is examined individually. This enables you to identify the problem and the severity. The next step involves the addition and removal of weight to correct the issue.

When equipment is misaligned, it is easily identified due to the noise it emits when in use. It can also significantly rise in temperature due to the friction. If you suspect your machinery is experiencing these issues, it is important to have it inspected as soon as possible. No plant or manufacturer wants to incur downtime, but the time it takes to assess the state of your equipment and correct the issue is much less than the time and money that can be lost if it is left to break down. By ensuring problems are resolved as early as possible, you can be sure of avoiding larger expenses and loss of production further down the line.

We regularly work with a wide range of industries on a global basis and we can carry out dynamic balancing on all kinds of machinery. We provide accurate analysis and balancing and the finest quality client care. If your machinery is showing signs of problems, or if you have concerns about its condition, we can assist you with thorough inspection and professional, accurate dynamic balancing. We approach our work with meticulous attention to detail and each item of equipment is carefully examined and fully assessed on an individual basis. When you work with us you can be sure that your mechanical equipment is in the best possible hands.

Protect your fans with the right maintenance

Industrial fans come in all shapes and sizes, from large scale centrifugal ones to smaller blower models. Regardless of the size, it is important to keep them properly maintained to ensure they function efficiently. Doing so will also help to reduce the wear and keep downtime to a minimum so there are fewer interruptions to your operations. In the long term this will save you a great deal of money by prolonging the lifespan of your fan.

One of the most important aspects of industrial fan maintenance is ensuring they are properly balanced. Over time the vibrations in the device will cause the centre of mass to shift and move away from the balance point. If you neglect to maintain them, fans will gradually move further from the rotation centre, resulting in wear and causing faults in the equipment.

To balance fans, you first need to examine them to determine the extent of the problem. The best way to do this is by conducting a vibration analysis. This will help to show how the device rotates and how far from the centre it has shifted. Once you know the situation, balancing the fan is typically a case of adding or removing weight until the balance evens out.

A well maintained and properly balanced fan will last much longer and work more efficiently than an unbalanced one. As an added bonus, you’ll also do away with the noises that are caused by blades catching and not rotating properly.

The process of balancing a fan is relatively straightforward, but you need to be careful when adding and removing weights. If you need any help you can call on our experts at Vibration Free. Our knowledge is extensive and has seen us conduct vibration analysis and dynamic balancing on a wide range of different fans. We work with industrial clients of every size and from a varied selection of industries. To find out more about how we can help you, please get in touch. We will discuss the importance of dynamic balancing with you and answer any questions you have.

Improving the quality and operation of your machinery

Many industries that use heavy machinery are at risk of the equipment becoming damaged over time. Even if machines are kept in top condition, there is still the possibility of damage and wear coming from excessive vibrations. These vibrations can be just as damaging to your machinery as outright blunt force or other causes of physical damage. In order to minimise the damage caused by excessive vibrations as much as possible, we offer a fully comprehensive dynamic balancing service.

Vibrations may not seem like much, but they are capable of damaging a machine in the long term. As they can affect the balance of the machine and shift components out of their proper place, they can have major effects on the overall operation of the machinery, meaning that results produced will eventually be inaccurate and poor. Over enough time, long term vibration damage becomes a real risk. From generators to tooling machines, excessive vibrations can seriously damage the internal components. Vehicles are also at risk of vibration damage, particularly in motorsports where the vehicles are constantly subjected to stress and high speeds. In these cases, any damage to the mechanical components of the vehicle can be downright catastrophic for all involved. It is because of this that our team offer comprehensive dynamic balancing services, specialising in the motorsport industry.

We provide expertise in managing excessive vibrations and noise for many different types of machinery. With twenty five years of practicable application knowledge, we can provide a service that is unbeatable. In doing so, we can extend the lifespan of your machinery and ensure that they are operating at their optimal condition. The motorsports industry is one of our specialist areas of knowledge. We provide engine balancing services that cater to all crankshaft configurations, particularly group 2 type cranks. We have provided our services to customers operating in motorsports such as F1 and NASCAR, so you can be completely assured of our expertise in this area.

We are considered to be one of the leading authorities in dynamic balancing and managing and minimising vibrations in machinery and vehicles. As an independent consultancy company, we are here to provide the best possible services to our customers. We strive to resolve a wide array of important vibration issues, and are able to provide a fully comprehensive service to our customers to minimise vibration and noise levels within their machines.

Why dynamic balancing is important for rotating machinery

If your business uses rotating machinery as part of your operations, you need to be aware of vibration. Excessive vibrations can cause high levels of noise, as well as significantly reducing the life of the bearings and other components if the problem is left for too long. Therefore, it’s important to take action to remove the causes of vibration, leaving the machinery operating as smoothly and quietly as possible. The ideal result is unobtainable, as there will always be slight vibration remaining. In these cases, you need to reduce the imbalance to a level that will not have an effect on bearing life and also reduce noise levels to an acceptable level. This process is called dynamic balancing, and aims to fix the problems caused by displacement of the mass centre line from the true axis as a result of mass eccentricity.

Balancing is the addition or removal of weight to the unit that allows the mass centre line to move closer to the true axis. The simplest form of balancing is static and involves placing the unit onto low friction bearings. Once this is done, it is allowed to rotate and fall into place with the heaviest point at the bottom. Following this, material is removed and the unit is gently rotated again until the newly allocated heavy point falls into position. This process is repeated until there are no obvious heavy points remaining. A more advanced method of balancing is mounting a unit onto a specialised balancing machine, connecting bearings to sensors that detect the heavy point whilst being rotated. This method increases sensitivity, providing a more accurate balance.

Vibrations can have a large effect on your machinery and vehicles, which emphasises the importance of regular balancing. Without it, you may find that you spend thousands of pounds repairing your machinery that you would have avoided with balancing. We been specialising in dynamic balancing and vibration analysis for many years, delivering service for clients in all industries. We can help you to make your equipment as vibration free as possible.

Treating different causes of vibrations

With any moving part in a machine, from rotors to steering wheels, there is always some level of vibration due to the movement and difficulty getting the balance perfect. As parts hit higher speeds the vibrations can worsen substantially and increase the wear on parts. In vehicles this is a big problem because it can lead to safety concerns and discomfort for the driver too.

Steering wheel vibrations are the most common kind that people will experience. These can be caused by many different things. If you notice the vibration more when you brake it is likely to be an issue with the brake discs or drums. Over time with use they can become warped and are no longer perfectly round, resulting in vibrations. To resolve the problem parts can be machined or replaced.

If your steering vibrates all the time it is typically caused by tyre or balance problems. When it happens at low speeds it is a clear indication there is a problem with the tyre. This could be because of a belt warping the shape or a change as a result of a collision. At higher speeds if you get vibrations it is due to the balance. Replacing tyres is a simple solution to the first problem. For the second you need to rotate wheels or have them professionally balanced.

Many people claim that loose suspension is responsible for vibrations but on its own it is very rare that it actually causes them. A loose part will exacerbate the situation but it is not the cause of the problem because it is not a rotating part. You can inspect the suspension to be sure but it shouldn’t be at the top of your list of potential causes.

Vehicles can experience vibrations when they are idling as well as moving. When you encounter this you should check the performance of the engine first before you look at anything else. If you still have the problem after you ensure the engine is running smoothly it is likely an issue with the mounts. Replacing them can be tricky but it is a solution.

Driveline vibrations are amongst the trickiest to diagnose. With an automatic transmission your first step should be to check the fluid levels and make sure there are no leaks. With manual transmission you need to check the operation and condition of the clutch. If you still experience vibrations with either type of vehicle it could be a problem with the CV joints. Unfortunately correcting this will usually require you replace the whole axle.

If you’re worried about vibrations in vehicles you may want to consider getting it checked by professionals. At Vibration Free we specialise in dynamic balancing and can offer a range of solutions to suit all kinds of vehicles. We have worked with countless motorsports teams and delivered bespoke services that help them maximise the safety and performance of their cars. Contact us to learn more about the dynamic balancing services we can offer to you.