Professional Documents
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by
W. H. Miller
Manager - Advanced Quality Control Engineering
73
74 PROCEEDINGS OF THE TENTH TURBOMACHINERY SYMPOSIUM
104 ��
� -- -==-- RPM; second critical- 3600 RPM) and the rotor will have to
� I .--- be balanced through two critical speeds in order to achieve the
!";
....
a
·DESIGN Sf'£ED I ? \ 3600 RPM design speed of 3600 RPM in the balance machine, (b) the first
-/vp \
�
"critical" speed is a translational mode (midspan - maximum
.,.. vibration), and (c) the second "critical'' speed is a conical mode
105 •• Kv (bearing journal amplitudes approximately ten times the rotor
v � f
!5 S H OE-TILTING PAD REARING
HARACT ERISTICS midspan amplitude).
ALANCE YACHINE
STIFFNES S
.I, . 10
10 10 10 FLEXIBLE SHAFT MOTOR DESIGN
Characteristics. - 17
OPP DRIVE END6RG.
3-4
ROTOR MIDSPAN A
- 38
DRIVE END BRG + -
SHAFT EXTENSION X
- 17
OPPOSITE DRIVE £NO BEARING
- 34
ROTOR MIDSPAN h
- 38
DRIVE END BEARING +
SHAFT EXTENSION X
fg��i�::e�5L�e�J�P IN
J
5 SHOE Til.TING PAD BEARING(LOAO ON PAD) " 14 \
..
�
' 12 \
� '\,
� 10
!
"' 8
�
..J --
i r--
:'!': 8
z
0 4
Figure 2. Calculated Response to Unbalance as a Function of t"'
Speed (As Designed- Pre-Balance Simulation). !!! 2
>
0
1500 2000 2!100 3000 MOO 4000 4!100
SPEED- R.P.M.
ROTOR BALANCING CONSIDERATIONS
In preparing to balance the "flexible" rotor "it was recog Figure 4. Speed Dependent Maximum Vibratio n Limits Dur
nized that the balance machine response would differ from the ing Balancing Process.
EXPERIMENTAL INVESTIGATION OF BALANCING FLEXIBLE ROTORS IN LARGE MOTORS AND GENERATORS 75
The procedure for modal balancing is to run the rotor up since weights in this area were distributed axially among the
to the neighborhood of a critical speed and measure the three planes.
resulting deflections. These rotor amplitudes are primarily due Figure 6 shows the locations of the noncontacting probe
to that particular critical speed with very little contribution surfaces which were machined into the rotor assembly. The
from the higher order modes. Kellenberger's paper on modal mechanical runout of each probe surface was measured and
balancing [8] concluded that the two rigid body modes also limited to 0. 2 mils. The noncontact probes were mounted in
needed to be balanced separately. Bishop and Parkinson [7] the horizontal direction on free-standing supports fixed to
disagreed with Kellenberger, . stating that (based on their ground. The probe signals were input to a vibration analyzer
eigenvalue formulation) the rigid body modes were not neces which provided an analog readout of amplitude and triggered a
sary to balance. strobe light. A stationary coordinate system was affixed to the
This author's experience with industrial size machines opposite drive end pedestal so that the phase angle could be
strongly supports Kellenberger's N + 2 method since many of measured using the strobe light.
the large motors and generators operate through or near a
fundamental mode, i.e., the translational and/or conical
modes. These modes, while well below the shaft natural TI-TRIAL WGT. T2-TRIALWGT. T3-TRIAL WGT.
(} <i-'
frequency, can experience significant bending as the rotor '
' '
Grams/
Degree
RES 2400
%� %%%%% 0 0 5 8 0 5 0
% % %%%%
Lag
RES 2800
%
/:::
0 0 5 0 8 285 0
% %%%% %
1
Tr 2400
20.8/0° 0 0 5 313 290 0
Tr 2800
% %%% %0 % 0 % 5 0 5 0 2
20.8/0°
T2 2400
% % %%%
305 % 0 % 0 8 7 0
% %% % %
2
T2 2800
% 0 % 0 8 303 0 5
20.8/0°
T3 2400
% %%% %10 % 0 % 5 252 310 310 210
T3 2800
. % % % % % % /.
0 0 0 8 3 290
3-Plane
Computer
Balance
RES 2400
% %% %% % %5 330 0 0 5 5
%%%% % % %
Shot
RES 2800
5 0 0 5 5 0
RPM where the outboard shaft extension vibration began to tion data at 3000 RPM shows that the rotor and bearing
approach the process limit. Therefore, a second balance at housing vibration have both increased. Hence, the two-plane
tempt was made. correction was detrimental to the rotor performance.
A two-plane balance was first attempted since the rotor The two-plane correction was removed and a trial weight
had achieved speeds well above the first critical speed. This of 24.5 grams was applied at T2 at 110°. The vibration was
test would also give some insight as to whether the multi-plane measured at all five planes at 3000 RPM and 3200 RPM. This
approach was necessary. A trial weight of 17.9 grams was data, coupled with the two-plane trial weight data, was used to
applied to T1 at 110° and the vibration measured at the five compute a three-plane balance correction which is given
planes. Next, a trial weight of 24.5 grams was placed at T3 at below:
ll0°. Table 2 gives the vibration amplitudes measured with the
trial weight applied and the residual vibration with the compu W (Grams) 6 (Degrees)
ter calculated correction in place. The calculated correction 36.8 315
was: 33.1 188
22.6 69
W (Grams) 6 (Degrees)
33.5 281 The resulting vibration amplitudes are given in Table 3. Com
43.9 104 paring the 3000 RPM vibration measurements from Tables 2
and 3, one can see that the three-plane corred:ion was very
The computed correction is, as would be expected, a couple, effective. Both the rotor and bearing housing vibration had
since the rotor is running well above the first critical and been reduced.
approaching the second critical speed. A review of the vibra- Next, the rotor was carefully accelerated in 100 RPM
EXPERIMENTAL INVESTIGATION OF BALANCING FLEXIBLE ROTORS IN LARGE MOTORS AND GENERATORS 77
Grams/
Degree
Lag
RES 3000
% % %% % % 0 5 % 0 5 8 0 5
RES 3200
% � � % % % 0 75 /. 65 0 5 0
Tl 3000
% % %%%% /,
%
5 0 5 0 312 0 0
� % % %% % /.
0
Tl 3200
70 0 0 0 0 50
T4 3000
%% %%% % %
�
0 325 8 5 8 0 25
110° T4 3200
% % %%% % % 5 260 0 8 55 45
2-Plane
Computer
Balance
RES 3000
% % Y. % % /< %0 0 8 54 8 0 0
W (Grams) 6 (Degrees)
68. 8 344
17. 1 74 2 3 4 5
10. 8 343
• PRE· BALANCE MODE SHAPE - 3 400 RPM
Figure 7 is a plot of the mode shape before and after the
balance correction. It can be seen that the computer calculated x POST· BALANCE MODE SHAPE - 3400 RPM
T2 3000
%%%%%%%
%
5 0 2 6 0
%% % %XX%
0
T2 3200
5 0 8 0 .
fi.ES 3000
% % % % % /- /-
5 0 0 2 .
RES 3200
% % % X % /. %
0 0 0 2 0 5
RES 3300
% % %%X % %0 5 7 0 2 5 5
RES 3400
% % % % X /. %
0 0 2 0 5 0
RES 3500
% %%%% %% 0 0 3 8 2 0 5
RES 3600
% % X% % X X
5 5 5 5 3 0 0
Experimental factors which contribute to the inaccuracy of While these limitations in the experimental arrangement exist
the predictions were: ed, the method was able to be applied successfully and accept�
able rotor response levels were obtained.
(a) The non-contract probes P2 and P4 did not measure
The rotor was installed in a stator and vibration coast down
the rotor response in the balance correction planes.
plots were made to study the rotor response. The results are
The probes measured the response several inches
presented and discussed in detail in reference [10]. In general,
outboard of the balance correction plane on the out
these tests showed good agreement with the placement ofthe
side diameter of the fan structure. This was done since
first critical speed as compared to Figure 2 of the present
it was easier from a manufacturing viewpoint to con
paper.
trol the runout of the solid fan structure as compared
to the rotor lamination stack. This offset between
measurement and correction planes introduces an er
ror in the measured response data input to the compu CONCLUSIONS
ter program. An evaluation of the magnitude of this
influence was not made during this study. The balancing of a large induction rotor was effected by a
combination of balance machine pre-balance and a multi
(b) The phase angle was measured using a coordinate
plane, multi-speed least squares influence coefficient balancing
system fixed to the balance machine pedestal. The
technique. The rotor was balanced through the first two critical
resolution of the phase angle was approximately ± 5°.
speeds (1500 RPM - translational and 3400 RPM - conical
This accuracy was a contributing factor in the error in
modes). It was necessary to balance both modes in order to
the computed balance correction vector and the pre
achieve the 3600 RPM design speed. The actual motor design
dicted response since it represented a limiting accura
has only a first "critical" speed at 2500 RPM in the design
cy in the data input to the computer program.
speed range since the motor frame and endshield assembly are
(c) The third experimental condition which affected the significantly stiffer than the balance machine supports. This
agreement between the predicted and measured re direct comparison of an industrial rotor operated to design
sults was the placement of the balance correction speed of 3600 RPM on two different flexible supports provides
weights. The balance provision in the rotor consisted a good check on the design simulation models and the balance
of a multiplicity of drilled and tapped holes around the calculation procedures. Good agreement was observed be
outside diameter of the rotor body. These discrete tween the predicted and measured critical speeds and mode
locations precluded applying the balance correction shapes.
exactly as calculated by the computer program. The multi-plane, multi-speed least squares influence coef-
EXPERIMENTAL INVESTIGATION OF BALANCING FLEXIBLE ROTORS IN LARGE MOTORS AND GENERATORS 79
% % % % 2/.
3 3
%
7
20°
T1 3400
% 0 % 330 255 290 10
X % %. % %� %
3 3
0
T2 3400
22 308 % 8 256 345 340
% % � %� %
7. 3 4
% 0
T3 3400
05 % 5 312 244 245 340 330.
% % % %
1.
RES 3400
% 0 % 5 305 % 250 0 330 310
% % % %
0 1 2 1
3-Plane
Computer
Balance
RES 3600
% 0 % 140 290 % 0 250 3 10 300
/ / %o % % / /
Shot 3000
RES
250 315
RES 2800
/ / % 0 % 3 % / / 22
TABLE 5. COMPARISON OF MEASURED AND PRE 5. Lund, J. W., "Stability and Damped Critical Speeds of a
DICTED VIBRATION AT 3400 RPM Flexible Rotor in Fluid-Film Bearings, " journ al of Engi
neeringfor I n dustry, Trans. ASME, Series B, Vol. 96, No.
Probe 2 3 4 5 2 (May 1974).
Meas. AJO l. 6/300 l. 25/305 6.9/250 2.3/290 1.0/330 6. Lund, J. W., "Modal Response of a Flexible Rotor in
Calc. AJO . 76/306 .48/314 3.3/234 2.9/44 1.3/307 Fluid-Film Bearings," journ al of Engin eering for Indus
try, Trans. ASME, Series B, Vol. 96, No. 2 (May 1974),
ficient technique was shown to be effective in minimizing rotor pp. 525-533.
vibrations. The vibrations arise from the complicated mass
unbalance inherent in the rotor operating through a "helical" 7. Bishop, R. E. D., and Parkinson, A. G., "On the Use of
shaped, second critical speed. Tpis technique coupled with a Balancing Machines for Flexible Rotors," Journ al of Engi
good low sp�ed bal::mce machine pre-balance has been used to n eering for Industry, Trans. ASME, Series B, Vol. 94, No.
balance several flexible shaft rotors. 2 (May 1972), pp. 561-576.
8. Kellenberger, W., "Should a Flexible Rotor be Balanced
REFERENCES in N or (N + 2) Planes?", journ al of Eng in eering for Indus
1. Thearle, E. L., "Dynamic Balancing of Rotating Machin try, Trans. ASME, Series B, Vol. 94, No. 2 (May 1972),
ery in the Field," Trans. ASME, Vol. 56 (1934), pp. 745- pp. 548-560.
753. 9. Prohl, M. A., "A General Method for Calculating Critical
2. Goodman, T. P., "A Least-Squares Method for Computing Speeds of Flexible Rotors," journ al ofApplied Mechan ics,
Balance Corrections," journ al of Engineering for Indus Vol. 12, Trans. ASME, Vol. 67 (1945), pp. A142-A148.
try, Trans. ASME, Vol. 86, No. 3 (Aug. 1964), pp. 273- 10. Dawson, R. N. and Eis, R. 0., "Specifying and Designing
279. Flexible Shaft Electric Machines," General Electric Com
3. Tessarzik, J. M., and Badgley, R. H., "Experimental pany, Large Motor and Generator Department (to be
Evaluation of the Exact Point-Speed and Least-Squares published).
Procedures for Flexible Rotor Balancing by the Influence 11. Ruhl, R. L., "Dynamics of Distributed Parameter Rotor
Coefficient Method," journ al of Engin eering for Industry, Systems: Transfer Matrix and Finite Element Tech
Trans. ASME, Vol. 96, No. 2 (May 1974). niques," Ph.D. Dissertation, Cornell University, Ithaca,
4. Gunter, E. J., et al, "Balancing of Multimass Flexible N.Y., 1970.
Rotors," Proceedings of the Fifth Turbomachinery Sym 12. Lund, J. W. and Tonnesen, J., "Analysis and Experiments
posium, Texas A&M University, College Station, Texas, on Multi-Plane Balancing of a Flexible Rotor," journal of
1976. E ngin eerin g for Industry, (February 1972), pp. 233-242.
80 PROCEEDINGS OF THE TENTH TURBOMACHINERY SYMPOSIUM