PHW-1000H Universal Joint Drive

Balancing Machine Operating Manual

Addr: NO.2151, Panchuan Road, Baoshan District, Shanghai, China

After-sales Service: (+86) 21 -39971327 Fax: (+86) 21- 39972969
Website: www.jpdph.com (Chinese) Zip Code: 200949
Website: www.jp-balancer.com (English) Email: shjpwj@126.com

Version:18.1
 Thank you very much for choosing our products.

Please read this manual carefully before using this product, and please pay
attention to the following items:

1. Unpacking acceptance: If the product and accessories are found to be

inconsistent with the packing list when the product is unpacked, please contact us.

2. Installation and use: The installation, environment, operation, adjustment and

other matters should be clearly understood in advance in order to maximize the
working efficiency and service life of the balancing machine.

3. The power supply used in this machine is three-phase AC 380V, 50HZ. In

order to protect personal safety, the workshop protection grounding should be firmly
connected with the protective grounding of the machine.

4. During the installation and use, if there are any requirements, opinions and
suggestions for this balancing machine, please contact our consulting service
department, we will be happy to answer and solve the problems in your production
and use.

Attention:

(1) It is strictly prohibited to reprint part or all of the contents of this operating
manual.

(2) The contents of this operating manual are subject to change without notice.
 Table of Contents
1.Warning.......................................................................................................................1
1.1 Firm Foundation...............................................................................................1
1.2 Be Careful of Electric Shock........................................................................... 1
1.3 Risk of Rotation............................................................................................... 2
2.Balancing Machine Working Conditions.................................................................... 2
3.Technical Parameters and Performance Characteristics............................................. 3
3.1 Technical Parameters....................................................................................... 3
3.2 Main Performance Indicators...........................................................................3
4. Machine Hoisting and Installation............................................................................. 4
4.1 Hoisting............................................................................................................4
4.2 Installation........................................................................................................4
5.Main Structure Overview............................................................................................6
5.1 Lathe Head....................................................................................................... 6
5.2 Universal Joint................................................................................................. 6
5.3 Bearing Pedestals............................................................................................. 7
5.4 Bed Base.......................................................................................................... 8
6.Operating Steps...........................................................................................................8
6.1 Adjust the Left and Right Position of the Rotor Brackets............................... 8
6.2 Adjust the Rotor Horizontal Position...............................................................8
6.3 Put Down the Safety Frame............................................................................. 8
6.4 Input Rotor Parameters.................................................................................... 8
6.5 Select Measuring Speed...................................................................................9
6.6 Power on & Measurement............................................................................... 9
6.7 Power off..........................................................................................................9
7.Maintenance..............................................................................................................10
8.Common Faults & Handling..................................................................................... 11
Appendix 1 Balancing Glossary.................................................................................. 13
Appendix 2 Balance Precision & Calculation............................................................. 15
Appendix 3 Balance Precision Grade for Typical Rigid Rotor.................................... 17
I
1.Warning

1.1 Firm Foundation

Warning:
The dynamic balancing machine must be installed on a
firm foundation. It needs to be fastened with expansion
screws or pre-embedded screws. (The levelness can be
adjusted by adopting the rigid material such as sizing
block. It is strictly forbidden to place rubber, wood,
paper and other soft materials under the base. ).

1.2 Be Careful of Electric Shock

Warning:
Electrical devices can pose a safety hazard. It is the
responsibility of the user to ensure that their installation
complies with the requirements of existing laws and
regulations. Only trained personnel can install, start up,
or maintain this equipment. Disregarding this warning
may result in personal injury or equipment damage. Do not operate the device until
the device is disconnected from the power source. The device must be grounded
safely, otherwise there will be risk of electric shock.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 1

1.3 Risk of Rotation
Warning:
Rotating parts can pose a safety hazard.
When working, the operator should stand
on the side to prevent the workpiece being
rotated from colliding. It is strictly
forbidden to stop the rotor with hands
when the machine stops.

2.Balancing Machine Working Conditions

The equipment works under the following conditions and environment.

a: Room temperature -10～45℃;

b: Relative humidity less than 85%;

c: The fluctuation of the power supply voltage should not exceed ± 10% of the
nominal value;

d: Keep away from the corrosive substance, vibration and electromagnetic

radiation.

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3.Technical Parameters and Performance Characteristics

3.1 Technical Parameters

Specification Parameters

Max.Weight of Workpiece (kg) 1000

Max. Diameter of Workpiece (mm) Ø1600

Distance from coupling flange of drive shaft to center
1600
of the farthest bearing(mm)
Distance between Two Bearing Pedestals (mm) Min. 60
Ø25~120
Journal Diameter (mm)
Can add to Ø120~240
600, 1095+stepless speed
Spindle speed (r/min)
regulation

Universal Coupling Torque (N.m) 250

Motor Power (KW) 4 (Variable frequency)

3.2 Main Performance Indicators

(1)Min. Achievable Residual Unbalance per Plane (emar) ≤ 0.5g.mm/kg

(2)Unbalance Reduction Ratio (URR) ≥ 95%

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 3

4. Machine Hoisting and Installation

4.1 Hoisting

Use a crane for hoisting. Keep the steel wires away from the bearing pedestals
and roller frames. Put wood pieces or furry stuff between the machine and steel wires
to prevent scratching the surface paint during the hoisting.

4.2 Installation

The balancing machine has to be installed to the required foundation and work
under the required environment as stated in chapter two. The foundation is of great
importance to a hard-bearing balancing machine. The weight of the foundation shall
be at least fifteen times as much as that of the largest rotor.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 4

 Please check the machine levelness in both the vertical and horizontal directions
with a level gauge after the installation, generally it shall be within 0.2/1000. The
machine bed has to be in good contact with the foundation. There shouldn’t be gasket,
wood pieces or other staff in between. Fasten the machine with the foundation with
anchor bolts. Calibration is recommended after the installation if it is found low
accuracy.

Please reserve a certain space around the machine during the installation,
providing convenience for future hoisting or maintenance.

It requires an AC power supply of 380V 3 Phase 50Hz. Make sure the earth wire
is well grounded to the earth wire in the workshop before switching on the machine.

Please connect the power of measuring instrument, the sensors and the
photoelectric head to the socket accordingly and correctly.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 5

5.Main Structure Overview

Universal
Lathe head joint

Bearing
pedestal

Bed base

5.1 Lathe Head

The lathe head is made of cast iron, and the inner motor is fixed on the base and
connected with the upper spindle through a triangle belt to provide power for driving
the workpiece.

5.2 Universal Joint

It adopts universal joint coupling for balancing machine, which is connected
with the workpiece, with stable power transmission, fast starting and convenient
operation.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 6

5.3 Bearing Pedestals

The bearing pedestal is an important part of the machine. It has two main
functions: First is to support workpiece; Second is to pick up the unbalance signal
through the sensor in the middle of the bearing pedestals and converts it into an
electrical signal for supply to the electronic measuring system.

The bearing pedestal is mainly composed of lower bracket, rigidity rib, upper
bracket, roller plate, safety frame etc.

1.Loosen the lock screw of the bearing pedestals, the ratchet wrench can be used
to move the bearing pedestals on the bed base. After moving to the desired position,
tighten the screw.

2.Loosen the locking bolt of the roller plate and turn the lifting nut to adjust the
height of the workpiece. After adjusting to the proper position, tighten the locking

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bolt of the roller plate.

3.There is a safety frame above the bearing pedestals, and the safety frame can
be turned up for easy assembly and disassembly of the workpiece.

5.4 Bed Base

The machine base is made of cast iron, which is the basis for placing the
components of the balancing machine. There are two guide grooves on the top, and a
chain is installed in the middle, which is used to move the bearing pedestals and the
driving unit.

6.Operating Steps

The cleaning work should be done in advance, especially the surface of the
rotor journal and the support. The surface roughness of the journal should not be
lower than Ra2.5, and the roundness should be no less than Level 2.

6.1 Adjust the Left and Right Position of the Rotor Brackets

According to the distance position of the rotor journal support point, adjust the
position of the left and right bearing pedestals and lock the screws of each part.

6.2 Adjust the Rotor Horizontal Position

Adjust the height of the roller on the bearing pedestals according to the journal
size of the rotor and the horizontal state of the rotor axis, and lock it.

6.3 Put Down the Safety Frame

Lay down the safety frame and lock it to prevent accidents.

6.4 Input Rotor Parameters

According to the bearing mode of the rotor mounted on the balancing machine

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 8

and the actual dimensions of a, b, c, r1, r2, input the parameters sequentially into the
electric measuring box, and select add weight or remove weight. (For details, please
refer to Electronic Measuring System Instruction)

6.5 Select Measuring Speed

The balancing speed selection should be based on rotor mass, outer diameter of
rotor, initial unbalance and the driving power. If the rotor initial unbalance is large,
and may even result in rotor swinging on the bearing pedestals, then you should first
use low speed to correct and balance.

6.6 Power on & Measurement

If it is turned on for the first time, please jog first to check the speed and
direction (the rotor should rotate clockwise when you see it from the right hand side
of the balancing machine).

6.7 Power off

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7.Maintenance

7.1 The balancing machine must always be kept clean, and the surface of the
guide rail should be frequently coated with oil to prevent rust.

7.2 The surface of the roller should be kept clean, and no iron filings, dust and
debris should be allowed to adhere. The roller and the rotor journal should be cleaned
before each work, with a little lubricating oil. When moving the support frame, the
rotor or the bearing pedestals on both sides should be moved at the same speed and
the same time to avoid scratches on the journal and roller surface, and it is not
allowed to knock or impact the rotor on the roller frame.

7.3 The electronic measuring box is a key component of the balancing machine.
It must be protected from vibration and moisture. It should be kept properly. After the
work is completed, the switch of the electric measuring box should be turned off.

7.4 If the electronic measuring box is not used for a long period of time, it
should be powered on regularly for a few hours.

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 8.Common Faults & Handling
Faults
Cannot start the motor
High discrepancy of
unbalance display
No reaction to weight
addition
Wrong angle of weight
addition
PLL light is off, and
no display of balancing
speed
©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd
Cause Handling
1.Power disconnection. Check the power input.
2.Fuse of the measuring instrument Replace the fuse.
is broken.
3.Poor contact of the power plug. Connect the plug again or
replace it.
4.Contactor is broken. Replace the contactor.
5.Button is broken. Replace the button.
6.Motor is broken. Replace the motor.
1.Poor contact of sensors. Connect the sensors again.
2.Poor contact of sensor plug. Connect again or replace it.
3.Bearing pad or rollers wear. Replace them.
4.Unstable foundation. Fasten the foundation.
5.The diameter of rotor axial is Replace the rollers or Choose
times of the roller’s diameter different axial.
1.Breakage of sensor’s wire Weld again or replace the wire.
2.Poor contact of sensor plug. Plug in again or replace it.
3.Sensors are broken. Replace the sensors.
4.Mother board is broken. Repair the mother board or
replace it.
1.Sensor’s order and position is Plug in the sensors again.
reversed.
2.Inaccurate calibration. Perform a new calibration.
3.Wrong detection angle of the Adjust the angle.
photoelectric head.
4.Reversed rotation of motor. Adjust the motor rotation
direction.
1.Reflective marks aren’t put in Put the mark in place.
place.
2. Photoelectric head is broken. Replace the photoelectric head.
3.The distance between the Adjust the distance.
photoelectric head and reflective
marks isn’t adjusted.
4.Sensitivity of photoelectric head Set the sensitivity of sensors.
isn’t set ready.
11
 Wrong setting of rotational speed Reset the SP parameter to the
SP parameter in Rotor actual speed currently
PLL light is on, the unit
Parameter. displayed;
of the speed indicator is
In the current measurement
beating, but the amount
interface, press the
and angle are not
[Calibration] key once to
changed
automatically rewrite the SP
parameters.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 12

Appendix 1 Balancing Glossary
1.Unbalance Amount: The unbalance amount in a certain plane of rotor regardless of
the angle. It equals to the product of the unbalance amount and the distance of mass
center to rotor’s axial line. It displays in Unit g.mm or g.cm.
2.Unbalance Phase: The unbalance angle under the polar coordinate system.
3.Specific unbalance: The unbalance amount per kilogram. Displays in Unit g.mm/kg.
It equals to the mass eccentricity for the static balance. Display is Unit micron.
4.Initial Unbalance: The unbalance amount of a rotor before it is balance.
5.Permissible Residual Unbalance: the permitted residual unbalance on the rotor to
ensure a normal working state. It is also named permissible unbalance ratio.
6.Residual Unbalance: the unbalance amount left on the rotor after correction.
7.Correction Radius: the distance from the mass center of the correction plane to the
rotor axial line, in Unit mm.
8.Correction Planes Interference (Cross Effect): The change of unbalance amount
on one correction plane of a rotor leads to the change of the unbalance amount on the
other correction plane. It is also called plane separation effect.
9.Balance Quality Grade: to assess the balancing quality of a rotor after balanced.
G=eperω/1000
G-the balance quality grade in unit mm/s. It ranks from G0.4 to G4000, cover 11
different grades.
eper-the permissible unbalance of the rotor in unit g.mm/kg or the mass
eccentricity μmω in relation to the angular velocity of the highest service
Rpm=2∏n/60≈n/10.
10.Permissible Specific Unbalance per Mass Unit
eper=(G×1000)/（n/10）Unit: g.mm/kg or mm/s
11.Minimum Achievable Residual Unbalance (Umar): in unit g.m.

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 Umar represents the minimum residual unbalance of a rotor which can be
gained after it is measured and corrected on a balancing machine. It is used to assess
the highest balance ability of a balancing machine. Umar can be Emar as well, in unit
g.mm/kg. Emar means the minimum achievable residual specific unbalance.
12.Unbalance Reduction Ratio (URR): the decreased unbalance ratio after one
balance run compared with the initial unbalance. URR is used to assess the the work
efficiency of a balancing machine, showed in percentage.
URR(%)= (U1－U2)/U1= (1－U2/U1) ×100
U1-the initial unbalance; U2-the residual unbalance amount after one balance
run.
13.Interference Ratio of the Couple Unbalance: it is used to assess the resistance to
the couple unbalance influence of a single-plane balancing machine.
14.Calibration Rotor: Rigid rotors designed to verify the performance and ability of
a balancing machine, with specific weight and size. There are horizontal type and
vertical type. A vertical proving rotor weighs 1.1kg, 3.5kg, 11kg, 35kg or 110kg while
a horizontal one weighs 0.5kg, 1.6kg, 5kg, 16kg, 50kg, 160kg or 500kg.

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Appendix 2 Balance Precision & Calculation

1.Ways to show the balance precision

A.In Balance Precision Grade of the rotor G in unit mm/s.
B.In Permissible Unbalance Ratio in unit g.mm/kg.
C.In Permissible Unbalance Ratio in unit g.mm or g.cm.
D.In eccentric distance in unit micron (1 micron = 1 g.mm/kg).

2.Required data for permissible unbalance calculation.

A. Balance grade G for the rotor.
B. Working speed of the rotor in unit r/min.
C. Weight of the rotor in unit kg.
D. To balance the rotor on one plane or two planes.
E. Radius of the unbalance position in unit mm.

Calculation steps：
Fox example: There is a rotor from the electric motor. It comes with a Rpm of
1400r/min, weight of 20kg and the rotor diameter of 120mm. It requires two-plane
balance with precision grade G6.3. So please calculate: To make the rotor acceptable,
what is the Permissible Residual Unbalance (eper)?

1.To calculate the permissible unbalance ratio

Formula 1: eper=(G×1000)/(n/10)
By the given case: G=6.3; n=1400r/min
eper=(6.3×1000)/(1400/10) =6300/140=45g.mm/kg

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 2. To calculate the permissible unbalance per plane (U/plane) since it adopts two
plane balance.
Formula 2: U/Plane=(eper×w)/(r×2)
By the given case: W=20kg, Rotor diameter=120mm, so
Radius=60mm
Uper/plane=(45×20)/(60×2)=7.5

The rotor is acceptable if it is with an unbalance of 7.5g/plane or less after

correction.

©Shanghai Jianping Dynamic Balancing Machine Manufacturing Co., Ltd 16

Appendix 3 Balance Precision Grade for Typical Rigid Rotor
Precisi
Mm /
on Rotor Type
sec
Grade
Low-speed crankshafts used in boat diesels with odd-number
G4000 4000
cylinders and rigid installation.
G1600 1600 Crankshafts used in two-stroke large engines with rigid
installation.
Crankshafts used in four-stroke large engines with rigid
G630 630 installation.
Crankshafts used in boat diesels with rigid installation
High-speed crankshaft used in four-cylinder diesels with rigid
G250 250
installation.
High-speed Crankshafts used in four-cylinder or multi-cylinder
G100 100 diesels.
Engines of cars, trucks and locomotives.
Automobile wheels, wheel hubs, the entire wheel, drive shafts,.
G40 40 Four-cylinder or six-cylinder crankshafts used in four-stroke
high-speed engines with flexible installation.
The drive- parts with special requirement(propellers,
universal-joint drive shafts);
Dis-integrator parts, agricultural machinery parts, automobile
G16 16
engine parts.
Four-cylinder or six-cylinder crankshafts with special balance
requirements.
Gears of main turbine from merchant ships or sea-going
vessels;
High-speed centrifugal drums, fans, rotors of aviation gas
G6.3 6.3 turbine;
Pump impellers, Parts of machine tools or general machinery;
Regular motor rotors, engine parts with special balance
requirement.
Gas turbine or steam turbine, drive parts of machine tools;
Rotor of medium or large electric motor with special balance
G2.5 2.5
requirements;
Rotor of small electric motor, turbo-pumps.

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 Tape recorders and recording players, drive parts of CD or
DVD player;
G1 1
Drive parts of grinding machine, small armatures with special
balance requirement.
Main spindle of precision grinding machine, rotor of electric
G0.4 0.4
motor, gyroscopes.

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