Active Balancer Presentation for ID fan.pdf
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About This Presentation
The presentation should cover automation technology, architecture with detail regarding Hardware Consoles (Operator interface), Workstations, Control station (controller), Communication protocols / Buses (server & interface), Chassis / Cabinet and Software for configuration as applicableThe pres...
Slide Content
Active Balancing System by,
Cement Chemical Steel Glass Factory Paper Foundries
Cement Chemical Steel Glass Factory Paper Foundries
A rotating body has an unbalance, if its mass inert ia axis
and the axis of rotation are not the same!
unbalance U = m·r = M·e
Centrifugal force based on unbalance during rotatio n F = U·wwww
2
m
r
M
e
axis of
rotation
F
F
inertia axis
wwww wwwwdeviation axis of
rotation to the mass
inertia axis
Unbalance and its consequences
Unbalance
and the axis of rotation are not the same!
unbalance U = m·r = M·e
Centrifugal force based on unbalance during rotatio n F = U·wwww
2
m
r
M
e
axis of
rotation
F
F
inertia axis
wwww wwwwdeviation axis of
rotation to the mass
inertia axis
Unbalance and its consequences
Unbalance
Centrifugal forces and the resulting vibrations cau se...
High vibration levels on the machine
Wear and reduction of the availability
Disturbance of production process
Degradation of the product quality
Damage an destruction because of dynamical loads re garding structures and
machine components
Higher strength in the bearing systems
High noise level
Dangerous operation conditions for humans and envir onment !
Unbalance and its consequences
Unbalance
High vibration levels on the machine
Wear and reduction of the availability
Disturbance of production process
Degradation of the product quality
Damage an destruction because of dynamical loads re garding structures and
machine components
Higher strength in the bearing systems
High noise level
Dangerous operation conditions for humans and envir onment !
Unbalance and its consequences
Unbalance
Methods for vibration reduction
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Unbalance and its consequences
Unbalance
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Unbalance and its consequences
Unbalance
Methods for vibration reduction
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Using active balancing machines
For getting an optimal vibration behaviour during t he
production process Unbalance and its consequences
Unbalance
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Using active balancing machines
For getting an optimal vibration behaviour during t he
production process Unbalance and its consequences
Unbalance
Methods for vibration reduction
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Using active balancing machines
For getting an optimal vibration behaviour during t he
production process
Why?
Machines change vibration behaviour during the proc ess because of
mass deviation, thermic and mechanical deformations , environment
influences, and so on
Unbalance and its consequences
Unbalance
Increasing the manufacturing accuracy in the part p roduction
High assembly accuracy
Balancing the rotating parts with balancing machine s
Process balancing
Using active balancing machines
For getting an optimal vibration behaviour during t he
production process
Why?
Machines change vibration behaviour during the proc ess because of
mass deviation, thermic and mechanical deformations , environment
influences, and so on
Unbalance and its consequences
Unbalance
Active balancing systems…
… are be able to correct the unbalance under rotati on and during the
running process
Different types:
electromagnetic
operated ring-
system AB 9000
Mechanic actuated
balancing system
MB 4002
Balancing system based
of filling water chambers
HB 6000
Active balancing systems / types
Active Balancing System
… are be able to correct the unbalance under rotati on and during the
running process
Different types:
electromagnetic
operated ring-
system AB 9000
Mechanic actuated
balancing system
MB 4002
Balancing system based
of filling water chambers
HB 6000
Active balancing systems / types
Active Balancing System
Process Industry / fan application …
… Cement production industry
… Chemical industry
… Steel industry
… Chipboard industry
Manufacturing machines / CNC
Grinding-and Milling-Applications
Centrifuge Industry
Medical Applications
Process Applications
and many others
Active balancing systems in process
Source Hettich
Source Scherr + Klimke AG, Ulm
Source Liebherr / Kempten
Source Ticona
Source Dieffenbacher
Source Venti Oelde
Source Liebherr / Kempten
Source Phönix Dortmund
Active Balancing System
Process Industry / fan application …
… Cement production industry
… Chemical industry
… Steel industry
… Chipboard industry
Manufacturing machines / CNC
Grinding-and Milling-Applications
Centrifuge Industry
Medical Applications
Process Applications
and many others
Active balancing systems in process
Source Hettich
Source Scherr + Klimke AG, Ulm
Source Liebherr / Kempten
Source Ticona
Source Dieffenbacher
Source Venti Oelde
Source Liebherr / Kempten
Source Phönix Dortmund
Active Balancing System
Active balancing system AB 9000
Active Balancing System
Active Balancing System
stator
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
Principle of the „single phase step motor“
2 balancing rotors in the balancing ring
with the
compensation
weights
are
equipped with some magnets
The numbers of the magnets is
identical with the possible angle
positions of the balancing rotor
The stator is equipped with 2
electromagnetic coils
Moving the balancing rotors :
Stator coils getting electromagnetically pulses
Interaction of permanent and electromagnetic
effects
The balancing rotor moved step by step;
magnet to magnet
Active balancing system AB 9000
components /
principle
compensation
weights
of the balancing rotors
Active Balancing System
Principle of the „single phase step motor“
2 balancing rotors in the balancing ring
with the
compensation
weights
are
equipped with some magnets
The numbers of the magnets is
identical with the possible angle
positions of the balancing rotor
The stator is equipped with 2
electromagnetic coils
Moving the balancing rotors :
Stator coils getting electromagnetically pulses
Interaction of permanent and electromagnetic
effects
The balancing rotor moved step by step;
magnet to magnet
Active balancing system AB 9000
components /
principle
compensation
weights
of the balancing rotors
Active Balancing System
controller
sensor
stator
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
sensor
stator
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
PC program for setup
and service
controller
sensor
stator
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
and service
controller
sensor
stator
balancing ring with
balancing rotors
Active balancing system AB 9000
components
Active Balancing System
Function AB 9000
Active Balancing System
Active Balancing System
Function AB 9000
compensation
weights
of the balancing rotors
rotating spindle shaft
of the AB 9000 for interface to the
machine spindle
roller bearing
gap between balancing
ring and stator
Principle design of the AB 9000
Active Balancing System
compensation
weights
of the balancing rotors
rotating spindle shaft
of the AB 9000 for interface to the
machine spindle
roller bearing
gap between balancing
ring and stator
Principle design of the AB 9000
Active Balancing System
Function AB 9000
rotating spindle shaft
without unbalance
compensation
weights
are in neutral position and rotate synchronous with the spindle shaft
Active Balancing System
rotating spindle shaft
without unbalance
compensation
weights
are in neutral position and rotate synchronous with the spindle shaft
Active Balancing System
Measuring unbalance and calculation of the
compensation
weights
rotating spindle shaft
with unbalance
Function AB 9000
Active Balancing System
compensation
weights
rotating spindle shaft
with unbalance
Function AB 9000
Active Balancing System
rotating spindle shaft
with unbalance
Moving
compensation
weights
Function AB 9000
Active Balancing System
with unbalance
Moving
compensation
weights
Function AB 9000
Active Balancing System
rotating spindle shaft
with unbalance
Moving
compensation
weights
Function AB 9000
Active Balancing System
with unbalance
Moving
compensation
weights
Function AB 9000
Active Balancing System
Function AB 9000
rotating spindle shaft
with compensated unbalance
Unbalance correction ist done
compensation
weights
in correction position
rotate synchronous with the spindle shaft again
Active Balancing System
rotating spindle shaft
with compensated unbalance
Unbalance correction ist done
compensation
weights
in correction position
rotate synchronous with the spindle shaft again
Active Balancing System
Active balancing system AB 9000
assembly principle
Active Balancing System
assembly principle
Active Balancing System
Active balancing system AB 9000
assembly principle / closed loop
stator
balancing ring
controller
speed and rotor angle position sensors
vibration sensor
input signal to the coils
AB 9000 system
spindle
PC program
for service
and setup
Active Balancing System
assembly principle / closed loop
stator
balancing ring
controller
speed and rotor angle position sensors
vibration sensor
input signal to the coils
AB 9000 system
spindle
PC program
for service
and setup
Active Balancing System
Fan application
Source Process Barron
Active Balancing System
Source Process Barron
Active Balancing System
Ventilator with changeable unbalance in running pro cess •
Unbalance in process comes from …
Caking of powder and abrupt
chipping of bigger powder parts
Wear in process
Breaking blades
(often not correctable)
Clearance and wear in clutches
or drive shafts
•
Unbalance is watched only in process
•
Unbalance is not correctable before final assemble
•
Unbalance is only correctable under running process
Fan application
Active Balancing System
Unbalance in process comes from …
Caking of powder and abrupt
chipping of bigger powder parts
Wear in process
Breaking blades
(often not correctable)
Clearance and wear in clutches
or drive shafts
•
Unbalance is watched only in process
•
Unbalance is not correctable before final assemble
•
Unbalance is only correctable under running process
Fan application
Active Balancing System
controller
balancing ring
mounted at
drive shaft
speed and rotor angle
position sensors
vibration sensor
input signal to
the coils
fan rotor with
unbalance
roller bearing
housing
stator fixed at
bearing housing
AB 9000 system
Fan application
PC program
for service
and setup
Active Balancing System
balancing ring
mounted at
drive shaft
speed and rotor angle
position sensors
vibration sensor
input signal to
the coils
fan rotor with
unbalance
roller bearing
housing
stator fixed at
bearing housing
AB 9000 system
Fan application
PC program
for service
and setup
Active Balancing System
System specification of size 406
Balancing capacity
3.25 kgm
Resolution ca. 2%
of capacity
Response time for moving
one step ca. 3 sec
Fan drive shaft diameter
until 325 mm
Working range balancing unit
-40°C until +90°C
Working range control cabinet
-20°C until +50°C
(heating system provided)
Fan application
Active Balancing System
Balancing capacity
3.25 kgm
Resolution ca. 2%
of capacity
Response time for moving
one step ca. 3 sec
Fan drive shaft diameter
until 325 mm
Working range balancing unit
-40°C until +90°C
Working range control cabinet
-20°C until +50°C
(heating system provided)
Fan application
Active Balancing System
System integration
Fan application
Auswucht-
ring
Stator-
halterung stator fixing
system
stator
bearing
housing
fan drive
shaft
balancing
ring
interfaces for sensors
and power supply
clamping
device
conical
principle
Active Balancing System
Fan application
Auswucht-
ring
Stator-
halterung stator fixing
system
stator
bearing
housing
fan drive
shaft
balancing
ring
interfaces for sensors
and power supply
clamping
device
conical
principle
Active Balancing System
System integration
... after mounting of the active balancing system before and...
Fan application
Active Balancing System
... after mounting of the active balancing system before and...
Fan application
Active Balancing System
Behaviour „with and without active balancing system “ (example)
0
20
40
60
80
0 10 20 30
Time / days
Vibration / mm/s
without active balancing system
with active balancing system
time / days
Zeit in Tagen
Zeit in
Tagen
vibration / mm/sec
Fan application
Active Balancing System
0
20
40
60
80
0 10 20 30
Time / days
Vibration / mm/s
without active balancing system
with active balancing system
time / days
Zeit in Tagen
Zeit in
Tagen
vibration / mm/sec
Fan application
Active Balancing System
Benefit C
Significant lower vibration level at fan and enviro nment structure
C
Unbalance control during running process
C
Automatic unbalance correction during the fan rotat ion, as soon as
the vibration limit has reached C
No process stop for fan balancing required
C
Increase of availability until the next planed proc ess stop
C
Reduction of Environment pollution regarding vibrat ions
C
Retrofit assembly easy possible because of ring des ign
Fan application
Active Balancing System
Significant lower vibration level at fan and enviro nment structure
C
Unbalance control during running process
C
Automatic unbalance correction during the fan rotat ion, as soon as
the vibration limit has reached C
No process stop for fan balancing required
C
Increase of availability until the next planed proc ess stop
C
Reduction of Environment pollution regarding vibrat ions
C
Retrofit assembly easy possible because of ring des ign
Fan application
Active Balancing System
Abstract
C
High-Tec product on excellent quality level
C
Optimal availability because of excellent process s tability
C
Balancing in one or two planes
C
Short response time because of step motor principle and adaptive
system C
Maximum process speed / high retaining torque reali zed by permanent
magnets C
Optimal integration possibilities because of ring d esign
C
Windows based user interface / High-Tec controller
C
Interface to machine control systems and PLCs
C
Modular set over the entire series
Active Balancing System
C
High-Tec product on excellent quality level
C
Optimal availability because of excellent process s tability
C
Balancing in one or two planes
C
Short response time because of step motor principle and adaptive
system C
Maximum process speed / high retaining torque reali zed by permanent
magnets C
Optimal integration possibilities because of ring d esign
C
Windows based user interface / High-Tec controller
C
Interface to machine control systems and PLCs
C
Modular set over the entire series
Active Balancing System
Process-Industry
British Gypsum, Penrith, United Kingdom
Castle Cement, Lincolnshire, United Kingdom
Lafarge, Dunbar, Scotland
Cementa AB, Slite, Sweden
Gorazdze Cement, Opole, Poland
Cement Plant "Odra" S.A., Poland
Lafarge, La Couronne, France
Lafarge Cementos, Madrid, Spain
Set Çimento San. Tic. A.S., Ankara, Turkey
Ambuja Cements (Holcim), Junagadh, India
Aditya Cement, Chittorgarh, India
Siddhi Cement, Veraval, India
Vigier Ciment S.A., Péry, Switzerland
Holcim Zement, Höver, Germany
Portlandzementwerk Wittekind, Erwitte, Germany
Lonza / Arch Chemicals, Charleston, USA
…
AB 9000 References / selection
Active Balancing System
British Gypsum, Penrith, United Kingdom
Castle Cement, Lincolnshire, United Kingdom
Lafarge, Dunbar, Scotland
Cementa AB, Slite, Sweden
Gorazdze Cement, Opole, Poland
Cement Plant "Odra" S.A., Poland
Lafarge, La Couronne, France
Lafarge Cementos, Madrid, Spain
Set Çimento San. Tic. A.S., Ankara, Turkey
Ambuja Cements (Holcim), Junagadh, India
Aditya Cement, Chittorgarh, India
Siddhi Cement, Veraval, India
Vigier Ciment S.A., Péry, Switzerland
Holcim Zement, Höver, Germany
Portlandzementwerk Wittekind, Erwitte, Germany
Lonza / Arch Chemicals, Charleston, USA
…
AB 9000 References / selection
Active Balancing System
www.masibus.com
Active Balancing System
Example for investment and payback period regarding a cement production plant
Fan-application
Active Balancing System
Example for investment and payback period regarding a cement production plant
Fan-application
www.masibus.com
Active Balancing System
Prices and costs,
eThe price for the AB 9000 of size 406 is
eTwo plane version approx. 175,000 USD.
eTwo plane balancer depends on the application
eThe additional costs for implementation support and training are approx. 10,000 USD
Active Balancing System
Prices and costs,
eThe price for the AB 9000 of size 406 is
eTwo plane version approx. 175,000 USD.
eTwo plane balancer depends on the application
eThe additional costs for implementation support and training are approx. 10,000 USD
www.masibus.com
Active Balancing System
Payback period regarding investment Benefit
eBy using an active balancing system AB 9000 the int erval between two fan
cleaning stops could be extended from approx. 2 mon ths to 8 months and more !
Example
eOutput production of the plant is 3,300 tons per da y
eDuration of cleaning stop is 2 days
eBy using an active balancing system type AB 9000, 4 .5 kiln shutdowns can be
avoid (9 days)
e29,700T of clinker can be produced additional Price base 2010: 49 USD per
ton. This is an amount of 1,455,300 USD
Active Balancing System
Payback period regarding investment Benefit
eBy using an active balancing system AB 9000 the int erval between two fan
cleaning stops could be extended from approx. 2 mon ths to 8 months and more !
Example
eOutput production of the plant is 3,300 tons per da y
eDuration of cleaning stop is 2 days
eBy using an active balancing system type AB 9000, 4 .5 kiln shutdowns can be
avoid (9 days)
e29,700T of clinker can be produced additional Price base 2010: 49 USD per
ton. This is an amount of 1,455,300 USD
www.masibus.com
Active Balancing System
Payback period regarding investment
eExample
eAB 9000 size 406 costs in two plane version 175,000 USD
eAdditional supporting costs for installation and tr aining of approx.10,000 USD
eAdditional costs on the plant side regarding instal lation of approx.175,000 USD
eTotal investment costs are approx. 360,000 USD
eOperating and personnel costs for the system are ne gligible
eEvery week, the additional production advantage: 1, 455,300 USD / 52 weeks =
27,986 USD per week
ePayback period: 360,000 USD / 27,900 USD per week = ~ 13 weeks !
Active Balancing System
Payback period regarding investment
eExample
eAB 9000 size 406 costs in two plane version 175,000 USD
eAdditional supporting costs for installation and tr aining of approx.10,000 USD
eAdditional costs on the plant side regarding instal lation of approx.175,000 USD
eTotal investment costs are approx. 360,000 USD
eOperating and personnel costs for the system are ne gligible
eEvery week, the additional production advantage: 1, 455,300 USD / 52 weeks =
27,986 USD per week
ePayback period: 360,000 USD / 27,900 USD per week = ~ 13 weeks !
www.masibus.com
Active Balancing System @ AmbujaCement
AmbujaCement,
Kodinar, Gujarat
India
Active Balancing System @ AmbujaCement
AmbujaCement,
Kodinar, Gujarat
India
Thank you!
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