Custom fabrication to repair rotating machinery can help add years to the life of equipment that may be too expensive – or even impossible – to replace easily. If your equipment has rotating parts, chances are good we can refurbish or repair it with our comprehensive custom fabrication services, saving you time and money.
Rotating equipment can take a beating in many commercial and industrial settings. Heavy use, constant loads, and spotty maintenance can all take a toll on the performance and reliability of turbines, pumps, gearboxes, compressors, and other machinery with rotating components. When it breaks down, we can often design and fabricate replacement parts that are better and will last much longer than the original equipment.
Rotating shafts are especially subject to stresses and strains that can eventually cause them to go out of balance and fail. Fortunately, shaft repairs are a specialty here at HI-TEK and sometimes custom fabrication is a solution that enables the shaft to be repaired in place. In our experience, producing a custom thick wall sleeve and inventing a different bearing arrangement using brackets and different style bearings is the answer. Shaft sleeve kits for onsite fabrication can usually be produced from photographs and basic measurements taken by on-site maintenance personnel. The sleeve kit can straddle the worn area, eliminating the need to replace the shaft, minimizing equipment downtime and unnecessary expense.
Dynamic balancing of rotating parts can be highly challenging when the component being balanced is part of an assembly and the shaft or spindle to which it mounts is not available for the balancing process. As a result, a specialized dynamic balancing arbor to simulate the in-situ mounting must be made to effectively clamp and hold the rotating part in place during the dynamic balancing process.
An additional challenge, however, is that custom dynamic balancing arbors often cost more than the components being balanced. While the tooling cost can be spread out over a number of components in large production lots, helping amortize the expense of the custom balancing arbor, the cost can be especially problematic for small numbers of components.
Here at HI-TEK Balancing, we are always looking for ways to reduce costs for our customers, especially when some level of customization is required for a particular job. Sometimes the balancing arbor needs to be durable and last for hundreds of cycles, which improves the return-on-investment (ROI) for developing the dynamic balancing arbor. However, there are also times when a unique arbor is only needed for just a few uses — or even just one use. In some cases, we can make a down-and-dirty single-use dynamic balancing arbor that works effectively for that specific part and project. Single-use dynamic balancing arbors may sometimes increase the time it takes to balance, but that is usually more than offset by the reduced up-front cost of the balancing arbor.
We recently received a call from a customer who makes fiber optic strands. Fiber optic strands are glass tubes that are heated and stretched into long optic fibers that are later incorporated into a data transmission cable. They hired us to help find the cause of a vibration problem in the fan enclosure used in the production of making the fiber optic strands.
The Job The main stranding room has a highly controlled atmosphere that is dust filtered, as well as, having the humidity and temperature control highly monitored. On a floor, just above the production room, sits a fabricated steel box enclosure with two 30 hp direct drive fans. The steel box is decent sized. To give you a good visual idea, it is about one-half the size of an overseas shipping container. There is some bracing in the long spans along with ductwork attached to the outside going in and out. The ducting is about 4’ square in cross section.
The Fans Inside the box are two 30 hp direct drive fans. The fan wheels are about 48” in diameter. The motors sit on a chassis suspended on vibration isolators with the required “more than an inch of static deflection.” The fans sit side-by-side. A series of airflow control devices are employed. There is an adjustable damper just outside the enclosure on the inlet duct. Both fans are speed controlled on variable speed AC drives. There are sophisticated inlet dampers built into each fan inlet. The complaint was that vibration was transmitting from the fans into the walls of the enclosure. During full production, the fan enclosure vibration was enough to concern the facility manager. His concern was vibration would begin to break apart the enclosure. Conversely, it seemed unlikely the fans were the culprit of the destructive vibration, as the isolators seemed to be doing what they were intended to do. The vibration seemed to be at much lower frequency than the fan speed. Finding the cause of vibration requires eliminating sources one at a time.
Rotating machinery is everywhere. We are often asked, ”What do you balance?” Rotating machines are responsible for making daily life possible. From heavy manufacturing to high rise building air conditioning – Rotating machinery utilizes high speed moving parts. These high speed moving parts need balancing. Over time those parts may go out of balance and begin to vibrate,causing the machine to run less efficiently. Also if the vibration and imbalance are not properly addressed it can cause adverse conditions on structures and the human environment. Severe vibration causes noise and human fatigue. That’s why there are companies such as ours that can analyze vibration and provide dynamic balancing and mechanical repairs and solutions to eliminate it.
There are any number of balancing service providers out there, so picking the right one to balance your machinery can be tricky. Here are three top reasons why you should balance with HI-TEK:
Vibration analysis and balancing is all we do.
Many companies and repair shops offer balancing as just one of many services. If balancing is not their primary business, you run the risk of getting just an okay balancing job that will eventually need to be rebalanced, costing more time and money. Just because a facility is certified doesn’t mean they’re especially skilled at balancing. From highly-precise micro and medical balancing to large rotator balancing – from prototype to production — dynamic balancing is our main business. Continue reading “3 Top Reasons for Balancing With Hi-Tek”→
Vibration in most machinery is not a good thing. It creates unnecessary noise and wear and can eventually result in failure that can be costly in terms of both time and money. Machine balancing is therefore vital for ensuring smooth and efficient operation and to help prolong the life of the machine.
Here at Hi-Tek Balancing we specialize in the art and science of dynamic machine balance. We can identify problems such as unbalance by recognizing the distribution of mass – called the dynamic — in relation to force and vibration and then correcting that unbalance by adding or removing weight from the rotating component to minimize the force and vibration.
Proper machine balance is, of course, critical to a wide variety of applications and systems such as manufacturing, scientific, and test and measurement equipment. These can vary greatly — from small, highly delicate, high-speed laboratory equipment to massive, rugged industrial machines. Despite the extremes between these two very different examples, the challenges of vibration and wear are the same, just on different scales. The process and methodology of machine balancing is theoretically the same in both cases, where the effects of centrifugal force are usually the cause of increased vibration and decreased performance.
All rotating components create some amount of vibration. When vibration becomes severe it can be very destructive when not corrected. Irregularities or asymmetries created either during the manufacturing process or due to wear are often the cause of vibration. They create a mismatch between the rotating axis established by the supporting shaft and bearings, and the axis of orbit around the actual center of mass of the rotating object. An unbalanced part tries to orbit about this axis of inertia while the shaft and bearings force the part to orbit about the different axis they dictate. This mismatch transmits the forces of vibration into the shaft and bearings, and their support structure causing stress and strain that these systems are not designed to handle.
Dynamic balancing is the process used to diagnose and correct the harmful vibration described above. We use purpose built dynamic balancing electronic instruments to aid in matching the axis of inertia about the center off mass, to the rotating axis established by the shaft and bearings.
Vibration is usually caused by parts that are unbalanced as a result of asymmetrical manufacturing. To really understand vibration and its sources, you need to have a thorough knowledge of manufacturing processes. Resolving a vibration problem requires going beyond just balancing components to address the manufacturing cause.
We know the questions to ask to get you the solutions you need. What sets us apart from the competition is our in-depth manufacturing expertise. Our firsthand experience in machining, molding, and finishing enable us to know where problems occur, quickly identify your vibration source, and provide the best, most economical remedy to eliminate it. Our vibration analyses and solutions are precise, practical, and presented in a clear, easy-to-understand way that enables you to implement them in hours or days, not weeks or months.
Complete vibration analysis and balancing services, from prototype to production Around the corner or around the world, we can accurately diagnose and solve your rotating or oscillating equipment vibration challenges quickly and cost-efficiently, in our facility or yours. Our in-house capabilities range from diagnosing and fixing components weighing under an ounce, all the way up to ten tons. From wire winders in China to prototype micro-medical breathing assist blowers, we can analyze and solve virtually any vibration problem, from the largest industrial applications to the smallest technological ones.