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.
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Large jaw type rock crushers are very common in the stone and gravel business. They are generally portable and can be towed by tractor trucks. The jaw crusher creates a pinch point that fractures larger rocks and reduces them to about the size of your fist. They are further crushed in a cone crusher and reduced to gravel as small as 1/4 inch.
The jaw crusher has two large flywheels powered by a diesel engine that spins an eccentric which causes a crush plate to oscillate making a pinch point fracturing rocks. The flywheels are indexable and have bolt-on plates to adjust the counterweight size to compensate for wear.
From a balancing standpoint, the crusher acts very much like a one cylinder engine. The counterweights in the flywheels act exactly as the counterweights in a crankshaft. The theory for adjusting the counterweights is identical.
Single cylinder engines are balanced to 50%. That means a bob weight is placed on the crankshaft that represents 50% of reciprocating weight, added to 100% of rotating weight. Reciprocating weight is 50% of, one piston and wrist pin and top of connecting rod, added to 100% the bottom of the connecting rod That weight is clamped to the crankshaft journal. The crankshaft is now balanced with the flywheels and the counterweights are adjusted for phase and amount.
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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.
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Precision Machine tool quill spindle is balanced to ISO g2.5 and corrections are made by drilling using our clamp on modified magneting base drill.
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Permanent magnet rotor sits in our custom 2500 pound balancer.
Paper machine rolls are balanced and material is removed or added by drilling to remove, or slugs are added deeper into the hollow roll shell to add weight.
We’re in print! Check out HI-TEK Balancing in Design World magazine! Just click the image to view a larger version.
Here’s the full text of the ad: Continue reading “HI-TEK Balancing is a Leader in Engineering”
Onsite balancing is one of the many services we offer for the equipment that you just can’t pack up and ship out. It’s important to maintain each piece of your equipment so you can enjoy a streamlined workplace. Our onsite balancing technology is top of the line equipment that detects imbalance and helps us figure out how to fix the problem. Continue reading “Onsite Balancing”