Balancing Machine Calibration Using Process Matrix
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Solution Overview
Problem
Existing calibration methods for balancing machines using master parts are prone to errors, leading to inefficient imbalance compensation in production processes.
Innovation Solution
A method that calibrates balancing machines during the compensating run, using only two measurements per rotor and updating the process calibration matrix with measurement data, eliminating the need for a separate master calibration and allowing for continuous improvement of the calibration matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate calibration run with a master part is performed, then the balancing machine can be calibrated, but the production cycle time increases and errors in master part calibration affect the entire production process
Solution Approach 1:
The patent combines the calibration function with the normal balancing operation by using the balancing run itself to determine the process calibration matrix. Instead of separating calibration and production into distinct steps, the method integrates calibration data collection into the regular balancing process, allowing continuous calibration without additional time expenditure.
Solution Approach 2:
The system performs self-calibration by using measurement data from the rotors themselves during balancing runs. The process calibration matrix is determined and updated using data from the rotors being balanced, eliminating the need for external master parts and allowing the system to calibrate itself continuously during production.
2Reliability
If a master part is used for calibration, then the calibration process can be established, but errors in the master part propagate to all subsequent production parts
Solution Approach 1:
The system eliminates dependence on external master parts by using the rotors themselves as calibration sources. Each rotor's measurement data contributes to determining the process calibration matrix, making the system self-calibrating and eliminating error propagation from master parts.
Solution Approach 2:
The patent implements continuous feedback by using measurement data from balancing runs to update the process calibration matrix. This feedback loop allows the system to continuously refine its calibration based on actual production data, improving reliability without depending on potentially erroneous master parts.
3Productivity
If traditional calibration methods are used, then the balancing machine can operate, but the imbalance compensation is unnecessarily poor due to calibration errors
Solution Approach 1:
The system continuously improves imbalance compensation precision by using feedback from actual balancing runs to update the process calibration matrix. This ongoing refinement ensures that calibration remains accurate without sacrificing production efficiency, as the calibration occurs during normal operation rather than requiring separate calibration runs.
Data Source
Figure 1
AI summary
A method for calibrating a balancing machine is described, in which a rotor (1) to be balanced is rotatably mounted in bearings (2) and a balancing run k is performed. At least one sensor (3) determines an initial vibration of the rotor (1) before unbalance compensation and transmits this to an evaluation unit (4), which stores the measured value as a vibration vector s0. After an unbalance on the rotor (1) has been compensated, a residual vibration of the rotor (1) is measured by the sensor (3), transmitted to the evaluation unit (4), and stored as a vibration vector s1. The difference δs = s1 - s0, calculated from the measurement data, and the compensated unbalance are stored by the evaluation unit (4) as δsk and uk for the balancing run k.To calibrate the machine, either a process calibration matrix K can be determined by solving the system of equations S = U KT using the measured data, or an existing process calibration matrix can be selected based on the output vibration s0 and/or the unbalance vector u and stored as a calibration matrix in the evaluation unit (4) and used to calculate an unknown unbalance vector of a rotor (1).