Balancing Machine Self-Calibration Without Master Rotors
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Solution Overview
Problem
Conventional balancing machine calibration processes require high-precision master rotors and manual calibration weights, leading to complex, error-prone procedures that disrupt production and reduce economic efficiency and safety.
Innovation Solution
An automatic calibration device integrated into balancing machines, comprising an electric motor-driven mechanical unbalance exciter with a rotating calibration disk and internal pulse generator, allows for automatic calibration without master rotors or manual weight application, enabling single or dual-plane calibration runs based on predefined unbalance and angle settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration weights and master rotors are used for calibration, then calibration precision can be achieved, but the calibration process becomes complex and error-prone
Solution Approach 1:
The calibration device generates its own calibration signal through an unbalance mass integrated into the calibration rotor, eliminating the need for external master rotors and manual calibration weights. The system calibrates itself by measuring the known unbalance of its own rotor, thereby simplifying the calibration process while maintaining precision.
Solution Approach 2:
The invention extracts the calibration function from the external calibration equipment (master rotors and calibration weights) and integrates it directly into the balancing machine's own rotor structure. The calibration rotor with integrated unbalance mass serves both as the measurement object and the calibration reference, removing the need for separate calibration artifacts.
2Ease of operation
If manual calibration weights are used, then calibration can be performed, but operator influence increases and errors occur
Solution Approach 1:
The system performs self-calibration by using its own rotor's known unbalance characteristics as the reference. This eliminates manual intervention entirely, removing operator influence and potential errors from the calibration process, thereby improving both ease of operation and reliability.
Solution Approach 2:
The invention replaces the mechanical process of manually attaching calibration weights with an automated electronic control system. The calibration rotor is driven by an electric motor with precise speed control, and the calibration process is managed through electronic measurement and calculation, eliminating manual mechanical operations.
3Measurement precision
If conventional calibration procedures are followed, then calibration accuracy is maintained, but production interruptions occur
Solution Approach 1:
The calibration function is integrated into the balancing machine's own operation. The calibration rotor can be measured and calibrated during the same measurement cycle as normal balancing operations, allowing calibration to be performed without separate production interruptions or dedicated calibration time.
Solution Approach 2:
The system maintains continuous operational capability by integrating calibration into the normal measurement process. The calibration rotor serves dual purposes: it can be used for actual balancing tasks and simultaneously provides the reference signal for calibration, ensuring uninterrupted productive operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates rapid, precise, and error-free calibration of balancing machines, reducing operator influence and production interruptions, enhancing process reliability and safety, and allowing for continuous operation and periodic checks.
Implementation Method 1
an electric motor-driven mechanical unbalance exciter with a rotating calibration disk... generating vibrations for calibration
Implementation Method 2
internal pulse generator... for speed detection of the rotating unbalance disc
Data Source
Figure 1~2
Figure 3(A)~3(B)
Figure 4~5
AI summary
The invention relates to a novel automatic calibration device for static or dynamic balancing machines and a method for automatic initial calibration and for spontaneous or cyclic automatic calibration control of these balancing machines without the additional use of reference rotors.