Dynamic Balancing Of Rotors And Armatures

Heavy Or Light Spot torque), whereas vibration is typically

Balancing consists of identifying a expressed in units of velocity (e.g.,
physically heavy or light spot in a inches or millimeters per second) or
rotating component and placing an displacement (e.g., mils – thousandths
equal weight in opposition to the of an inch or millimeters). Also note
heavy or light spot. To simplify the that the distance measurement is a
explanation we will consider the case radius, not a diameter. A weight of 1
of a die cast squirrel cage rotor. If the unit at radius r would have the same
unbalance is due to a heavy spot, that effect as a weight of 1/2 unit at a
means there is too much weight on radius of 2r. The further the weight
one side of the rotor. By placing an can be safely located from the center
equal weight on the opposite side of of the shaft, the less weight is
the rotor, at the same effective radius, required.
the heavy spot is cancelled out. For A general caution: balance
By Tom Bishop, P.E. example, let’s assume the heavy spot correction weights must not extend
EASA Technical Support Specialist is 1.2 ounces at a radius of 2.5 inches. above the outer diameter of the
The terminology for the units of rotating component. Otherwise, the
This article describes machine unbalance in this case is ounce- balance weight could come in contact
balancing of the rotating components inches, and the unbalance would be with a stationary component such as
of motors and generators, primarily 3.0 ounce-inches (1.2 ounces times the stator winding, or could prevent
rotors and armatures. The methods 2.5 inches). insertion of the rotating component
described here, in general, can be Note that the units of unbalance Continued On Page 2
applied to on-site balancing if the are a force at a distance (much like
rotating component is accessible. The
intent is to describe the methods of
attaching balance weights, not
determining acceptable balance level Table 1
or the location and amount of Keyseat Dimensions
correction weight. (in inches)
The advent of computerized
balancing machines has made the
latter steps rather straightforward.
However, the challenge of how to Frame Keyseat
attach a weight in such a way that it Designations R ES MIN. S
will remain secure and not negatively
213 0.986 2.03 0.250
affect machine operation remains at
213T 1.201 2.41 0.312
times a vexing problem. 215 0.986 2.03 0.250
What is the purpose of dynamic 215T 1.201 2.41 0.312
balancing a rotating part? It is to
224 0.859 2.03 0.250
reduce unbalance and consequently to
225 0.859 2.03 0.250
bring vibration to acceptable levels to 254 0.986 2.03 0.250
allow for normal bearing and other 254U 1.201 2.78 0.312
component life. The acceptable levels
of vibration are described in EASA 254T 1.416 2.91 0.375
256U 1.201 2.78 0.312
Tech Note 32, “Standards For
256T 1.416 2.91 0.375
Dynamic Balancing,” thus we won’t
284 1.112 2.03 0.250
explain them here.

EASA CURRENTS ■ September 2006 1

 Dynamic Balancing Of Rotors And Armatures
Continued From Page 1
into the frame. Bolt and nut threads
should be locked with a thread-
locking compound and the ends of the
bolts “staked,” if possible, to prevent
the nut from loosening.
Weight Of The Shaft Key
Balance quality can be affected if
the weight of the shaft key is not
determined correctly. The half-key for
most shafts should be the length and
width of the actual key used in that
keyseat (keyway), but half of the key
height. Avoid using a full-size key of
half the length. That raises the center
of gravity of the key, making it have
the effect of being too heavy. If the
machine was received without
coupling or key, the length of the key
being used is usually evident with a
visual inspection of the keyway. If
you are unsure of the correct length
for the key, use the “ES” value for the
applicable frame size from NEMA
MG 1 standard. (See Table 1.) The
ES dimension is given in the EASA
Technical Manual, Electrical Engi-
neering Pocket Handbook and
Mechanical Reference Handbook. For
a metric motor, the IEC stipulates that
the shaft and rotor be balanced using
a full key. The pulley or coupling for
an IEC motor is balanced without a
key, to compensate.
For 2-pole machines, after the
rotor has been balanced to the
appropriate tolerance, add the fans,
coupling, etc., and balance them. Use
the rotor as a balance mandrel for
those parts, making weight correc-
tions directly to the fan/coupling.
Weight corrections should not be
made to the rotor at this stage. Doing
so will result in unbalance in multiple
planes, and may cause the shaft to
deflect at operating speed.
Die Cast Rotors
The most prevalent locations for
balance correction on a die cast rotor
2 EASA CURRENTS
are the projections between the end
ring cooling fan extensions, some-
times referred to as “nibs.” Typically,
flat washers are added to correct for
unbalance. After installing washers on
these nibs, the nib ends are peened
over to secure the washers. (See
Figure 1.) The washers should then
Figure 1. Nib ends should be
peened over to secure
the washers.
be checked for tightness before the
next balance run, i.e., there should not
be any clearance between the balance
washers and the nibs. If the nibs are
deformed so as to facilitate washer
removal, the affected nibs should not
be reused for attaching balance
weights. The probability is great that
the nib structure may no longer be
capable of retaining a balance washer.
The die cast end rings should not
be used to correct for unbalance by
removing material from them, such as
by drilling or grinding. Fan blades on
the end rings may be drilled to
accommodate a bolt, nut and washers
for balance correction if there are no
nibs on the end rings or the existing
nibs cannot be used. Make certain that
the balancing machine is protected
from particles and debris whenever
drilling or grinding or other such
machining operations are used to
adjust the part being dynamically
balanced.
As a guide, the bolt hole diameter
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in the fan extension should not be
more than about one-fifth of either the
extension height or length from the
end ring; the bolt length should not be
greater than about three times its
diameter. Preferably, the bolt hole
should be in the middle one-third of
the fan extension, as measured from
any edge.
Balancing Epoxy
If there are no provisions for
attaching washers, or bolts and
washers, balancing epoxy may be the
only alternative. Balancing epoxy is
epoxy formulated for the purpose of
correcting mechanical unbalance, and
is “loaded” with a high-density filler
material. Care must be taken in
attaching the epoxy because there are
few rotor surfaces that will retain it.
Often the only acceptable location is
under the end rings, where there will
be a relatively flat surface that can
restrain the weight against centrifugal
force. Other considerations in locating
the balancing epoxy are to be certain
that air flow will not be restricted,
such as by epoxy blocking a vent
duct.
Fabricated Rotors
Common methods of correcting
balance on fabricated rotors are
insertion of bolts into pre-tapped
balance ring holes, and attachment to
cooling fans or fins. Less frequently,
weights are bolted or welded to fans
or fins. Care must be exercised to be
certain that air passages are not
blocked or changed.
The bars and end rings should
never be used to correct for balance
by removing material from them,
such as by drilling or grinding.
Drilling or grinding could jeopardize
the mechanical integrity and possibly
affect the rotor electrical characteris-
tics. Care must be exercised to be
Continued On Page 3
 Dynamic Balancing Of Rotors And Armatures
Continued From Page 3
certain that air passages are not
blocked or changed by balance
weights. Also, differential thermal
expansion of the various rotor parts
must be considered. A balance weight
attached to a balance ring or internal
fan should not be positioned where the
end ring might contact it. The acciden-
tal circuit to ground may cause arcing
between the end ring or bars and the
weight.
If there is no place to attach a
weight by use of threads or welds,
balancing epoxy may be an alternative
as long as the following conditions
apply: airflow will not be restricted,
the epoxy is applied to the inner
diameter of a part such as an end ring,
the part can support the weight
without adverse effect on the part or
weight, and the weight will not be
prone to becoming loose or otherwise
damaged. The surface to which the
balance compound is to be affixed
must be clean and dry.
If the rotor has a spider, and a new
shaft has been made, pre-balance the
shaft and spider before mounting the
core. That will reduce the amount of
correction weight to be placed on the
completed rotor assembly.
Wound Rotors And Armatures
The most common method for
balancing wound rotors and armatures
is to apply balancing epoxy to the bore
side of the coil extensions or to the
glass bands on the periphery of the
coil extensions (See Figure 2.) Be
sure to verify that correction weights
on bands do not have a diameter
greater than the core; otherwise, they
may come in contact with stationary
parts such as the stator windings or
field coils. Going around the core
outside diameter with a straight edge
extending over the winding extensions
on both ends can be used to check this
Figure 2. Apply balancing expoxy
to the bore side of the
coil extensions or to the
glass bands on the
periphery of the coil
extensions.
clearance. As a guide, the minimum
radial distance between straight edge
and weight should be 1/16” (1.5 mm).
Balancing Ring
If the rotor or armature has a
balancing ring, that should be used for
balance correction. Most rings consist
of a narrow flange-like circular plate
with drilled and tapped holes to
accommodate bolts and washers as
balance weights. Some commutators
have dovetail shaped grooves with
pre-installed balance weights. The
weights can be redistributed within the
dovetail groove to improve or correct
unbalance.
Balance weights should only be
attached to fan blades if weights
cannot be attached to the windings or
balance ring as described above.
Many internal fans are of light metal
or plastic construction and are not
intended for attachment of relatively
heavy balance weights.
If an armature is rewound, remove
the old balance weights and pre-
balance the bare core before inserting
coils.
Leave the balancing provisions
(e.g., dovetail slots) clear for final
EASA CURRENTS ■ September 2006
balancing after the rewound armature
has been varnish-treated and the
commutator has been machined.
Synchronous Rotors
There is no predominant method
of correcting balance on these rotors.
On smaller rotors it is a common
practice to apply balancing epoxy to
the underside of the coil ends. Larger
rotors are usually corrected for
balance by welding or bolting weights
to the hub to which the bolts are
attached, or by adding washers to the
bolts holding fan blades in place. If
the force of rotation (centrifugal
force) is too great, the weld may fail
and the weight could strike the
winding or other components. Avoid
using the amortisseur cage for
attaching balance weights as the bars
and end rings are relatively low in
structural strength.
If the rotor is rewound and the
poles are removed, pre-balance the
bare-rotor assembly before reinstall-
ing the pole pieces and coils. That
will reduce the amount of correction
weight to be placed on the completed
rotor assembly.
Balancing Of Other Rotating
Components
Fans/Blowers
For guidance on balancing fans
and blowers, see the November 2004
Currents article “Fan Balancing
Tips.”
Impellers
Impellers are often balanced by
grinding or drilling to remove weight.
The balance machine must be
protected from debris particles
generated during the drilling or
grinding process. Balance weights
should not be attached to the flow
passages (nor the flow passages
drilled) within the impeller or to the
inlet faces. Likewise, the impeller
Continued On Page 4
3

Dynamic Balancing
Continued From Page 3
wear rings should not be used for
balance correction, such as by
grinding them.
Care must be exercised when
drilling to be certain that the struc-
4 EASA CURRENTS
tural integrity of the impeller is not
compromised. For instance, too large
a hole could cause the blade to crack.
Holes should not pass completely
through a wall or face, except for the
specific purpose of providing for bolt
attachment. Make certain that metal
chips are completely removed from
the impeller, and likewise protect the
balance machine by capturing all the
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chips that are generated.
Single vane impellers are a special
case for balancing. The fluid that
flows through them becomes part of
the dynamic mass, thus they should
be balanced in a fluid, not dry.
Balancing single vane impellers dry
can result in unbalance in actual
operation with fluid in them.