101 | Balancing of rigid rotors - Basics
(in German language)

Practice and Theory

Target

• Fundamentals of balancing and its application,
• Operation of balancing machines (measuring machine) with demonstration and exercising of typical balancing procedures.

Motivation

• Using the capabilities of balancing machines and correct application of balancing procedures.
• Chance to agree on a clear common “language of balancing” which can boost understanding between your various divisions dealing with balancing.

Participants

• All staff members who need to learn about fundamentals of balancing or who want to update their know-how and skills:
  Operators, supervisors, production planners, also process engineers, quality staff, designers, R&D members, all persons in charge of a balancing process and being asked from time to time for a decision.

Required qualifications
Understanding technical principles.

Duration
2 Days

Possible combination of courses
These courses are often followed by an advanced course (102), so that both courses can be booked together.

Topics

Fundamental know-how Knowledge	Practicing Using the fundamental know-how
Definitions, balancing, vibration unbalance, eccentricity, rotation, centrifugal force unbalance vectors and –components, unbalance types	Experience using demo-rotor, set of weights user-related examples of calculations setting measuring units
Measuring unbalance, set-up, drive systems, working ranges, speed, safety, mass-spring-system, resonance	Experience with demo-rotor and machine Setting of measuring unit, mechanical components and drive units, using hard-bearing machines and soft-bearing machines. Independent, but coached hands-on of complete set-up including determination of balancing tolerances acc. to quality grades (ISO), acting radii, etc.
Balancing tolerances unbalance correction (principles)	Application related calculations and choice of options on measuring units of universal balancing machines

101 | Balancing rigid rotors - Basics
(in English language)

Practice and Theory

Target

• Fundamentals of balancing and its application,
• Operation of balancing machines (measuring machine) with demonstration and exercising of typical balancing procedures.

Motivation

• Using the capabilities of balancing machines and correct application of balancing procedures.
• Chance to agree on a clear common “language of balancing” which can boost understanding between your various divisions dealing with balancing.

Participants

• All staff members who need to learn about fundamentals of balancing or who want to update their know-how and skills:
  Operators, supervisors, production planners, also process engineers, quality staff, designers, R&D members, all persons in charge of a balancing process and being asked from time to time for a decision.

Required qualifications
Understanding technical principles.

Duration
3 Days

Possible combination of courses
These courses are often followed by an advanced course (102), so that both courses can be booked together.

Topics

Fundamental know-how Knowledge	Practicing Using the fundamental know-how
Definitions, balancing, vibration unbalance, eccentricity, rotation, centrifugal force unbalance vectors and –components, unbalance types	Experience using demo-rotor, set of weights user-related examples of calculations setting measuring units
Measuring unbalance, set-up, drive systems, working ranges, speed, safety, mass-spring-system, resonance	Experience with demo-rotor and machine Setting of measuring unit, mechanical components and drive units, using hard-bearing machines and soft-bearing machines. Independent, but coached hands-on of complete set-up including determination of balancing tolerances acc. to quality grades (ISO), acting radii, etc.
Balancing tolerances unbalance correction (principles)	Application related calculations and choice of options on measuring units of universal balancing machines

102 | Balancing of rigid rotors - Advanced course
(in German language)

Practice and Theory

Target

• Advanced knowledge to define suitable balancing procedures
• Assess typically employed methods (e.g. indexing balancing)
• Recognition of typical errors and according troubleshooting

Motivation

• Use of the capabilities of balancing machines more efficiently and generally optimise the balancing process as a whole.
• Improved targeted approach to trace errors
• Understanding interaction between several rotor parts including fitting errors.

Participants

• All having responsibility for balancing.
• Operators who are working as professional, competent partners in the company, supervisors,  designers, process and production engineers, staff active in development, quality assurance and those who are in contact with customers or suppliers.

Required qualifications
Participation in seminar 101 – Balancing rigid rotors – Basics or good knowledge of balancing technology.

Duration
1.5 days

Possible combination of courses
These courses are often preceded by a basic course (101), so that both courses can be booked together.

Topics

Advanced know-how Knowledge	Practicing Using the advanced know-how
Tracing errors on a rotor with prepared errors, with wrong electronic and mechanical setting, and misadjusted machine Use of vector indication to interpret behaviors and find conclusions Setting on measuring unit to support finding errors.	Tracing errors on a rotor with prepared errors, with wrong electronic and mechanical setting, and misadjusted machine Use of vector indication to interpret behaviors and find conclusions Setting on measuring unit to support finding errors.
Rotor assemblies, additional change of unbalance by mounting errors Distribution of balancing tolerances to tolerance planes and to single rotor parts. Alternatives to G-grades.	Experience effect of changing mounting angle. Decide how to distribute unbalance correction with discussion of solutions Calculation and prove of deviations vs. Tolerance.
Specific balancing procedures: Key compensation Indexing balancing – principle, examples of auxiliary parts like adaptors, balancing shafts …	Specific setting of measuring unit with demonstration, explanation and discussion of examples. Mounting a rotor part to an auxiliary balancing shaft Preparation of measuring unit Carry out the indexing procedure Doing the graphical solution step by step with recognition of plausibility and allocation of various influences followed by correction of unbalance on the rotor part, check the quality. Comparison of graphical results with indication on after guided dialog in the measuring unit.

102 | Balancing rigid rotors
(Advanced)

Practice and Theory

Target

• Advanced knowledge to define suitable balancing procedures
• Assess typically employed methods (e.g. indexing balancing)
• Recognition of typical errors and according troubleshooting

Motivation

• Use of the capabilities of balancing machines more efficiently and generally optimise the balancing process as a whole.
• Improved targeted approach to trace errors
• Understanding interaction between several rotor parts including fitting errors.

Participants

• All having responsibility for balancing.
• Operators who are working as professional, competent partners in the company, supervisors,  designers, process and production engineers, staff active in development, quality assurance and those who are in contact with customers or suppliers.

Required qualifications
Participation in seminar 101 – Balancing rigid rotors – Basics or good knowledge of balancing technology.

Duration
1.5 days

Possible combination of courses
These courses are often preceded by a basic course (101), so that both courses can be booked together.

Useful hint
Booking the two courses en-bloc will save you EUR 150.-

Topics

Advanced know-how Knowledge	Practicing Using the advanced know-how
Tracing errors on a rotor with prepared errors, with wrong electronic and mechanical setting, and misadjusted machine Use of vector indication to interpret behaviors and find conclusions Setting on measuring unit to support finding errors.	Tracing errors on a rotor with prepared errors, with wrong electronic and mechanical setting, and misadjusted machine Use of vector indication to interpret behaviors and find conclusions Setting on measuring unit to support finding errors.
Rotor assemblies, additional change of unbalance by mounting errors Distribution of balancing tolerances to tolerance planes and to single rotor parts. Alternatives to G-grades.	Experience effect of changing mounting angle. Decide how to distribute unbalance correction with discussion of solutions Calculation and prove of deviations vs. Tolerance.
Specific balancing procedures: Key compensation Indexing balancing – principle, examples of auxiliary parts like adaptors, balancing shafts …	Specific setting of measuring unit with demonstration, explanation and discussion of examples. Mounting a rotor part to an auxiliary balancing shaft Preparation of measuring unit Carry out the indexing procedure Doing the graphical solution step by step with recognition of plausibility and allocation of various influences followed by correction of unbalance on the rotor part, check the quality. Comparison of graphical results with indication on after guided dialog in the measuring unit.

103 | Balancing flexible rotors
(in German language)

Practice and Theory

Target

• Mediation of knowledge about balancing flexible rotors.
• Assess applied methods and select typically suitable procedures.
• Understanding the behavior of the system rotor and machine in general

Motivation

• Background knowledge to assess / identify rotor structure and classification.
• Acquired skills to derive suitable procedures and their appropriate application
• Improved practical proceedings with better assessment of rotor condition

Participants
All who shall apply their know-how and skills for this challenging task:

• Balancing staff, machine operators and plant operators with basic knowledge
• Process engineers, designers, developers, … who are facing these kind of rotors
• Staff who need competence like in rotor dynamics…

Required qualifications
Good knowledge of the concepts of balancing rigid rotors, or attendance at our courses dealing with rigid rotors: 101 – Basic course and 102 Advanced course

Duration
3 day

Topics

Fundamentals Specific knowledge	Practicing Application of the know-how
Unbalance distribution and its separation into static unbalance, couple unbalance and modal unbalance Rotor state (constant, variable) Bending modes, influence of bearings Mode shapes and natural frequencies	Experience on a non-rotational rotor: development oft the mode shape, natural frequency, change of bearing stiffness with adjustable test rig. See the difference of a steep speed increase vs. a creeping low acceleration. Do your own evaluation, identify mode shapes and discuss it with your trainer.
Structure and characteristics of rotors: Classification of suitable procedures with examples from turbines, generators, compressors, jet engine rotors, pumps, turbochargers, paper rolls, decanters, electric motors… Low-speed balancing procedures	Balancing a multistage rotor assembly using low-speed procedures. Check your success using our training arrangement allowing this high speed runs.
High-speed balancing procedures Unbalance correction of the various kind of unbalances, orthogonal unbalance set, influence coefficients. Non isotropic phenomena Various tolerance criteria	Manuel high-speed balancing of a shaft-flexible rotor. Use graphical determination of influence coefficients using a weight set then balance the rotor. Computer-aided high-speed balancing of a shaft-flexible rotor with calculated weight sets from the measuring equipment. Each time including the setting of the measuring equipment using display of ramp-up, measuring and evaluation.

103 | Balancing flexible rotors
(in english language)

Practice and Theory

Target

• Mediation of knowledge about balancing flexible rotors.
• Assess applied methods and select typically suitable procedures.
• Understanding the behavior of the system rotor and machine in general

Motivation

• Background knowledge to assess / identify rotor structure and classification.
• Acquired skills to derive suitable procedures and their appropriate application
• Improved practical proceedings with better assessment of rotor condition

Participants
All who shall apply their know-how and skills for this challenging task:

• Balancing staff, machine operators and plant operators with basic knowledge
• Process engineers, designers, developers, … who are facing these kind of rotors
• Staff who need competence like in rotor dynamics…

Required qualifications
Good knowledge of the concepts of balancing rigid rotors, or attendance at our courses dealing with rigid rotors: 101 – Basic course and 102 Advanced course

Duration
3 day

Topics

Fundamentals Specific knowledge	Practicing Application of the know-how
Unbalance distribution and its separation into static unbalance, couple unbalance and modal unbalance Rotor state (constant, variable) Bending modes, influence of bearings Mode shapes and natural frequencies	Experience on a non-rotational rotor: development oft the mode shape, natural frequency, change of bearing stiffness with adjustable test rig. See the difference of a steep speed increase vs. a creeping low acceleration. Do your own evaluation, identify mode shapes and discuss it with your trainer.
Structure and characteristics of rotors: Classification of suitable procedures with examples from turbines, generators, compressors, jet engine rotors, pumps, turbochargers, paper rolls, decanters, electric motors… Low-speed balancing procedures	Balancing a multistage rotor assembly using low-speed procedures. Check your success using our training arrangement allowing this high speed runs.
High-speed balancing procedures Unbalance correction of the various kind of unbalances, orthogonal unbalance set, influence coefficients. Non isotropic phenomena Various tolerance criteria	Manuel high-speed balancing of a shaft-flexible rotor. Use graphical determination of influence coefficients using a weight set then balance the rotor. Computer-aided high-speed balancing of a shaft-flexible rotor with calculated weight sets from the measuring equipment. Each time including the setting of the measuring equipment using display of ramp-up, measuring and evaluation.

104 | **Statistics in balancing technology
(in German language)

Engineers in design and production planning, who wish to get a general idea of the statistical evaluation of unbalance measurements.

Required qualifications
Basic knowledge of balancing technology, or participation in the seminar 101 – Basics.

Duration
1 day

Type of training
Theoretical background and examples. Level: medium

Topics

105 | ***Quality assessment involume production by means of diagnostic systems
(in German language)

Target group
All staff members interested in this subject, particularly staff working in planning, development, design, production and quality assurance of mass produced rotors.

Required qualifications
Basic knowledge of physical, mathematical and statistical concepts.

Duration
2 days

Subjects

106 | Handling vibration throughefficient process design
(in German language)

Theory and Case Studies

Target
Gaining information to assess

• characteristics of a number of typical rotors, special design features of these rotors.
• balancing in production – one-off rotors /small batches / large volumes
• determination of tolerances, analyzing drawings regarding machining and fittings
• capability in the balancing process, testing process and process capability
• planning a balancing procedure, factors contributing to errors, influences resulting from adjacent processes

(crash course)

Motivation

• competence in fundamentals, understanding interactions in efficient production and quality assurance of product properties
• improve assessment of procedures and possible implementation of innovations

Participants
Staff with process responsibility, typically in middle management, production managers, quality managers, method planners, design engineers, section leaders, work schedulers etc.

Required qualifications

• Sound knowledge of physical and technical principles
• Experience in rotor design or process design or supervision etc.

Duration
2 days

Topics

Theory Specific fundamentals	Case studies Run through various scenarios
Fundamentals: Vibration and unbalance Eccentricity as a kind of general scale Centrifugal force and bearings… Types of unbalances and consequence on the process	Discussion using frequency identification chart Consideration of machining and fitting tolerances Typical effects on bearing parts and rotor Correction in one, two or multiple planes
Consideration of rotor characteristics: Rotors with its own axis Rotors without own axis Rigid rotor behavior Various flexible rotor behaviors Rotor assemblies and partial exchangeability	Degree of assembly, bearing influences Balancing shafts, adaptors, indexing process Consequences for the process Discussion of different procedures and consequences Option and consequences to balance single parts, subassemblies or/and completely assembled rotors
Balancing in production Options for correction, in principle and typically practiced Cycle time, one of a kind rotor, serial production	Discussion of different possibilities, Consequences for degree of automation
Determination of balancing tolerance Various approaches Consideration of rotor being built into the stator housing Estimation of unbalance for a completed assembly	Quality grades (G-grade) for rigid rotors, criteria with flexible rotors Discussion: balancing as completed assembly in its (stator) housing on a balancing machine, balancing in situ Deduction of influences from deviations (errors)
Statistics and balancing Fundamentals Characteristics of unbalance in view of statistics Capability studies Drafting a simple exemplary balancing concept and a production step Selection of optional topics: Estimating initial unbalance Simulation of rotor characteristics and behaviors	Balancing machine as measuring device Balancing tooling as measuring tool Certification and metrological traceability of measuring standards Unsymmetrical distribution limited by zero on one side, bivariate statistics, suitability of evaluation procedures, examples Aspects, calculation of influences, discussion about its meaning Short impressions: Prediction methods (verified) Simulation methods and verification

107 | Field balancing and more...- Smart Balance
(in German language)

Practice and Theory

Target

• Balancing rotors in situ
• Operation of various modes (SmartBalancer or similar) and use of its properties
• Knowledge of application conditions
• Understanding of important interactions and
• Gaining competence in typical applications

Motivation

• Detecting vibrations, resonances, finding suitable measuring ranges, making frequency analysis
• Capability to balance rotors in situ, e.g. to treat unbalance developing from mounting influences
• Avoiding extreme production tolerances for the rotor
• Targeted approach for correct measurement and in tolerance prove

Participants

• Operators, supervisors, team leaders, designers, process engineers
• Staff members of service team, test field, prototype testing
• All who want to be introduced to balancing in situ or who need to have competence

Required qualifications
General understanding of technical and physical principles

Duration
1 day

Topics

Fundamental know-how Knowledge	Practicing Using the fundamental know-how
Fundamentals: Reasons for balancing , definition of unbalance, vibration, frequency, meaning of adding parts of rotors and eccentricities, types of unbalances, centrifugal force	Experience on training equipment: Attaching vibration sensors Set-up of reference sensor (key phaser) Setting on the SmartBalancer unit
Tolerances Unbalance Overall vibration	Measuring the overall vibration Comparison with tolerances acc. to ISO Standard
Equipment / Options of the SmartBalancers: Frequency analysis Ramp-up and ramp-down curves   Reference to DIN ISO 10816 Data transfer Sensors, measuring points and attachment	Frequency analysis and assessment of the first order for possible balancing, use of frequency identification chart. Finding suitable measuring speeds using ramp-up / ramp-down curve Determination of the balancing speed.
Balancing in situ: in 1 plain in 2 plains Special conditions	Frequency selective measurement Rotor-specific unbalance calibration Measuring Correction of indicated unbalance Check-measurement of unbalance Check-measurement of overall vibration Discussion of process and results and possible further course of action

107 | Field balancing and more...- Smart Balance
(in English language)

Practice and Theory

Target

• Balancing rotors in situ
• Operation of various modes (SmartBalancer or similar) and use of its properties
• Knowledge of application conditions
• Understanding of important interactions and
• Gaining competence in typical applications

Motivation

• Detecting vibrations, resonances, finding suitable measuring ranges, making frequency analysis
• Capability to balance rotors in situ, e.g. to treat unbalance developing from mounting influences
• Avoiding extreme production tolerances for the rotor
• Targeted approach for correct measurement and in tolerance prove

Participants

• Operators, supervisors, team leaders, designers, process engineers
• Staff members of service team, test field, prototype testing
• All who want to be introduced to balancing in situ or who need to have competence

Required qualifications
General understanding of technical and physical principles

Duration
1 day

Topics

Fundamental know-how Knowledge	Practicing Using the fundamental know-how
Fundamentals: Reasons for balancing , definition of unbalance, vibration, frequency, meaning of adding parts of rotors and eccentricities, types of unbalances, centrifugal force	Experience on training equipment: Attaching vibration sensors Set-up of reference sensor (key phaser) Setting on the SmartBalancer unit
Tolerances Unbalance Overall vibration	Measuring the overall vibration Comparison with tolerances acc. to ISO Standard
Equipment / Options of the SmartBalancers: Frequency analysis Ramp-up and ramp-down curves   Reference to DIN ISO 10816 Data transfer Sensors, measuring points and attachment	Frequency analysis and assessment of the first order for possible balancing, use of frequency identification chart. Finding suitable measuring speeds using ramp-up / ramp-down curve Determination of the balancing speed.
Balancing in situ: in 1 plain in 2 plains Special conditions	Frequency selective measurement Rotor-specific unbalance calibration Measuring Correction of indicated unbalance Check-measurement of unbalance Check-measurement of overall vibration Discussion of process and results and possible further course of action