balancing newsbalancing newsInformation for the quality and performance of rotating equipment - From the Schenck Balancing & Diagnostic Systems Group

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2016_Vol.1

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IN THIS ISSUE:Where Are They Now? Joe Gibbs .................................................1

Product Showcase..Schenck Launches New Spare Parts Kit....3

Introducing the CABflex3...Flexible Rotor Balancing System...4

New Faces At STC............................................................................5

Angel “Sonny” Julian Retires..........................................................5

Community Affairs..........................................................................6

Off-Line Condition Monitoring......................................................7

2016 Events.......................................................................................8

Where Are They Now? Joe Gibbs Racing

The Challenge:

It was approximately five years ago when the Joe Gibbs Racing Team received driver complaints about driveline vibration and approached Schenck about balancing their redesigned driveshafts.

The Solution:

JGR and Schenck partnered to develop and fine-tune a balancing process to balance their newly designed driveshafts for their NASCAR racing teams.

Working closely with the engineering staff at Joe Gibbs Racing to meet their require-ments, Schenck established a procedure, and through a series of testing and analysis, fine-tuned and executed the procedure, to balance and correct the JGR’s driveshafts to a better balancing tolerance than what was currently being used.

The Schenck HK40 / CAB 920 driveshaft balancing system installed at Schenck in Deer Park, NY provides excellent repeatability and accuracy, and has been applied successfully to balance hundreds of JGR driveshafts over the past 5 years.

Balancing Theory: What is unbalance?

According to ISO 1925, Unbalance is that condition which exists in a rotor when a vibratory force, or motion, is imparted to its bearings as a result of centrifugal force.

Rotation and unbalance in a driveshaft causes centrifugal force to act on the driveshaft. The centrifugal force increases with the square of the speed.

The Schenck HK40 - Specifically developed for high-speed balancing tasks

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The remaining unbalance in the driveshafts, when they are rotated, creates a centrifugal force that is imparted to the rest of the vehicle’s driveline as vibration. Reducing the driveshaft unbalance is one way to reduce overall vibration and improving performance.

Result:

The improved JGR shaft design and assembly process, as well as control and precision pro-vided by the balancing process, have resulted in superior vibration measurements made on dynamometers at the Joe Gibbs Racing facility in Huntsville, NC as well as on the track. This has resulted in no reported complaints of driveline vibration by their team of now 4 drivers.

It has been more than five years of balancing these driveshafts with improved results noted by the JGR team when tested at approximately 9600 rpm. On race day, all four JGR teams (No.18, No.11, No. 19 & no. 20 cars) in the Sprint Cup Series had improved results. The minimized driveline vibration directly resulted in increased horsepower and performance!!

Joe Gibbs Racing looked to Schenck to provide balancing expertise, high quality, and reliable service needed to help keep them at the front of the field.

The 2015 Sprint Cup season resulted in all four cars making the Chase for the Cup.

The ultimate goal was achieved by Joe Gibbs Racing in 2015 as their Number 18 race team, with driver Kyle Busch, won the Sprint Cup Championship!

All of us at Schenck congratulate our customer and partner on the championship win and another very successful season!

Schenck’s Unique In-House Balancing Service Capabilities Include:

• Low and high speed driveshaft balancing(automotive & aerospace)

• R&D / Prototype development balancing

• Contract and large volume balancing

• Turbine and Compressor and Blade momentmass weighing, and blade set distribution

• Balancing of Rotors from a few ounces up to10,000 pounds

• Balancing of Rotors with and withoutjournals, and self-driven assemblies

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For more information on our Balancing Services please contact us at 631-242-4010 and ask for our Balancing Service Department or simply write us at sales@schenck-usa.com

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Schenck’s Spare Parts Department introduces its HM4/40B Spare Parts Kit! The kit consists of the 15 most common replacement parts for the AHF series balancers including a set of 130mm (5.12") diameter rollers. Each part is nested in separate custom laser cut slots with “part number / description tags” for safe storage and easy identification. The kit comes in a lightweight, durable storage and carrying case with pull-out handle and wheels for ultimate safe keeping and convenience.

The kit provides our customers with an organized way to keep the necessary replacement parts on hand and also to facilitate an easy means to re-order.

The kit is supplied with a handful of business size cards with our contact information on the front and the parts check-off list on back.

The kit also comes equipped with a QR label that al-lows our customers a direct link to Schenck’s web-site for ordering via any mobile devise.

The kit is suitable for all Schenck AHF-series belt-driven balancer models HM4B, HM4BU, HM40B, HM40BU, H4M, H40M and H-6500-I that were manufactured in 2001 or newer. Our introductory selling price represents a 20% discount on ALL of the contents plus the FREE storage/carrying case.

For more information, please write to parts@schenck-usa.com or call 631-242-4010 and ask for the Parts Department.

New Product Showcase

Schenck Launches New Spare Parts Kit

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Introducing the CABflex3

Schenck is excited to announce our latest flexible rotor balancing solution!

The vast majority of high-speed balancing and over-speed testing facilities employ Schenck’s CABFLEX Flexible Rotor Balancing System for balancing and testing of compressor, turbine, and generator rotors. The CABFLEX Systems are used to analyze rotor vibrations to calculate unbalance corrections.

The latest CABFLEX System, CABflex3, follows in the footsteps of its successful predecessors, and provides additional capability and increased efficiency. The new CABflex3 provides significant advances in measuring and process functions. An improved measuring chain and expanded analysis tools, integrated into a modern, simple user interface, makes it all possible.

High-speed balancing of turbine and generator rotor requires extensive knowledge, since these rotors are flexible and therefore exhibit different dynamic behavior and vibration amplitudes with a change in speeds. Balancing is often time consuming and therefore expensive in terms of operating costs, especially considering balancing of the largest turbine rotors requires accelerating rotors in excess of 300 tons to their service speeds.

For balancing of these bladed rotors, the facilities are equipped to operate under vacuum conditions to reduce frictional losses and heat generated by windage. With an evacuation time of up to 45 minutes in the largest facilities, this is a time consuming step required prior to each measuring run.

CABflex3 offers exactly that. Vibration is measured dur-ing run up, data is analyzed, influence coefficients areprocessed, and corrections are calculated. This simpli-fies and speeds up the complex high-speed balancingprocess and reduces the correction steps to a few runs.The Schenck software uses unbalance influence coef-ficients from the measuring runs to calculate the correc-tion steps. It is possible to then apply the evaluation toolto analyze the effective correction of the various calcula-tions. The operator can also make conclusions about thedynamic rotor behavior.

After evacuating the test chamber, the rotor is accelerated to its service speed or predefined balancing speed and the measuring run is conducted. After measuring, the rotor is decelerated to a stop, and air is reintroduced into the test facility. Since each balancing run includes these additional, time-consuming processes, it is easy to understand that an operator will seek to balance the rotor with the least amount of measuring and correction runs as possible.

CABflex3 features expanded capabilities such as on-line evaluation, for real-time measuring and analysis processes conducted in parallel. Remote diagnostics for Schenck Service, remote monitor display for customer viewing areas, and an off-line software version for office use, provide reliability and flexibility for the new CABflex3 System. Integration of force monitoring and process data is also built-in.

Our template-based printing with built-in Microsoft Word® templates automatically populates certain fields with measurement data and graphs. This standardizes your printout formatting with data such as rotor information, test data, procedure, and notes, and allows for customized layouts to incorporate your company branding and logos with your customer data.

CABflex3 offers a new operating concept that increases efficiency of the balancing process. Clearly-arranged, interactive graphics, combined with a logical navigation structure, ensure quick and error-free operation of the software.

The CABflex3 System further improves the efficiency of the flexible rotor balancing, and will continue to be the standard at test facilities worldwide. It is available as a new system and modernizations of existing systems. Regardless of the existing hardware setup, the new CABflex3 System can be configured with hardware and software options to meet the specific needs of each end-user.

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For more information please contact us at 631-242-4010 and ask for our High Speed Department or simply write us at sales@schenck-usa.com

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Off-Line Condition Monitoring: Power Generation and Beyond

In our last issue, we focused on online condition monitoring. This issue focuses on Schenck's off-line condition monitoring services.

Schenck has been providing condition monitoring equipment and services for over 20 years! Here is a clear example of how our service can result in cost savings.

We have been contracted by a Power Generation Plant to perform off-line condition monitoring service for their plant since 2013.

This service includes routine-based data collection and analysis of auxiliary plant equipment. The plant has a total of 50 machines made up of various pumps, compressors and fans.

The routine data collection includes taking overall vibration readings and FFT spectrums to see the overall machine condition plus the BCU (Bearing Condition Unit) and envelope spectrum to analyze the bearing condition. After the data is collected our software program is used to analyze the vibration readings and look at the overall trend.

Figure 1 shows the trend diagram from July 2013 to January 2016 for a motor’s outboard bearing in the horizontal direction. The overall vibration reading taken in January 2016 is high (greater than 0.3 in/sec). Figure 1 also shows the frequency spectrum with a high peak at the running speed which is an indication for unbalance.

For more information on our Condition Monitoring Services, please contact us at 631-242-4010 and ask for our Vibro department or simply email us at sales@schenck-usa.com

Figure 1

Based on this unbalance indication, the plant's maintenance department was notified of our findings and an appropriate balancing procedure was performed on this motor! Statistics show that a reduction of the vibration level by 20% will increase the bearing life by 95%.

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New Faces at STC

Schenck Trebel Corporation is proud to welcome new employees Sabrina Seecharan, Anthony Polimeni, Grace Cardano, Albert Stark, and Michael DeLuca.

Sabrina Seecharan Anthony Polimeni Grace Cardano

Albert Stark Michael DeLuca

Sabrina Seecharan is currently in our Parts department while attending Suffolk Community College, working towards a degree in Mechanical Engineering. Sabrina has a multitude of interests including Robotics, Photography and Sports.

Anthony Polimeni received his Bachelor of Science in Mechanical Engineering and joins Schenck as an Applications Engineer. He brings with him experience as a Mechanical Design Engineer, Machine Operator and Machinist.

Grace Cardano joins Schenck as a Mechanical Design Engineer, and has nearly 20 years of experience in design and drafting for commercial businesses and military contractors.

Albert Stark received his Masters of Science in Mechanical Engineering and joins Schenck as an Applications Engineer in the Universal Balancing group. He brings with him experience with HVAC Systems, ergonomic products and athletic equipment.

Michael DeLuca earned his Bachelor of Science in Mechanical Engineering Technologies from Farmingdale State College and joins Schenck as a Service Engineer. Most recently, he assisted the Department of Environmental Protection in Queens with a plants and pumping project.

For more information about Schenck career opportunities click here.

Retirement

Angel “Sonny” Julian – January 15, 2016

After an impressive 47 years of employment, Sonny Julian said goodbye to his Schenck family. His supervisor, Bob Bekman gave a nostalgic and moving testimonial at his retirement celebration and co-workers enjoyed a home-made slideshow of photos throughout the years.

Sonny was a Draftsman and Mechanical Designer in the Engineering department for most of those 47 years. Sonny is looking forward to spending time with his wife, Barbara and their grandchildren.

Sonny Julian - Then and Now

We wish Sonny all the best in his retirement, and will always have fond memories of his work ethic and great attitude!

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Community Af fairs

Food For Thought

Schenck's new employees Albert Stark and Anthony Polimeni have officially been indoctrinated into Schenck’s monthly volunteer efforts!

Both Albert and Anthony recently volunteered at the Mercy Inn, a nearby soup kitchen, sponsored by the Interfaith Nutrition Network (INN). Anthony served the beverages and Albert served the desserts.

Their efforts were welcomed and appreciated by all!

Schenck’s Volunteers pictured from left to right: Anthony Polimeni, Albert Stark

Knowledge Is Power

Schenck Trebel Corporation participates in valuable educational events!

On March 10, 2016 Schenck exhibited at SUNY Farmingdale’s Technology Job Fair. There was a promising turnout of prospective employees and future graduates who had chance to learn about careers at Schenck.

On April 1, 2016, Schenck was part of the STEM Diversity Summit, also held at SUNY Farmingdale. The STEM/STEAM organization helps promote careers in the fields of Science, Technology, Engineering and Mathematics to students ages K-12. With the help of businesses, universi-ties, government and non-profit organizations, students are exposed to the latest developments through presentations and interactive activities.

Schenck was again a proud sponsor of the FIRST Robotics Long Island Regional competition, contributing to the development and nurturing of our future engineers!

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2016 Events

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For more information on Schenck's events, visit us at www.schenck-usa.com