BVI-03-78
Semi-automatic driveshaft balancer with automatic flange clamping and multiple several welding stations
Maximal weight, kg
Maximal diameter, mm
Precise, high-volume balancing for series production
Model BVI-03-78 is a special equipment for balancing 2-, 3- and 4-axis universal joint shafts. The machine is designed for industries that specialize in the production of driveshafts in series production. High performance and precision (5 g*mm / kg) equipment merits a unique design of the machine and the hardware-software complex PAK-4.
The balancing machine includes four pre-resonance supports located on the monolithic frame. The outermost supports have spindle assemblies and pneumatic self-clamping chucks with guide pins for quick orientation of the driveshaft flanges during clamping. The rear spindle support can move along the entire bed, allowing the machine to be set up for different lengths of PTO shafts. For easy changeover, the rear spindle bearing has a movable quill and a weight compensation mechanism for its movement. The two intermediate supports can also be moved along the bed when the machine is set up. In addition, they feature a unique support table height adjustment mechanism for time-saving installation of outboard bearings.
In addition to the vibration mounts, the machine bed is also equipped with pneumatic cylinder safety brackets. The protective brackets have two functions: They provide collective protection and serve as additional support for the PTO shaft during machine setup. One of the bracket’s pneumatic cylinders has a mounting prism and raises the PTO shaft to the desired height to secure the flange. The second pneumatic cylinder is a lock and limits the area for the gimbal during rotation, using its own rod.
The machine is equipped with an unbalance correction module, which includes one or three (depending on customer preference) spot welding units for attachment of correction weights after unbalance detection. The welding unit can be moved along the machine bed to adapt to any driveshaft.
The electrical equipment of the machine is located in a separate electrical cabinet. The electrical equipment includes a frequency converter, which provides smooth control of the machine’s electric drive and protection of the equipment. The electrical cabinet also includes a control panel and a hardware-software complex with an industrial computer. The computer has a touch screen for easy operation of the software and hardware complex, and the control panel, in addition to the machine controls, is equipped with signal lamps that clearly indicate the status of all systems of the equipment.
- The monolithic design of the machine supports and bed eliminates vibration loss and ensures high quality measurements;
- The design features of the clamping chuck, safety bracket and intermediate supports allow you to change the machine without wasting even 3 minutes;
- The safety brackets and protective enclosure of the cabinet type ensure a high level of safety of the equipment;
- Self-clamping pneumatic chuck design ensures rapid clamping of flanges with overall dimensions of up to 125 mm (chuck can be made to order for any flange size);
- High maintainability of the machine due to the use of reliable available components during its construction.
Advantages of the PAK-4 hardware and software complex:
- Display of the position and unbalance magnitude of the four supports on one screen by means of a pie chart and a digital format allows the quick determination of the relative unbalance position in all correction planes.
- Calibration of the machine by the operator takes 1 Min. and maintains high machine accuracy over the whole period of use without having to spend time and money on a technician’s visit to calibrate the machine;
- Stored calibration results allow quick adjustment of the machine for different batches of driveshafts and eliminate the need for permanent calibration of the machine;
- Automatic unbalance averaging is used to shorten measurement cycles and improve balance accuracy by combining multiple unbalance vectors into one unbalance vector;
- Auto-diagnostics of machine systems tell you which machine components are malfunctioning and enable you to troubleshoot problems in advance, minimizing downtime for repairs;
- The function of harmonic analysis of vibration and the ability to create and print reports on the results of the balancing allows you to organize the output quality control of manufacturing of a propeller shaft and control the quality of the balancing operation.
High-Volume Production Engineering
- Multi-support cardan shaft specialization– Engineered specifically for serial production balancing of two-, three-, and four-bearing cardan shafts up to 4200 mm long weighing 5-150 kg. The machine accommodates complex multi-bearing drive shaft configurations commonly used in commercial vehicles, industrial equipment, and heavy machinery applications.
- Simultaneous multi-plane measurement– Performs automatic unbalance measurement in 2, 3, or 4 correction planes simultaneously with cycle times of 11-25 seconds including acceleration and deceleration. This parallel processing capability maximizes production throughput while ensuring comprehensive balancing across all critical shaft sections.
- High-speed production operation– Operating speed range of 400-4000 rpm with 5 gĀ·mm/kg balancing accuracy optimized for production efficiency while maintaining quality standards. The extended speed range accommodates various shaft designs and production requirements for maximum manufacturing flexibility.
Advanced Automatic Clamping Systems
- Pneumo-mechanical chuck automation– Features automatic pneumatic clamping of cardan flanges with universal cam adapters, eliminating manual setup time and ensuring consistent clamping force. The automatic system accommodates flange sizes up to 125 mm with centering adapters manufactured per specification for each flange configuration.
- Movable support positioning– Right spindle support and intermediate supports equipped with ball guide movement mechanisms for precise positioning during shaft installation and removal. The adjustable support system automatically accommodates 3- and 4-support cardan shaft designs of any configuration within machine dimensional limits.
- Automatic rotational positioning– Integrated automatic rotation to welding positions for each correction plane activated by button press at corresponding support locations. This automation eliminates manual shaft positioning and ensures precise correction weight placement for optimal balancing results.
Integrated Correction Welding System
- Contact welding correction stations– Multiple welding stations with contact welding tongs corresponding to the number of correction points eliminate unbalance by welding corrective weight plates directly during the balancing cycle. The integrated correction capability eliminates external welding operations and maintains shaft positioning accuracy.
- Real-time correction execution– PAK-4 balancing system controls automatic positioning and welding operations in real-time, enabling complete balancing and correction in a single machine cycle. This integration maximizes production efficiency while ensuring precise correction weight placement and verification.
- Welding safety interlocks– Automatic blocking prevents spindle rotation during welding operations and when welding tongs are extended, ensuring operator safety and equipment protection. The interlock system prevents accidental shaft movement during critical correction procedures.
Comprehensive Safety Systems
- Pneumatic protective brackets– Equipped with pneumatically-operated protective brackets designed to prevent shaft and component ejection in case of hinge or spline connection failure during high-speed operation. This safety feature protects operators and equipment from potentially dangerous shaft component separation.
- Sectional protective guarding– Complete sectional guard system protects against ejection of poorly secured correction weights, bearing grease, and other debris during shaft rotation. The guard system includes automatic rotation blocking when guards are not properly closed, ensuring complete operator protection.
- Multiple safety interlocks– Comprehensive interlock system prevents spindle rotation during fixture clamping, welding operations, and when protective guards are open. The multi-level safety approach ensures secure operation in high-volume production environments with multiple operators.
Production-Optimized Control Systems
- PAK-4 specialized software– Balancing system specifically designed for cardan shaft applications with automatic and manual operating modes for production flexibility. The automatic mode completes measurements independently, allowing operators to perform auxiliary operations such as load preparation for increased productivity.
- Industrial documentation capabilities– Integrated protocol printing via laser printer connected through USB port, with data recording on USB flash drives or Ethernet transfer capabilities. The comprehensive documentation supports quality control requirements and production traceability in manufacturing environments.
- Frequency-controlled drive system– Asynchronous electric drive with stepless speed control enables optimal balancing mode selection without motor shutdown while providing precise positioning for correction welding operations. The variable frequency control ensures smooth operation across the complete speed range.
Manufacturing Integration Features
- Compact production footprint– Machine weight not exceeding 1900 kg (excluding base cabinet) with efficient space utilization for integration into production lines. The compact design maximizes functionality while fitting standard manufacturing floor space allocations.
- Pre-resonant measurement stability– Pre-resonant machine design provides stable, accurate measurements despite the variable loading and high-speed operation typical of production environments. The design ensures consistent measurement quality regardless of production volume fluctuations.
- Calibration weight system– Three-run calibration method using calibration weights enables operator-performed system verification and adjustment, maintaining production uptime without external service requirements. The standardized calibration approach ensures consistent measurement accuracy across production shifts.
The PAK-4 unbalance measuring unit is specially designed for cardan shaft balancing.
synchronous measurement in multiple planes saves time and simplifies the operator’s work.
The screen displays information about the welding location and correction weights for all planes at once.
Based on an industrial fanless computer with a touchscreen and a multi-channel measuring unit, the system ensures reliability and a long service life, even under intensive use. The PAK-4 utilizes a universal measuring path and modern component base, allowing for equally high accuracy when working with all types of rotors.
Its intuitive interface, self-calibration capability, and automation of key operations make the complex a convenient tool for both experienced specialists and beginners.
Useful features for driveshaft balancing
- Simultaneous multi-plane balancing is available, with the option of 2-, 3-, or 4-plane balancing.
- Information about the welding location and correction weights is displayed simultaneously on the screen for all planes.
- Disbalance is displayed in real time. For example, if there is a rotor defect or interference, it will be immediately visible as a fluctuation in the measurement result.
- Harmonic analysis of vibration sensor signals helps diagnose mechanical issues in the cardan shaft and analyze individual vibration components and their sources.
- The automatic measurement start system increases work productivity by starting the measurement when the set rotation speed is reached.
Features of the PAK-4 System:
- High-precision dynamic balancing for rotors of any configuration.
- Industrial fanless PC with touchscreen and multi-channel measuring unit.
- Setup using trial runs with calibration weights on production rotors.
- Self-calibration by the operator, eliminating annual service adjustment costs.
- Calculation of permissible unbalance values, even without technical documentation.
- Determination of trial weight mass to simplify setup for a specific rotor.
- Real-time display of unbalance magnitude and angular position, including āhighlightingā of the correction zone.
- Automatic measurement start upon reaching a set speed and automatic stop after cycle completion.
- Display of unbalance magnitude in grams, gmm, gcm, gmm/kg.
- Vector and exponential averaging for working with moving elements and in noisy conditions.
- Additional functions that significantly simplify the balancing process and expand the technological capabilities of the balancing machine.
- Generation and printing of balancing reports directly from the system.
- USB ports and Ethernet interfaces for connecting a printer, data storage, and integration into a local network.
|
Parameter |
Value |
|---|---|
|
Balancing rotors weight range, kg |
5 – 150 |
|
Maximum rotor diameter, mm |
140 |
|
Maximum flange diameter, mm |
250 |
|
Maximum cardan shaft length, mm |
4200 |
|
Machine type |
Hard-bearing |
|
Number of simultaneously measured planes |
2, 3, 4 |
|
Minimal achievable residual specific unbalance, gmm/kg |
5 |
|
Rotor rotation speed range, rpm |
400 – 4000 |
|
Drive type |
Asynchronous variable-frequency electric drive |
|
Electric motor power, kW |
7.5 |
|
Power supply parameters |
400V Ā± 10%, 3 Ph, 50Hz Ā± 1 |
|
Balancing system |
PAK-4 |
|
Overall machine dimensions (length x width x height), mm |
6000 x 1500 x 1800 |
|
Machine weight, kg |
1900 |
TO ENSURE SAFE WORKING CONDITIONS MACHINE IS EQUIPPED WITH:
- Protective staples with pneumatic drive – to prevent the shaft and its elements from ejecting when hinges or splines are broken;
Spindle rotation engagement locks during their fixation and when pulling the welding pliers.
The machine is equipped with: a sectional protective guard of the propshaft, to protect against a possible ejection, when the shaft rotates, poorly fixed correction weights, lubrication from bearings, etc.
The safety shield is equipped with a spindle rotation engagement lock when the protection is not closed.
