Four-plane balancer uses modular design

Four-plane dynamic balancing machine provides optional two, three or four plane balancing capabilities for processing everything from simple rotors to multiple-link propshaft assemblies.

Universal Balancing has launched a four-plane dynamic balancing machine.

The Kiss-234 provides optional two, three or four plane balancing capabilities for processing everything from simple rotors to multiple-link propshaft assemblies.

Using modular design principles, the machine is constructed from CNC laser and flame cut components.

The small footprint can fit within a standard 12.2m container for easy shipment to site.

The balancers also incorporate standardised components and controls based on Universal's Uni-44 system.

Design features include: the superseding of traditional spindle and motor arrangements with compact, spindle motors that have been designed in-house for ease of assembly and servicing; servo control as standard; and secure fibre optic machine communications that are immune to electrical noise.

The machines employ established Ethernet-based communications that provide remote diagnostic monitoring of all key components - such as motors, weld heads and support bearers.

The HMI is within the main control screen, using object linking and embedding for process control programming.

As a result, all HMI options can be accessed quickly and easily from the equipment's touchscreen menu.

For accurately balancing multi-link automotive propshafts up to 3m long, Kiss-234 machines, for maximum production throughput, will specify the value of balance weight to be attached to the workpiece at each of the balance planes.

After the operator has loaded the correct weight into the welding head, the machine automatically indexes to the correct orientation for the automatic weld sequence to be completed in one operation.

As a menu-switchable alternative, the machine can be instructed to use vector splitting techniques to attach a pair of identical weights at two positions on the balance plane.

This has the advantage of using common balance weights at every weld head, simplifying automation or lights-out operation.

Similar flexibility is built into the component handling capabilities.

If the workpiece and tooling permits, machines can be equipped with a low-cost, automated load and unload work handling option, which typically increases manufacturing throughput by 5%.

At an operational level, the system's standardised twin motor configuration provides in-built redundant capacity, which enables production to be maintained until a convenient time can be found for motor repairs.

In the event of a weld head failure, the remaining weld stations can be quickly reprogrammed to compensate - again until a repair can be made, or replacement unit installed.

The Uni-44 controller's switchable touchscreen menus are ready-configured for various component options.

As a result, the system provides the flexibility for users to process several types of workpiece in one shift, with short change-over times.

The Unibal machines use precision ground machine bed rails, rather than widely-used T slot alternatives.

"This enables us to align the machine components extremely accurately," said Universal Balancing's Managing Director, Steve Fowler.

"It not only ensures more accurate component balancing, but also reflects the automotive sector's drive towards increasingly tight production tolerances".

"Eight years ago, we might have been expected to balance a propshaft assembly to 240gm.mm".

"Today, OEMs are typically looking to achieve 80gm.mm." "Armed with the results of an in-depth market research exercise, we went right back to basics and questioned everything - to remove cost, without ever compromising quality".

"Through its combination of high accuracy, durability and extremely competitive pricing, we expect the new machine to generate a great deal of interest in the market".

"Perhaps it's just as well that we can build them 40% quicker than our previous four-plane equipment - otherwise lead times may start to increase".

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