MD100-OD / Automatic Inline Drum Balancing Machine

The MD100-OD is a belt-driven, automatically loaded vertical balancing machine. This type of machine is recommended for balancing brake discs. It is capable of balancing static components. With its automatic balancing function, it automatically calculates the hole position and depth using the milling system and brings the balancing value within the specified tolerances.

1-Measurement Plane
The machine will have a hard pedestal. It features fixed servo-controlled belt drive. The workpiece is clamped by means of a special chuck and diaphragm according to the workpiece hub diameter.

2-Drilling System
One drilling system with a power of 5.5 kW will be independently servo-controlled on the Z-X axes. It can perform channel cutting up to 40 mm. A milling cutter can be connected, and the system is equipped with a dust extraction attachment.

3-Dust Extraction System
A 3 kW blower system collects chips in its chamber. The system is portable and movable.

4-Hydraulic System
During the drilling operation, the rotor is locked in position with the help of two jaw pistons.

5-Safety Cage System
The system automatically opens and closes using linear guides and pistons. The system does not operate when the cover is open thanks to the PILZ safety system. A switch checks whether the cover is closed.

6-Robot System
The linear guide system features a servo-controlled X axis. The workpiece is transferred using two independent Z axes.

Drive type: Belt-driven
Maximum capacity: 100 kg
Minimum capacity: 2 kg
Maximum rotor diameter over the plane: 600 mm
Minimum rotor diameter over the plane: 150 mm
Number of planes: 1 hard foot - 1 servo-controlled
Balancing quality rate: 95%
Minimum unbalance: ISO 21940 balancing quality G grades
Power supply: 400V, 50 Hz, 3 phase
Motor power (belt drive): 3 kW
Maximum rotational speed: 830 rpm
Minimum rotational speed: 200 rpm
Air pressure: 6 bar
Measurement time: 60 sec.
Safety system: Automatic cover with safety switch
Workpiece loading/unloading: Manual (by operator)
Operating system: Microsoft Windows
Display: 15” industrial display
Remote technical support: TeamViewer/AnyDesk
Storage: 256 GB SSD
Passwords: Operator, supervisor, admin
Communication interfaces: Ethernet, Wi-Fi and USB
Balancing units: Grmm-Grcm-Gr
Electronic compensation: Weight control
Connection adapter compensation: Resets adapter imbalance
Rotor database: Data records with quick search function
Measurement results display: Digital/Polar
Factory rotor calibration: Balancing operation is performed by entering measurement data
Standard calibration process: Manual calibration, test weight introduction
Report printing: Writes the final balancing value in Excel format. USB options are also available.
Automatic measurement backup: Automatically records every test measurement.

Balancing Quality Parameter
The MDBalans balancing software includes an integrated residual unbalance calculation module compliant with the ISO 21940 standard. You can easily determine the appropriate balancing quality grade (G) for your rotor type using the explanations provided in the relevant sections. Tolerance values are calculated automatically.

Report
The balancing machine software automatically records all balancing operations in Excel format. It automatically records the initial high unbalance value and the balancing value after the balancing operation. Excel files can be copied by connecting a USB drive.

Operation Steps

• When the doors are open and the system is ready, a workpiece loading signal is sent to the robot.
• The robot loads the workpiece, sends the loading-completed signal and moves to the safe zone.
• The covers close.
• The rotor clamping chuck pushes the rotor to the center.
• Measurement starts, the unbalance values are read, and the system stops.
• The system positions the unbalance point under the milling cutter, locks the hydraulic clamps and performs the milling operation.
• All components on the system are moved to the safe zone.
• A final measurement check is performed. If the balancing value is within tolerance, the robot receives the workpiece unloading signal and the doors open.
• The robot removes the workpiece, sends the unloading-completed signal, and the balancing machine returns to the ready position.

Calibration
The calibration process is performed using a master workpiece and a certified calibration weight (the master workpiece will be the customer's workpiece). Once gram calibration has been performed for the selected workpiece in the software, no further calibration is required as long as there is no model change (different workpiece). When a model change is made for a different workpiece, calibration is required to ensure precise and accurate measurement.

Occupational Safety
The enclosed safety cage prevents the operator from coming into contact with the workpiece during rotation. Occupational safety is controlled by PILZ relays and switches. Emergency stops and the door system comply with occupational health and safety standards. User access levels are restricted through ADMIN-SUPERVISOR-OPERATOR passwords on the automation screen. Critical interventions can only be performed by authorized users.

MES System Data Transfer (OPTIONAL)
The automation system of the balancing machine is equipped with the necessary infrastructure for customers to retrieve the required data through their own MES systems. The automation system of the balancing machine is based on SIEMENS technology. In this infrastructure, the values that customers can retrieve from the machine are updated after each production cycle in a datablock with predefined addresses. The customer's existing MES system can read the required information from this datablock, store it on its own server and process it. The machine information can be shared with the MES system.