Dynamic Propeller Balancing

ACES Systems Aviation Division

10737 Lexington Drive
Knoxville, TN 37932-3230
865-671-2003
[email protected]
[email protected]
 Goals for This Seminar
• Understand Basics of Vibration
• Understand the Benefits of Balancing
• Understand Fundamentals of Dynamic Propeller Balancing
 Overview
• The Basics of Vibration
• Definition
• Why it happens
• How it is measured
• How we correct it
 Overview
• Understanding the Benefits of Balancing
• Reduces the negative effects of vibration
• Increases service life and economy of operation
 Overview
• Understanding the Fundamentals of Propeller Balancing
• Required equipment
• Setting up the equipment
• Data collection and processing
• The balancing process
• Avoiding the pitfalls
 The Basics of Vibration
Definition
• For the purpose of Propeller Balance,
vibration can be described as:
• “the unwanted, unproductive, cyclic oscillation of the propeller
and engine assembly about its rotational axis.”
 The Basics of Vibration
Remember:
• All noise and/or vibration is not generated by an imbalance in the
propeller.
• To verify the vibration source, a vibration survey should be conducted
and manufacturer’s limitations adhered to.
 The Basics of Vibration
Why does it happen?
• When the weight of a rotating propeller and engine assembly is not
equally distributed, the dominant or heavy point attempts to continue
moving in a straight line. The resulting force attempts to pull the
assembly outside its rotational axis. The assembly then orbits what
would be the normal center of rotation, causing vibration.
 The Basics of Vibration
Vibration Related Complaints
• Cracked exhaust stacks and sheet metal
• Higher than normal occurrence of engine and prop oil leaks and light
bulb failures
• Physical movement of airframe (buzz in the seat, yoke, rudder pedals)
• Malfunctioning or failed avionics
• Passenger complaints of noise in the cabin
 The Basics of Vibration
Effects of Vibration - Examples
• Vibration excites natural frequencies in other components throughout
the airframe and engine assemblies.
• The expended energy from vibration causes wear of components,
reduced performance, passenger discomfort.
 The Basics of Vibration
How It Is Measured
• Sensor Types
• Sensor Engineering Units (EUs)
• Characteristics of Different Sensor Types
• Sensor Specifications
• Sensor Mounting
 The Basics of Vibration
How It Is Measured

• The vibration sensor generates a

small voltage when the mass
compresses the piezoelectric element.
That voltage is proportional to the force
being exerted on the element.
 The Basics of Vibration
How It Is Measured
• Sensor Types
• Displacement - Measures
physical change of position.
• Velocity - Measures the rate of
change of displacement with time.
• Acceleration - Measures the rate of
change of velocity with time.
 The Basics of Vibration
How It Is Measured
• Engineering Units
• Mils (0.001 inches) - displacement
• gs (equivalent gravities) - acceleration
• IPS (Inches Per Second) - velocity
 The Basics of Vibration
How It Is Measured
• Sensor Characteristics
• Displacement Sensor
• Measure Change in Position
• Typically Reported in mils (0.001 of an inch) Peak to Peak
• More Sensitive to Low Frequencies
• Directly Related to Movements Due to Unbalance
• Seldom Used in Balance. (However, Displacement
Units are Often Used)
 The Basics of Vibration
How It Is Measured
• Sensor Characteristics
• Accelerometers
• Measure Acceleration
• Typically Reported in g’s
• More Sensitive to Higher Frequencies
• Directly Related to Force Caused by Unbalance
• Used in Balancing (after conversion to velocity or
displacement)
 The Basics of Vibration
How It Is Measured
• Sensor Characteristics
• Velocimeters/Velometers
• Measure Velocity
• Typically Reported in IPS Peak
• More Sensitive to Medium Frequencies
• Directly Related to Energy from Unbalance
• Often Used in Balance
The Basics of Vibration
How It Is Measured
 The Basics of Vibration
How We Correct It
• Improve manufacturing methods
• Remove and replace
• Static Balance
• Static Balance + Dynamic Balance
 Review
• The Basics of Vibration
• Definition
• Why it happens
• How it is measured
• How we correct it
 The Benefits of Balancing
• Reduces: • Increases:
• Noise • Economy of operation
• Vibration • Service life of airframe
and components
• Airframe damage
• Comfort
• Avionics damage
• Fatigue and stress on
passengers
 The Benefits of Balancing
Review
• Reduces the negative effects of vibration
• Increases service life and economy of operation.
 Fundamentals of Balancing
When to Balance
1.25 IPS Danger - Remove and Static
1.00 IPS Very Rough - Static recommended

.50 IPS
.25 IPS Slightly Rough - Balance for ride
.15 IPS Fair - Maximum after Dynamic
.07 IPS Good - Not felt by occupants
0 IPS
 Fundamentals of Balancing
When to Balance
• McCauley Service Letter 1989-4D
• Revised July 20, 2001
• Endorses dynamic balance on propellers installed on piston
and turbine powered aircraft.
• Over 0.8 IPS initial reading - list of corrective actions.
• “McCauley Propeller Systems agrees that 0.15 – 0.2 IPS is
an acceptable level, but our experience has shown that
0.07 IPS or lower is noticeably smoother.”
 Fundamentals of Balancing
When to Balance
• Hartzell Service Letter HC-SL-61-165/Prop Owner’s Manual
147/Standard Practices
• Warns that all propellers need to be inspected for abnormal
grease leakage or vibration.
• Perform Troubleshooting and evaluate possible sources of
vibration IAW engine/airframe mfr. instructions.
• Sets Balance limit at 0.2 IPS
 Fundamentals of Balancing
Equipment Required
• A device to collect
vibration and phase
data.
• A phase angle /speed
sensing device
• A vibration sensing
device
• Accessories: Cables,
balance weights, hand
tools.
 Fundamentals of Balancing
Equipment Required
• Approved reference
• Airframe manual
• Propeller Manual
• Engine manual (in some
cases)
• FAA-approved “Guide
to Propeller Balancing”
Fundamentals of Balancing
Equipment Required
• Make sure the approval letter
is attached to the Guide and
references the material being
used (document number,
date, revision, and change
numbers if applicable.)
 Fundamentals of Balancing
Equipment Required
AC20-37E Chapter 3 Paragraph 300.C.2.(d)
When approved aircraft or propeller manufacturer’s procedures are not available,
there are other acceptable dynamic propeller balancing procedures. These include
but are not limited to the Chadwick-Helmuth Publication No. AW-9511-2, entitled
“The Smooth Propeller”, and ACES Publication No. 100-OM-01, entitled “ACES
Systems Guide to Propeller Balancing”. Dynamic balancing of propellers using FAA-
approved or -accepted dynamic propeller balancing procedures is not considered a
major propeller repair unless the propeller static balance weights are altered or
when using the Chadwick-Helmuth or ACES type documents on propeller
installations of 500 horsepower or more.
(emphasis added)
 Fundamentals of Balancing
Before Equipment Setup
• Propeller Inspection Prior to Balancing
• Ensure all Airworthiness Directives have been complied with
for the propeller you are going to balance.
• Determine if there is a balancing procedure published by the
airframe, engine or propeller manufacturer; if there is, it will
take precedence.
 Fundamentals of Balancing
Before Equipment Setup
• Inspect the propeller blades for damage, nicks etc. refer to FAA
Advisory Circular 20-37E which outlines care of metal propellers,
and to applicable propeller manufacturers maintenance
requirements.
• If balancing composite propeller blades, refer to the
propeller manufacturer's procedures for repair of the
propeller.
• Inspect propeller assembly for proper installation and
security.
 Fundamentals of Balancing
Before Equipment Setup
WARNING
• Perform a visual inspection of the spinner and spinner bulkhead
for cracks, stop drills and welding. Mass trim weights MUST NOT
be attached to a part with any of these conditions.
• To prevent an excessive number of weights from being attached
to the spinner, remove any mass trim weights attached from
previous dynamic balance jobs.
 Fundamentals of Balancing
Before Equipment Setup
WARNING
• Static balance weight attached to the propeller hub by a certified
propeller shop MUST NOT be removed.
 Fundamentals of Balancing
Setting Up the Equipment
• Always attach the vibration • The vibration sensor should
sensor as near as possible to the not be in line with a cylinder
forward most point of the and should be positioned at
engine supporting the prop 12:00 or 6:00 whenever
shaft. The base of the sensor possible.
should always point to the
center of the prop shaft.
 Fundamentals of Balancing
Setting Up the Equipment
• If using a Phototach, attach it so • The reflective tape should be
as to be between 12 and 18 3M brand 7610, and not less
inches from the surface of the than 1 inch wide. It should be
target blade and not installed no more than 14
perpendicular (90 degrees) to inches out the prop blade
the surface of the blade. A 5- from the center
degree offset is best. of the prop shaft.
 Fundamentals of Balancing
Setting Up the Equipment
• Cables should be routed • Do not close windows or
away from electrical and high doors on the cables as this
temp components. Attach may pinch or cut them. Make
with wire ties or tape to sure connections at the
prevent excessive movement analyzer are secure.
and possible damage.
 Fundamentals of Balancing
Setting Up the Equipment
• If using an onboard vibration • Always obtain your interface
monitoring system, cables for these onboard
synchrophazer or other signal applications from a qualified
sources, make sure you know source.
the sensitivity and voltage
outputs of the system.
Fundamentals of Balancing
Setting Up the Equipment
Fundamentals of Balancing
Data Collection & Processing
• The vibration sensor is installed on
the engine as near the front
bearing as possible. The Phototach
is mounted on the cowling, behind
the propeller. The reflective tape is
applied to the back side of the
target propeller blade in line with
the Phototach beam. The mass is
located by the relative occurrence
of tach trigger and mass passage at
the radial sensor location.
 Fundamentals of Balancing
Data Collection & Processing
• The Reflective tape triggers a
response as it passes the
Phototach, which then sends an
electrical signal to the analyzer.
As the heavy spot on the
propeller passes the location of
the vibration sensor, the sensor
generates and sends an electrical
pulse to the analyzer.
 Fundamentals of Balancing
Data Collection & Processing
• In this illustration, the
vibration sensor and
Phototach beam are
co- located at the 12:00 or 0-
degree position. Rotation is
clock-wise from the viewer's
position. This is our starting
point, elapsed time = 0
 Fundamentals of Balancing
Data Collection & Processing
• The speed is 1 RPM. Fifteen
seconds (90 degrees) of
travel has occurred. In this
sequence, the reflective tape
has just entered the
Phototach beam to trigger
the tach event. Elapsed time
= 15 seconds.
 Fundamentals of Balancing
Data Collection & Processing
• In this sequence, the mass
(heavy spot) is passing the
accelerometer position, 15
seconds (90 degrees) after
the tape passed the
Phototach beam. Elapsed
time = 30 seconds (180
degrees of travel).
 Fundamentals of Balancing
Data Collection & Processing
• The tape and mass have both
passed the 0 degree location.
The unit now waits for the
exact sequence to repeat for
averaging. Elapsed time = 45
seconds (270 degrees of
travel)
Fundamentals of Balancing
Data Collection & Processing
 Fundamentals of Balancing
Data Collection & Processing
• The process is repeated while
the analyzer averages out
errors caused by momentary
vibration events outside the
running average.
 Fundamentals of Balancing
Data Collection & Processing
• When sufficient data has
been collected, the process is
stopped by the operator and
the averaged data displayed
on screen. Notice that you
have the option to Retake the
data if desired.
 Fundamentals of Balancing
Data Collection & Processing
• A solution is then provided by
the instrument based on a
stored influence coefficient
or a calculated test weight. If
required, the process is then
repeated for refinement of
the solution.
 Fundamentals of Balancing
The Balancing Process
• With the equipment installed
and all previously installed
trim weights removed, head
the airplane into the wind (10
KTS maximum) and begin the
data collection.
 Fundamentals of Balancing
The Balancing Process
• On run 1, allow the analyzer
to collect and average data
until the bars in the scale
stop converging on the
center. This should take
between ten and thirty
seconds under ideal
conditions.
 Fundamentals of Balancing
The Balancing Process
• When the ENTER key is
pressed to stop data
collection, the Review Job
screen shows the averaged
amplitude and the phase
angle of the out of balance
condition.
 Fundamentals of Balancing
The Balancing Process
• REMOVE the previously
installed trim weights
before installing the new.
Enter the “Actual Weight
Installed” as near as
possible to what you
weighed and at the angle
measured.
 Fundamentals of Balancing
The Balancing Process
• Where to place the weights
• Test weights can be placed under the spinner retention
screws. It may be necessary to use longer screws for the test
weights. If doing so, account for the delta between the
normal and the longer screw. Be sure you are measuring the
angles in relation to the sensor or tape as you specified in
the setup being used.
 Fundamentals of Balancing
The Balancing Process
Permanent weights may be installed under the flange or on the
bulkhead. If installed under the flange, offset from spinner attaching
screws by four times the diameter of the spinner screws.
 Fundamentals of Balancing
The Balancing Process
DO NOT use the spinner
attachment screws for
permanent weight applications.
Apply an equal number of
washers to each side of the
bulkhead and compensate for
the shortened arm when moving
weight(s) to the spinner
bulkhead.
 Correction Calculation

• Diameter of spinner divided by 2 = radius of spinner (ex: 14 / 2 =

7.0”)
• Minus distance from test weight to permanent weight =
permanent weight radius (ex: 7.0 - 1.5 = 5.5”)
• Required weight to balance x radius of spinner = net effect (ex: 25
g x 7.0 = 175 Gram inches)
• Divide by permanent weight radius = permanent weight
(ex: 175 / 5.5 = 31.8 grams)
 Fundamentals of Balancing
Avoiding the Pitfalls
• If you remove the spinner in order to remove previously installed
trim weights, index it and make sure it is always reinstalled by
the index mark. Check inside the spinner for foreign objects,
excess grease and trapped water.
 Fundamentals of Balancing
Avoiding the Pitfalls
• Unstable or erratic RPM readings on the analyzer are most
commonly caused by:
• Angle of the Phototach relative to the tape.
• Phototach outside the 18-inch maximum or inside the 12-
inch minimum distance.
• Tape too narrow for the velocity of the prop.
• Dirty or misaligned tape.
• Defective Phototach or Cable.
 Fundamentals of Balancing
Avoiding the Pitfalls
• Unstable or erratic vibration amplitude readings on the analyzer
are most commonly caused by:
• Damaged or inoperative sensor
• Pinched, Cut, or shorted cable
• Unstable tachometer input.
• Mechanical defects of the assembly being balanced.
 Fundamentals of Balancing
Avoiding the Pitfalls
• You may also adjust the
Phototach gain. Remove the
screw holding the clear
plastic cover on the aft end
of the unit.
Fundamentals of Balancing
Avoiding the Pitfalls
• The gain adjustment is the
brass screw at the right.
Make adjustment in a
controlled environment such
as with a bench grinder in a
shop.
 Fundamentals of Balancing
Avoiding the Pitfalls
• Adjust the speed of the prop as closely as possible to the exact
target RPM on EVERY run. A change in RPM will change the
influence of an attached weight. Subsequent solutions will not
have the same calculated results at different speeds.
 Fundamentals of Balancing
Avoiding the Pitfalls
• If an established influence for the engine and prop combination
being balanced is not being used, the first weight the analyzer
will ask you to install is a TEST weight. This weight may cause the
vibration amplitude to increase. The intention of the test weight
is only to induce a measurable change, not necessarily reduce
the vibration.
 Fundamentals of Balancing
Avoiding the Pitfalls
• If the suggested TEST weight is greater than your experience tells
you is necessary to induce a change, reduce the weight and enter
the exact amount and angle of attachment into the analyzer.
Remember that the amplitude may actually go up. This is not a
malfunction of the equipment. Continue the balance process.
 Fundamentals of Balancing
Avoiding the Pitfalls
• Test Weight in Grams = ((Engine Horsepower/10)+30)*IPS
• g = (1000/10)+30)*1.0
• g = (100+30)*1
• g = 130
 Fundamentals of Balancing
Avoiding the Pitfalls
• There is no difference in the propeller balance procedure for a
radial engine, opposed engine, turboprop, geared, variable pitch,
or fixed pitch propeller.
 Fundamentals of Balancing
Avoiding the Pitfalls
• The “% error” is reduced very rapidly if the margin for error is
large, (i.e., Higher amplitudes). As these amplitudes are reduced
through the balancing process, that margin is greatly reduced
and the “% error” may average down very slowly and may
actually stall at some point. This is not a malfunction and is not a
reason for concern.
 Fundamentals of Balancing
Avoiding the Pitfalls
• A variety of mechanical problems can show up at propeller turning speed
these include
• Propeller out of track.
• Crankshaft unbalance.
• Bearing problems.
• Loose or worn components in the engine.
• Defective crankshaft counterweights.
• Loose or worn components in the propeller hub.
• Loose airframe components.
 Fundamentals of Balancing
Avoiding the Pitfalls
• Some indications are:
• Applying numerous (more than 3 or 4) solutions without
reducing the amplitude.
• Phase angle changing radically between runs.
• Phase angle that changes dramatically during data
acquisition. (At amplitudes below approximately .05 IPS this
is not a defect.)
 Fundamentals of Balancing
Avoiding the Pitfalls
• In any of these cases, you will have little to no success with your
balancing efforts. If you feel you are chasing the solution, check
the equipment on another application before blaming your
difficulties on the analyzer.
 Review
• Understand the Fundamentals of Propeller Balancing
• What equipment is required
• Setting up the equipment
• Data collection and processing
• The balancing process
• Avoiding the pitfalls
 www.acessystems.com
865-671-2003
[email protected]
[email protected]