The "Balancing Center" Zella-Mehlis - Start and Development
The innovative "Balancing Competence Center", hereinafter referred to as "Balancing Center" (www.Auswuchtzentrum.com), was gradually established in Zella-Mehlis in 2019. The initiators of this ambitious project were Thomas Niehle, Managing Director of Turbokompakt GmbH, and Dr. Kersten Kämpfer, a renowned balancing specialist and now Technical Director of the Balancing Center, who also holds two innovative patents ('Universal Balancing Machine' and 'Fine Balancing and Vibration Testing Station') in the field of industrial balancing technology.
The vision of these two gentlemen was to establish a powerful and specialized facility for precise contract balancing (www.Lohnwuchten.de) of various rotating industrial products and additionally to create a solid basis for new developments in balancing machines and other innovative balancing solutions. In the following years, the continuous expansion took place, particularly of the Balancing Center's balancing machine park.
New balancing machines were conceived, designed, and built, and numerous used balancing machines were acquired, wear parts replaced, and the balancing measurement electronics brought up to the latest state of the art, so that subsequently, even with the used balancing machines, the highest balancing accuracies could be achieved.
At the beginning of 2023, the "Balancing Center" already had access to more than 14 special vertical and horizontal balancing machines as well as specific special machines with multiple application principles.
This diversity has since made it possible to cover a very wide range of rotor types with complex rotor geometries, from under 100 g to over 3,000 kg of rotor masses to be balanced. The technical innovations of the "Balancing Center" include high-precision balancing systems equipped with sensitive velocity and acceleration sensors for unbalance detection on the balancing machines.
These enable the exact recording of vibration amplitudes and unbalance vectors. The determined unbalance amounts are minimized in the mass compensation planes at the various unbalance angles, for example, with mass removal methods such as drilling, milling, or welding processes on the balancing machine itself or at external balancing stations to the desired balancing quality grade. In most cases, this requires several measurement, testing, and mass compensation processes.
Advanced frequency analysis methods, based on Fast Fourier Transform and adaptive filter algorithms, select and eliminate interference signals. High-resolution encoder incremental systems ensure precise determination of unbalance positions in the existing balancing planes to reliably determine the unbalances. For the various unbalance corrections, the "Balancing Center" uses, in addition to the classic methods, other innovative compensation methods such as laser-based material removal systems with highest positioning accuracy and fine corrections.
Adaptive mass correction strategies with automatic feed and depth control, which are used particularly in powerful automatic balancing machines, complement the aforementioned methods. Intelligent and increasingly AI-based algorithms in industrial balancing technology for optimizing unbalance detection and compensation weight placement take into account not only the mass but also, in special cases, the aerodynamic or other special properties of the rotors.
The high performance, professional competence, and competitiveness of the "Balancing Center" are based on the interdisciplinary and highly experienced team of experts and the continuous research and development of new balancing concepts and balancing machines. AI-supported analysis methods, based on neural networks and machine learning, are increasingly optimizing balancing processes and significantly reducing cycle times.
Comprehensive AI-supported data and experiential knowledge management enables fast and precise analysis of demanding customer-specific problems and the resulting balancing technical solutions. Currently (year 2024), the Balancing Center is undergoing further expansion to provide customers with increasingly powerful and economical contract balancing and service offerings.
In addition to pure balancing services, the center now also offers comprehensive consultations, training, service, repairs, and much more. The extensive range of services underscores the effort to offer holistic solutions for various aspects of industrial balancing technology, from the development of new balancing technical approaches to the conception and manufacture of new, innovative balancing machines or efficient modernizations and general overhauls of solid used balancing machines.
Through the listed technical innovations and the bundled know-how of the involved experts, designers, and balancing technical specialists of the company, the "Balancing Competence Center" is able to efficiently, very precisely, and affordably solve even complex and very demanding balancing tasks for customers.
The "Balancing Center" in Zella-Mehlis thus positions itself as one of the leading providers for demanding and competitive balancing solutions in the industry.
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