New generation of high capability, low cost 4-plane balancers

Component and assembly balancing specialist, Universal Balancing Ltd has launched a new generation of high capability, 4-plane dynamic balancing machines at prices equivalent to, or less than, most competitive 2-plane units.

Designated KISS-234, the new machines provide optional 2, 3 or 4 plane balancing capabilities for processing everything from single piece to multiple-link propshaft assemblies. Their attractive pricing is the result of extensive market analysis, detailed value engineering, and Universal’s 50-year track record of building state-of-the-art balancing equipment. This powerful combination has enabled the company to achieve major savings in the installation, operation, training and servicing cost elements of the equipment; ensuring minimum cost of ownership, while maintaining the highest levels of precision and accuracy.

Employing modular design principles, KISS-234 machines are constructed from CNC laser and flame cut components, rather than heavy and costly machined castings. They also feature a small footprint and have been designed to fit within a standard 40 ft container for easy shipment to site. The new balancers also incorporate a large number of standardised components and latest generation controls based on Universal’s sophisticated UNI-44 system.

Other novel design features include the superseding of traditional spindle and motor driveline arrangements with compact, spindle motors that have been designed in-house specifically for ease of assembly and servicing; servo control as standard of all weld guns and all 4 bearers with the addition of the centre bearers automatically moving pass the others for the fastest possible setup between 2,3,4 planes; and secure fibre optic machine communications that are immune to electrical noise. In addition, the new machines employ established Ethernet-based transparent communications that provide remote diagnostic monitoring of all key components - such as motors, weld heads and support bearers.

The new KISS-234 machines score over competitive balancers by incorporating the system’s Human Machine Interface (HMI) within the main control screen, using Object Linking and Embedding for Process Control (OPC) programming. As a result, all HMI options can be accessed quickly and easily from the equipment’s simple touch screen menu.

Designed for accurately balancing multi-link automotive propshafts up to 3 metres long,
KISS-234 machines incorporate a number of further novel features.

For maximum production throughput, the system 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 a single operation. As a menu-switchable alternative, the machine can also be instructed to use vector splitting techniques to attach a pair of identical weights at two angular positions at each balance plane. This offers the advantage of using common balance weights at every weld head, simplifying automation or lights-out operation. In addition the weights can be placed on the holders whilst the shaft is being loaded so the operator does not have to return to the machine until the whole balancing process is complete.

Similar customer flexibility is built into the KISS-234’s component handling capabilities. If the workpiece and tooling permits, machines can be equipped with a low-cost, automated load / unload work handling option, which typically increases manufacturing throughput by 5 per cent.

At an operational level, the system’s standardised twin motor configuration not only allows torque to be applied whilst balancing to reproduce vehicle conditions it provides in-built redundant capacity, which enables production to be maintained until a convenient time can be found for motor repairs to be undertaken. Likewise, in the unlikely 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.

KISS-234 units come equipped with the latest generation UNI-44 controller, whose switchable touch-screen menus are ready-configured for a wide variety of component options. As a result, the system provides the flexibility for users to process several different types of workpiece in a single shift, with absolute minimal change-over times.

A further example of the detail design invested in the new Unibal machines can be seen in the use of precision ground machine bed rails, rather than widely-used T slot alternatives.

“This enables us to align the machine components extremely accurately,” says 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 240gmm. Today, OEMs are typically looking to achieve 80gmm.”

“The new KISS 234 machines represent many man-years work for us,” he continues. “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 place because you will only ever have to buy the KISS 234 what ever you propshaft balancing requirements are, now and in the future. Perhaps it’s just as well that we can build them 40 per cent quicker than our previous 4-plane equipment – otherwise lead times may start to increase!”