Roller balance is one of the most frequently overlooked components when addressing product quality and production output. Just one single roll out of balance can cause excessive equipment wear, a slower production throughput as well as increased downtime. Even while new rollers are usually balanced, a slightly imbalanced recovered or repaired roll may inflict more harm than you might expect.
In the past weeks, we’ve talked about our Industrial Roll Service program and how it can reduce production downtime in the long run. The program offers a complete, start to finish Industrial Roll Service with onsite consultations, roll recovering, regrinding, core parts repairs or new core parts acquisition if needed, pickup, and delivery.
In today’s Timber Talk, we’ll discuss the importance of maintaining balanced rolls in your manufacturing process.
Maintaining Your Balance!!
An uneven surface can make the rotor or core, bearings, and supporting structures all vulnerable to excessive stress when your production line is running with just one imbalanced roll. There are many signs that a roll has become unbalanced:
- Unexplained noises during production.
- Vibration and Chatter
- Decreased production speed and quality
- Irregular wear patterns on machinery
- Increased frequency of needing repairs.
While these are a few key signs to look for to catch rolls currently unbalanced, it is also essential to know when it’s time to have your rollers checked and/or re-balanced. This is even if you are not noticing any of the signs mentioned above to prevent rolls from becoming unbalanced.
If you determine your rolls are imbalanced… What should you do?
Our experts at TI Rolls recommend you have the balance checked whenever you send a roll in for service. There is no need to wait for a balance issue to affect your manufacturing output. While it is more common when dealing with higher-speed machines, even low-speed rolls may experience roll damage, bent shafts, etc., that will require balancing services.
When working with our team of experts, it is crucial to provide all the information that can help determine the ISO grade specifications needed to balance your rolls. The balancing specifications will be determined using roll speed, weight, roll position, and any additional required tolerances. Most rolls fall into three ISO grades start from the most demanding environment G1.0
G1.0 high-speed rollers with tight tolerances that are performing precision processes.
G2.5 high-speed rollers in critical applications.
G6.3 lower speed rollers requiring standard tolerances.
The grade lists the maximum permissible offset between the rotational axis and the center of gravity axis of the spindle measured in μm.
Roll balancing maintenance is vital in the manufacturing industry and can significantly impact your production process. Remember, if one link breaks down, it will affect the rest of the chain, and the business can experience costly consequences.
If you are experiencing any of the signs listed above and think you might have an imbalanced roll, contact one of our experts at TI Rolls and let us help! We firmly believe your company can benefit from our IRS program! We can not wait to hear from you!