Dual-Plane Rotor Balancing on a DIY Machine (ISO-Level Accuracy) Turbine project part 5

Описание: Balancing a turbine rotor in a single plane is challenging.
Balancing it in two planes is real rotordynamics.
In this video, I upgrade my DIY balancing machine to perform true dual-plane dynamic balancing using the influence coefficient method.
Unlike single-plane correction, dual-plane balancing requires solving a coupled system where correction masses in one plane affect vibration measurements in both planes. This involves:
• Dual accelerometer integration (BMI160)
• ESP32-S3 dual I2C high-speed acquisition at 1600 Hz
• Butterworth band-pass filtering
• Lock-in amplification technique
• Offset calibration with speed compensation
• Experimental identification of influence coefficients
• 2×2 matrix inversion for correction mass calculation
After implementing the full procedure, the system converges in two iterations to correction masses as low as 3 mg per plane.
This project demonstrates that high-precision dual-plane balancing can be achieved with:
• 3D printed mechanical components
• Low-cost MEMS accelerometers
• Proper signal processing
• Correct mathematical modeling
 

00:00 – Introduction
00:36 – About me & my workshop
00:54 – Mechanical setup summary
01:22 – Second sensor integration
02:20 – Software architecture
02:57 – First measurement &turbulence problem
04:00 – Optimal frequency window
04:22 – Offset calibration
05:32 – The Dual Plane Math
06:37 – Practical implementation
08:39 – Conclusions



📂 Files and Resources:
• ESP32 firmware: https://drive.google.com/file/d/1RhiI...

• Excel balancing calculator (influence coefficient method): https://docs.google.com/spreadsheets/...

• 3D printed parts: https://drive.google.com/file/d/1qELA...

This method assumes linear rotor behavior and operation below first critical speed.
If you enjoy CNC machining, turbine engineering, vibration analysis, and precision DIY instrumentation, consider subscribing.
Next step? Possibly piezoelectric sensors and further resolution improvements