bilz - vibration isolation of foundations & frameworks

V I B R A T I O N T E C H N O L O G Y

VIBRATION ISOLATIONOF FOUNDATIONS

AND FRAMEWORKS

Measurement Techniques – FEM AnalysesInterpretation and supply of the suitable isolation systemStatic calculationsPreparation of static and building plansAssembly of the isolation system

2

Today the reduction of vibration emission and vibration immissionplay an important part in the operation of plant and machinery, etc.The constant improvement in machine performance over recent yearshas generally been accompanied by increased speeds and cuttingrates, as well as an increase in impact power in the field of forming.This means an increase in the vibrations transmitted to the surroundings,which must be efficiently controlled.

The basic principle of vibration isolationThe objective of using insulating devices for machine mounting is thereduction of pulsating (repetitive), or sinusoidal vibrations. The taskis to keep the motion (amplitude) of the flexibly mounted machinewithin permissible limits for operation. The vibration insulators selectedmust have sufficient dampening capacity!

Impact insulationThe physical properties of impacts are their duration, direction andmagnitude. The object of impact insulation is to change the forcingfrequency consisting of a high kick into an impulse of longer durationaccompanied by small residual forces. Different from periodicallyexcited vibrations, the system provided with springs vibrates in the

excited natural frequency of the insulated system, not according toits number of strokes. The residual forces transferred via the insulatorsbecome increasingly smaller, the longer the natural vibration periodlasts and therefore the smaller the natural frequency of the systemsitting on a foundation equipped with springs.

Important DefinitionsDamping = the physical property of an insulator to limit resonancevibration to the permissible level. During this process, mechanicalenergy is converted into heat.Isolation = insulating of an actuating force.

Vibration emission = vibration created by the machinery that ispropagated to the surroundings.Vibration immission = vibration present in the surroundings that ispropagated to the machinery.

Insulation of sinusoidal vibrationsThe efficiency of vibration insulation depends to a large extent on therelationship between the machine speed/stroke rate and the naturalvibration frequency of the insulator (matching ratio). In general, it canbe said that the lower the natural vibration frequency of the insulator,i.e. the greater the ratio between forcing frequency and naturalfrequency, the greater the efficiency of the insulator. The diagrambelow shows that vibration insulation does not take effect until thematching ratio (�) is greater than 2.

No insulating effect can be expected at frequency ratios of less than2. Quite the opposite: an increase in (excessive) vibration must be

anticipated.As a rule a matching ratio (�) between 3 … 4 is attempted, with 3being taken as the technical minimum and 4 the economic maximum.

A bigger matching ratio (�) than 4 cannot be justified for economicreasons, as the material expense would increase out of proportion tothe insulating effect.

�b = natural frequency of the system rigidly secured to the ground�e = natural frequency of the system when placed on insulators

containing springs

Matching up the important factors

General Information on Vibration Technology

So, the efficiency factor of an impact insulation is:

Types of Vibration InsulationWe differentiate between active and passive insulation. If the objectiveis to prevent spreading of the vibrations caused by a machine (vibrationemission), we talk of active insulation. If, on the other hand, precision

machining equipment which is extremely sensitive to vibrations is tobe protected from vibration immission, this is described as passiveinsulation.

100908070605040302010

00 1 2 3 4 5 6 7 8 9 10 11 12

D =0.25

D =0 und D =0.5Ef

ficie

ncy

fact

or o

f ins

ulat

ion

Js in

%

Matching ratio �

fo = natural frequency of isolatorfm = forcing frequency of the machine

It follows that: Efficiency of vibration insulation

Tran

smiss

ibili

ty V

p

3.0

2.5

2.0

1.5

1.0

0.5

00.3 0.6 1 2 3 4 82

Undamped steel spring

D = 1.0

Matching ratio � = –fmfo

�s = ––Js = 100 x (1 – – ) % ;1�s

�b�e

Js =fmfo( )2

– 1· 100 %

fmfo( )2

– 2

Transmissibility by taken dampening factor Dinto consideration is:

1 + 4 D2 �2

(1 - �2)2+ 4 D2 �2Vp = forcing frequency

natural frequency of isolates� =;

1 2

63 4

5 6

7 8

Load (daN/cm2)

dyna

mic

nat

ural

freq

uenc

y Hz

dynamic natural frequency vertical dynamic natural frequency horizontal

Load (daN/cm2)

dyna

mic

nat

ural

freq

uenc

y Hz

8

7

6

5

4

3

2

1

00 1 2 3 4

181716151413121110987654

0 1 2 3 4

B13-W(2)/B8

B13-W(3)/B8

B13-W(4)/B8

B13-W(5)/B8

B13-W(6)/B8

B13-W(2)/B8

B13-W(3)/B8B13-W(4)/B8

B13-W(5)/B8B13-W(6)/B8

3

The main purpose of the foundation is to stabilize the machine as wellas to increase the moment of inertia. The foundation thus positivelyinfluences machine vibration by reducing the amplitude of oscillation.It is wrong, however, to assume that any foundation large enoughwould eliminate all vibration problems. It is important that as muchinformation as possible be supplied regarding the machine to beisolated, this will include machine size and weights, any dynamicfeatures of its operation, location including ground type, conditionwhere optimal performance is required and a vibration analysis of themachine and site conditions. A correct isolation between machinefoundation and the surrounding area will result in trouble free operation.

As a result of years of experience we have the necessary experiencein this field. At your request we can offer all other related servicesincluding measuring of vibrations, planning and construction design. Illustration 1, 2, 3: Depositing of BILZ insulation plates (green) and

padding of the spaces with mineral fibre insulation plates (sacrificeformwork). Illustration 4: Covering of the entire area first with PVCsheeting as used for construction work, and then with mineral fibrecover plates. All joints must be pasted/glued together.Illustration 5, 6: Mounting of reinforcement. Illustration 7, 8: Fillingin of concrete.

Application example in the plant of a major automobile manufacturer.Passive insulation protection of a Waldrich-Coburg portal millingmachine from the pressing mechanism sector.Total mass: approx. 1200 to.

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Foundation insulation

1

2

3

45

6

4 1 Foundation (side wall)2 Mineral fibres and cover plates

(lost formwork)3 Foundation block4 PVC film cover5 Mineral fibres and cover plates

(lost formwork)6 BILZ insulation plates7 Foundation (base)

BILZ insulating plates are ideally suitedfor vibration suppression of foundations andbaseplates

Isolated Foundations

Precast form,steel mould

The mechanical-pneumatic relief valves are a simple yet effectivesolution. The level is constantly scanned by a plunger. The plungerposition in transmitted to a slide valve. Depending on the slide valveposition, pressure is applied to the air spring or the inside pressureis reduced. The level can be maintained at an accuracy ± 1/10 mm.

Principally three control valves are used. A pressure control valve tolimit system pressure to a maximum of 6 bar, water trap to removevapour and an air filter to remove dust and any foreign bodies fromthe air supply.

FAEBI® mechanical-pneumatic control valvesCombined Rubber-Airspring-Insulator

FAEBI®-HD with adjustable dampening

Rubber air-spring insulator FAEBI®-HD is made of a combination ofhigh-grade elastomer and metal with an enlarged sidewall. In orderto obtain as high a dampening effect as possible, the air space is splitinto two chambers (load / dampening volume) linked by an air pipe.By the adjustable valve the dampening can be changed easily fromoutside. Due to the friction caused by the air-stream passing throughthe bypass valve, it is possible to adapt the dampening to eachapplication.

Because of the very high dampening, the resonance amplitude is muchsmaller and therefore you are able to achieve less machine movement.(see graph 1a + 1b) Furthermore the increased transformable energytakes effect on the production quality of your machinery.

Note:In contrast to viscous dampers, the air dampening is absolutely wear-resistant and free of maintenance. Furthermore it is possible to changethe dampening from outside.

FAEBI®-HD

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FAEBI® 200 HDFAEBI® 300 HDFAEBI® 430 HDFAEBI® 580 HD

625 - 15001150 - 34002750 - 65005150 - 12500lo

ad d

aN/p

c.

max

. pre

ssur

e / b

ar

A m

m 130200315380

d m

m

D m

m 909090

136

H ap

prox

. mm

= w

orkh

eigh

t M 16M 20M 20M 24

M

type 236

340480650

260370500680

6666

FAEBI® 200 HDLoad (daN)

natu

ral f

requ

ency

(Hz)

– v

ertic

al –


natu

ral f

requ

ency

(Hz)

– v

ertic

al –

1150 1600 2050 2500 2950 3400


natu

ral f

requ

ency

(Hz)

– v

ertic

al –

2750 3500 4250 5000 5750 6500


natu

ral f

requ

ency

(Hz)

– v

ertic

al –

625 800 975 1150 1325 1500

4

4,5

5

5,5

6

6,5

4

4,5

5

5,5

6

6,5

4

4,5

5

5,5

6

6,5

4

4,5

5

5,5

6

6,55150 7225 8275 9325 11425 12500

Rubber-Airspring Insulator FAEBI®

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Example: Stamping Machine Type PIVATIC PCC80 TTI + HT

Machine weight incl. work piece app. 23 to. Dynamic vertical forces app. 60 KN, horizontalforces app. 30 KN, Foundation block: app. 5,1 x 3,5 x 1 m, weight app 40 to.

Equipment: 8 x Bilz FAEBI type 580-HD with mechanic level control system LCV andfollowing services:

foundation design

static foundation calculation

formwork plans

steel- and bending schedule list

Special request:Target: loss of production not longer as 3 weeks. Small space from the revision channeltrough to foundation block.Very low horizontal movement of the machine was excepted. Efficiency of the isolation ofmore than 80 % was requested.

Example: Foundation Insulation with FAEBI and Level Control System

natu

ral f

requ

ency

(Hz)

– v

ertic

al –

600 1000 1500 2000 2400

1,2

1,65

2,1

2,55

3,0 natu

ral f

requ

ency

(Hz)

– v

ertic

al –

1000 1750 2500 3250 4000

1,2

1,65

2,1

2,55

3,0 natu

ral f

requ

ency

(Hz)

– v

ertic

al –

2000 3000 4000 5000 6500

1,2

1,65

2,1

2,55

3,0 natu

ral f

requ

ency

(Hz)

– v

ertic

al –

4000 6000 8000 10000 12000

1,2

1,65

2,1

2,55

3,0 natu

ral f

requ

ency

(Hz)

– v

ertic

al –

8000 13000 18000 23000 28000

1.9

2,05

2,2

2,35

2,9

BiAir ®2-ED2-ED/HELoad (daN)

BiAir ®2,5-ED2,5-ED/HELoad (daN)



BiAir ®5-EDLoad (daN)

BiAir®

Product DescriptionThe Air-Spring Insulator BiAir® consists of a cast aluminum bodywhose air volume is enclosed by a thin-walled, flexible and pressure-resistant rolling diaphragm. The piston is seated on this diaphragmand is pushed into the air volume.This design causes highly effective vibration insulation.In order to obtain as high a dampening effect as possible, the air spaceis split into two chambers (load/dampening volume) linked by air pipe.By the adjustable valve the dampening can be easily changed fromoutside. Due to the friction caused by the air-stream passing throughthe bypass valve, up to 20% dampening can be effected.Additional safety valves will protect the roller diaphragm from gettingdamaged by over-inflation.

Range of ApplicationHighly effective vibration insulation of sensitive measuring and testingmachines, fine-machining plant, as well as optical and electronicequipment. Another important range of application is the vibration-insulated foundation of vehicle, motor and other performance testers.BiAir® Air-Spring insulators are extremely well suited for the insulationof foundations e.g. equivalent machine loads.

Advantages compared with conventional steel springsBiAir® Air-Spring insulators with level control are an active system.The machine/foundation level consistancy will always be preserved!Automatic leveling/adjustment!

BiAir®

BILZ level controller systems

Level control is an important part of an optimally functioning air spring system. The automatic level controller can be utilized to overcome theproblem associated with load changes in air-spring insulated machines, which can result in tilting of the machine.The height of the specific elements BiAir® or FAEBI® can be controlled by changing the air pressure in the air-spring insulators. Quick inflationor deflation will hold the machines level even if their center of gravity keeps changing.

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before

after

Control circuitThe circuit consists of at least three air springs. If more air springs areneeded for structural or loading reasons, the system must alwaysinclude 3 position pickups, e.g. three controlled components in orderto avoid statical overdefinition. This is achieved by connecting setsof air springs in parallel.

Membrane Air-Spring Insulator BiAir®

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Example: Foundation Insulation with BiAir® and Level Control System

Example: Grinding machine Type GLEASON PFAUDER P 1200 G

Equipment::Vibration isolated Inertia Block app. 20 to. On Bilz Membrane –AirspringSystem BiAir4 – ED with mechanic pneumatic level control systemMPN-LCV-HF

Special request:Because of surrounding machines, crane runaway etc. installation ofan isolation system is difficult. Workpieces with app. 10 to. Createsa large change in loading on the isolation system. To compensate this,a high flow level control system with level accuracy of 0,1 mm isneeded.

TasksThe measurement-technological coverage of oscillation emissions e.g.immissions as a basis for vibration technological measurement toobserve legally laid down limit values (see graph 1).As can be seen from graph 2, different limit values must be observed,depending on the location of the machine. This standard aims at layingdown principles according to which mechanical shocks can be measuredin buildings, enabling the determination of effects of vibrations onhuman beings and building construction.Another relevant example for the necessity of a vibration analysis isthe mounting of high-precision coordinate measuring machines aswell as of other testing, measuring or grinding machines. As a rule,measurement-tests must be carried out on proposed locations for suchmachines to ensure that local ground oscillations do not exceedpermissible values.

To this end oscillation accelerations within a given frequency spectrum(1–100 Hz) are taken down, because a simple summation valuemeasurement would give only an approximate indication of the exactenvironmental conditions. The evaluation of the power-path signalstakes place with a Fast Fourier analyser, indicating the measured valuefor each frequency of the spectrum (vibration acceleration in g). Shouldthe interferences (vibration magnitude) be outside the admissiblerange, a suitable insulation can be worked out with the assistance ofour computer calculation programs.

Measurement-technological vibration analysis

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Very accurate and sensitive vibration analyses at low frequencies arecarried out with a high-tec Geophone. With the Geophone it is possibleto measure vibration amplitudes from 0,01 μm/s at frequencies from0,2 to 30 Hz. Especially in the nano-tec and semiconductor industryas well as in the field of cutting edge 3D metrology absolute accuratevibration measurements is of great importance to achieve optimaland customer specific vibration isolation.

BILZ test bench (1600 Newton X-Y-Z Shaker)

0.05

0.04

0.03

0.02

0.015

0.010.0090.0080.0070.0060.005

0.004

2 3 4 5 6 7 8 9 10 12 15 20 25 30 40 50 60 70 80 10090

Any acceleration values in thisrange require vibration attenuation.

admissible range

frequency (Hz)

( 0.2

KB

( acc

ordin

g to V

DI 20

57 )

( 0.1

KB (

acco

rding

to VD

I 205

7 )

Vibration acceleration in g

Vibration acceleration in m/s –22

5·10 –3

4·10 –3

3·10 –3

2·10 –3

1,5·10 –3

1·10 –3

9·10 –4

8·10 –4

7·10 –4

6·10 –4

5·10 –4

4·10 –4

Vibr

atio

n ac

cele

ratio

n (e

ffec

tive

valu

e) in

m/s

–2

10–3

1 2 3 5 8 10 20 30 50 80 100Frequency (Hz)

Vibr

atio

n ac

cele

ratio

n (p

eak

valu

e) in

m/s

–2

10–2

10 –1

10–0

8

5

3

2

8

5

3

2

5

3

2

8

10–3

10–2

10 –1

5

3

2

8

5

3

2

5

3

8

8

2

KB = 0,1KB = 0,14

KB = 0,2

KB = 0,28

KB = 0,4KB = 0,56

KB = 0,8

KB = 1,6

KB = 3,2

KB = 6,4

KB = 12,8

Measurements of vibration and mechanical shocks.We use the most modern measurement equipment(FFT-Analyser + PC calculation programs).Our decades of experience in the fieldof vibration technology guarantees technically andeconomically reliable solutions for your problems.

Measurement-technological vibration analysis

9

1

2

10

Example: FEM representation of Foundation Block /natural forms

Example: FEM representation. Bend reinforcementin nodal points.

11

Static and dynamic calculations / formwork and reinforcement plans / FEM analyses

Example: construction plan for foundation isolation with insulationplate sets

Bilz Vibration Technology AG · Böblinger Str. 25 · D-71229 Leonberg · GermanyFon + 49 (0) 71 52 / 30 91- 0 · Fax + 49 (0) 71 52 / 30 91-10 · [email protected] · www.bilz.ag

01.2

008

· 200

0 · G

B

bilz - vibration isolation of foundations & frameworks

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