DESIGN &ANALYSIS OF BALANCER

SHAFT FOR PARALLEL TWIN

CYLINDER DIESEL ENGINE

SAI VIGNESH .V
116107010

EXTERNAL PROJECT:ASHOK LEYLAND TECHNICAL CENTRE

EXTERNAL GUIDE INTERNAL GUIDE

SUNDARAM .K Dr. KARTHIKEYAN .M
MIDHUN.VS Associate Professor SoME
BALANCE SHAFT
TATA NANO balance shaft (primary balancer shaft)
 TWO WAYS OF BALANCING
SMALLER
RADIUS INCREASING RADIUS
&ADDING &SMALL MASS
MORE MASS

For reference
Tata Nano
 Shaft design
Factor of safety 2
Torque(Nm) 220
Power(watts) 55292.03071
ultimate stress(Mpa) 1300
Permissible bending stress(yield)(Mpa) 900
Permissible shear stress(Mpa) 450
value of Km 2
value of Kt 2
Distance of gear from right end bearing(mm) 120
Distance of gear from left end bearing(mm) 150
Total distance between bearings(mm) 270
Tangential force acting on gear (Pt)(N) 2933.333333
Radial force acting on gear(Pr)(N) 1067.646021
Horizontal reaction(due to gear forces)(Nmm) 195555.5556
vertical reaction(due to gear forces)(Nmm) 71176.40137
Total bending forces(Nmm) 208105.8755

Equivalent twising moment(Nmm) 605666.7579

shaft diameter(mm) 23.93378468
fatigue factor 0.18
Stress reduced by 25%( for keyway) 0.75
permissible bending stress(Mpa) 175.5
shaft diameter(mm) 32.75843738
Assembled model
CENTER DISTANCE -180MM
GEAR PITCH DIA-180MM

DRIVE GEAR FITTED IN

CRANK WEB FOR FULL
THICKNESS-22.5MM

GEAR
PROJECTING
OUTSIDE
CRANKCASE
CENTRE DISTANCE-150MM

FROM BOTTOM FACE OF ENGINE

BLOCK TO BALANCE SHAFT CENTRE-
90MM

GEAR PACKED IN
CRANKCASE
PROPOSAL 1
 Vertical
clearance-
1.8mm

Adjacent
clearance
-1mm
 Assembly of edited mass location

Radius-
69mm

Mass-1.1
Clearance kg
between
adjacent
parts-
3mm
Proposal 2
 Vertical
clearance -
5mm
Damper side crankpin
Flywheel side crankpin
MODIFIED CRANKSHAFT BALANCING TABLE
 Eccentric mass for 180 crankshaft

Eccentric mass for 360 crankshaft

 FUTURE WORK

• Balancer shaft has to be checked for its natural frequency by modal analysis
• Unbalance vector will be validated with theoretical calculations by using AVL EXCITE
MODAL ANALYSIS
Mode Frequency (Hz)(Rigid body mode)
01. 1162.2

02. 1536.2

03. 1548.8

04. 2067.4

05. 3148.5

06. 4163.5
AVL EXCITE
AVL BOOST
Load curve for example
Balancing rate = 𝑢𝑛𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑒 𝑡𝑜 𝑐𝑜𝑢𝑛𝑡𝑒𝑟𝑤𝑒𝑖𝑔ℎ𝑡
unbalance force due to crank+(rotating mass of conrod*crank throw)

• From the above formula it has been found out that a balance mass of 0.06 Kg m
has to be designed in a form of eccentric mass
CRANKTRAIN GRAPH RESULT
References:

• D. Meek and M. Roberts, “Balance Shaft Conversion of a Four Cylinder Engine – The Challenges of Packaging
and Mechanical Integration”. SAE Paper No. 981084.
• J. Saunders and P. Walker, “Design and Development of a Novel Balancing System for Single and In-Line Twin
Cylinder Engines”, SAE Paper No. 2003-32-0026.
• Theory of Machines and Mechanisms, by R.S Khurmi