BALANCING

Outline

1. Introduction
2. Type of balancing
3. Primary and secondary inertia forces explained
4. Reciprocating masses
5. Balancing of reciprocating engines
6. Solved examples

1.0 Balancing
It is a method or technique of eliminating or reducing to minimum unwanted inertia
forces or moments in rotating or reciprocating masses acting within machines such as
engines and rotor driven systems.

Balancing is generally defined as a process of designing or modifying a machine such

that the unbalance within the system during motion is partially or totally eliminated. This
is achieved by simply changing the location of the centres of masses (redistributing the
masses) by the removal or introduction of additional mass to various members of the
mechanism.

Balancing in engines ensures that the centre of gravity (CG) of the entire system
remains static during a complete revolution of the crank shaft, thereby eliminating
unpleasant vibrations. Furthermore, it ensures that the couples and other moving parts
within the engine are balanced when undergoing acceleration.

1
For this course, our emphasis shall be on balancing of reciprocating masses as contained
in the module guideline (learners guide).

2.0 Types of balancing

1. Static balancing
2. Dynamic balancing

Static balancing
It is a balance of forces due to action of gravity. An object is said to be in static balance
when the action of gravity is in the axis of rotation.

Dynamic balancing
It is a balancing due to action of inertia forces acting on the body. When the resultant
moments or couples within moving parts of a body undergoing acceleration is zero, the
body is said to be in a state of dynamic balance. The resultant of all the forces acting on
the body of the engine due to inertia forces only is known as unbalanced force or
shaking force.

When a mass moves along a circular path, it experiences a centrifugal acceleration. The
centrifugal force remains balanced in a revolving rotor as long as the centre of mass of
the rotor lies in the axis of rotation of the shaft. An equal and opposite erroneous force
acts radially outwards and its magnitude remains constant but the direction changes with
the rotation of the mass for an unbalanced object. These is common in rotors of air
compressors, crankshaft of engines, centrifugal pumps and steam turbines. Designing for
optimal balance eliminates these unwanted eccentricity.

Another classification/subdivision of balancing is based on the method of introducing and

manipulating the masses acting on a system.

A. Active balancing: When mass(es) is/are added or subtracted from a given system
to achieve a dynamically balanced state, it is called active balancing
B. Passive balancing: When the balancing of a system is achieved without addition
or removal of masses, by simply manipulating the inherent parameters of the
system, it is termed passive balancing.

BALANCING OF MASSES IN THE SAME PLANE

1. If the masses are rotating for dynamic balance the vector sum of the centrifugal
forces must be zero: m 2 r 0 . Because is the same for all masses (shaft
angular velocity): mr 0

2
 m1
m2 m4 is the balancing mass
r1 m4 r4 is the balancing
product of mass and radius

r2
r2

2
In the mr polygon:

m 3 r3
r4 - all arrows must point in
r3 the same direction,
m4
- the closing side

m1
r4 represents the balance

r1
m3
m4 mass x radius

2. If the masses are rotating in different planes, for dynamic equilibrium (transverse
plane)
F 0
Moments 0
- The balancing mass is found
P m2
from the mr polygon.
m1
- The balancing couple is found
2
2L
m1 r2
from mrL polygon

m 3r 3
r1
2r

m2
- All distances measured to one
m

r2
r1
side of the reference plane P
L3
r3
L1
r4 L2 are treated as positive and to
r3
L3 m3 the other side as negative.
m4
- All positive couples are
m1

m3
treated as acting radially
L4
r1

r4 outward and negative couples

L1

m4 radially inwards.
- All arrow heads in the couples
polygon must follow one
direction

3
RECIPROCATING MASSES.

In the reciprocating engines shown in figure 1, the linear acceleration of piston C is

cos 2 l
approximately: f c 2 r cos 2 r where n
n r

big end

small end
l
r B
conne
cting
rod
R pcos q A
reciprocating

mass = R
Qp cos C
Q crank shaft

R psin
Qp sin
Fig. 1

R 2 r
R 2 r cos

R

A B

R 2 cos
R cos
2
C inertia force
acceleration force

Fig. 2

r
R 2 n
R 2 r cos 2
n
R

2

R 2 r cos 2
n

Fig. 3

4
FORCES AND MOMENTS: IN-LINE RECIPROCATING ENGINES
Figure 4 shows the principal forces in an in-line engine:
1. Unbalanced vertical forces create movement along the Y axis;

2. Crankshaft torque variations create rotational forces (moments) about Z axis;

3. Unbalanced forces acting transversally along the engine create rotational forces
about X axis.

vertical forces
Y Four cylinder engine

Engine flywheel

rotational moments
Z
rotational moments

Fig. 4

Figure 5 shows the separate and combined wave forms of unbalanced forces in a single
cylinder engine.

Piston at top dead centre Total force

primary force
Force

secondary force

Crankshaft rotation
0 0 0 0 0
00 45 90
0
135
0
180
0
225 270 315 360

Piston at botton dear centre

Fig. 5 The wave forms of the unbalanced forces in a single cylinder engine

Unbalanced force due to reciprocating mass = varies in magnitude but is constant in direction

Unbalanced force due to a revolving mass = constant in magnitude but varies in direction

5
The Force required to accelerate the reciprocating parts:
cos 2

F R 2 r cos R 2 r
n

primary inertia secondary inertia
force force

The primary and secondary inertia forces are constant in direction but varies in magnitude
therefore cannot be completely balanced by a rotating mass, on which the inertia force is
varying in direction but is constant in magnitude.
1. The primary inertia force F R 2 r cos can be partially balanced by a mass Q
rotating at a radius q such that Qq = Rr . The component of the inertia force on Q

in the line of stroke: FQ Q 2 r cos . A force
FQ Q 2 r sin in a
direction perpendicular to the line of stroke is introduced which is unbalanced.
cos 2
2. The partial balancing of the secondary inertia force F R 2 r can be
n
achieved only if a balance mass rotates at twice the crank speed (2). Due to
practical constrains usually the secondary force is ignored.
3. In many cases the reciprocating mass is partially balanced by a rotating mass
reducing the inertia force in the line of stroke and introducing a force
smaller than R 2 r (figs. 1 & 2) in the perpendicular direction.
2
4. In practice a mass of R is placed at Q so that there is an unbalanced
3
1 1
horizontal force of maximum value of R 2 r R p and an unbalanced
3 3
2 2
vertical force of R 2 r R p .
3 3
2
5. Hence it is usual to consider of the reciprocating masses acting at Q and
3
combine with rotating masses for balancing. Thus if R1 = revolving masses at
crank pin and R the reciprocating masses, then:
2
Equivalent mass at crank pin = R1 R
3
Primary and secondary balancing for multi-cylinder in-line engines:

Condition for primary balancing:

algebraic sum of primary accelerating forces = zero ( R 2 r cos 0 )

algebraic sum of primary couples about any point in the plane = zero
R 2 ra cos 0 where a is the distance from the reference plane
r cos 2 r cos 2
Condition for secondary balancing: R 2 0 ; R 2 a 0
n n

6
Firing order: The firing order is the sequence of power delivery of each cylinder in
a multi-cylinder reciprocating engine. This is achieved by sparking of the spark plugs
in a gasoline engine in the correct order, or by the sequence of fuel injection in a
Diesel engine. In multi - cylinder engines there are several possible firing orders for
the cylinder, each having a different effect on the balance of the engine. The firing
order may be influenced by torsional vibrations, fuel and exhaust distributions etc. It
gives balance to engine and load is uniformly distributed in crankshaft. Proper firing
order minimises vibration, ensures smooth running and gives high life to the engine.
In modern engines firing order are controlled by the ECU.
Firing order used in 4 cylinder engines include 1-3-4-2; 1-2-4-3; 1-3-2-4; 1-4-3-2.

In a 4-stroke engine firing takes place once after every 4 stroke.

1. Piston moving out (of bore/cylinder) : Charge(air+fuel) in

2. Piston moving in: Charge compressed
At the end of 2nd stroke, spark plug fires.
3. Piston moving out: Power stroke (this is where engine delivers power)
4. Piston moving in: Exhaust gas out.
5. Go to step 1.

As you can see, for 4 stroke engine, it needs 2 complete cycle of piston for 1 spark.

For 800rpm, 400 times firing per minute per cylinder.

For four cylinder engine, 4x400=1600 times firing per minute. (Engine capacity has
nothing to do with firing rate in this case). There can be any number of cylinders in a
4 stroke engine. From single cylinder to 8 or 12, all can have 4 strokes for combustion
of charge. The number of cylinders will depend on the power required to be derived
from that engine.

Most cars below 2000cc or 2.0L will customarily have 4 cylinders (unless it is a
downsized engine).

Please remember that firing doesn't take place at one time. Four (4) Strokes for
example is a measure of number of strokes taken for the combustion of air-fuel
mixture (also called 'charge') in a cylinder.

1. In a two stroke engine the cycle of operation is completed in one

revolution of the crank shaft, and the angular interval between cranks is
360o/number of cylinders; the order of cranks corresponds to the given
firing order.
2. In a four stroke engine, the cycle of operations requires two revolutions of
the crank shaft and the angular interval between cranks is 720o/number
of cylinders; the order of cranks corresponds to the given firing order.

7
Exercise 1 (Example 1 from the text book)

A five cylinder in line engine has the successive cranks at 144o apart, the distance
between the cylinders centre lines = 450 mm.
The following data is available:

Reciprocating mass of each cylinder = 16 kg,

Crank radius = 135 mm,
Connecting rod length = 540 mm,
N engine = 600 rev/min.

Examine the engine for balance of primary and secondary forces and couples. Determine
the maximum values of these and the position of central crank at which these maximum
values occur.
Solution:
The reference plane is usually chosen so that it passes through the centre of gravity of
the engine. Unbalanced couples will then have their least values since the lever arms of
the couples will not be longer than half the length of the engine. Negative couples can
under certain circumstances cancel out the positive couples, which will further reduce
the disturbance and improve the balance of the engine.
In this example is recommended that the reference plane passes through crank 3. All
couples values situated to the left of the reference plane will be negative and all couples
values situated to the right of the reference plane will be positive.
This rule translate graphically as follows:
For cranks 1 and 2 the vector arrow will point toward the centre o (inward)
For cranks 4 and 5 the vector arrow will point away from point o (outward)

Crank R [kg] r [m] Rr a [m] Rra 540/135 Rr/n (R r a)/n

[kgm] [kg m2] n=4
1 16 0,135 2,16 - 0,9 - 1,944 4 0,54 - 0,486
2 16 0,135 2,16 - 0,45 - 0,972 4 0,54 - 0,243
3 16 0,135 2,16 0 0 4 0,54 0
4 16 0,135 2,16 + 0,45 + 0,972 4 0,54 + 0,243
5 16 0,135 2,16 + 0,9 + 1,945 4 0,54 + 0,846

As there is no firing order given, Crank 1 is placed on the firing line (positive vertical
direction) and the rest of the cranks in numerical order at 1440 from each other, in
clockwise direction (see Fig. 4)

N.B. The counter-clockwise direction can be used as well as the result will be the same.

Once the rotating direction is decided, the same rotating direction must be used for both
primary and secondary forces

N 600
62,83 rad / s
30 30

8
From figure 4, it can be seen that there are no unbalanced primary forces. However the
primary couples are unbalanced by a magnitude of: F a 2,55 62,832 10,07 kNm at
720, (180 from crank 1). For the maximum unbalanced couple to be on the firing line i.e.
on vertical direction all cranks must be rotated counter-clockwise by 180. When vector
O5 is on vertical direction (firing line) upward, the central crank 3 will be on horizontal
direction at 1800. When the whole system is rotated by 1800 vector O5 will be on vertical
direction (firing line) downward, crank 3 will be on horizontal at 00 as shown in figures
4 a and 4 b.
1 2 3 4 5 18
1
P

72
14

4
3 4

14
4
o
45 450 450 450
o
P
144
- 1,944
Unbalanced primary
couple = 2,55 x 62,83
2
5 2
72
=10,07 kNm
+ 0,9 4 primary cranks
1
2
4
-0

R x r = 2,16 [kgm]
,97

3
2
4
,94

2
+1

o 5 1
72

No unbalanced

primary forces
5

P
1

3 3
o 3
o

5
b) a)
Fig. 4

Consider the secondary forces and couples below (Fig. 5):

9
N.B. The secondary forces and couples diagrams can be drawn using the primary
forces and couples values, provided that in the end the values obtained from the
diagrams are divided by the n ratio.

From figure 5, it can be seen that there are no unbalanced secondary forces. However the
4,133
secondary couples are unbalanced by a magnitude of: F a 62,832 4,079 kNm
4
at 540 from crank 1. For the maximum unbalanced couple to be on the firing line i.e. on
vertical direction all secondary cranks must be rotated clockwise by 540, with crank 3
being on horizontal direction at 1800, and the situation is repeated every 1800 of
secondary crank rotation, i.e. 540, 2340, 4140 etc. Because for the construction of the
secondary couples diagram the angle 2 was used, the rotation of the real cranks will be
only 540 / 2 = 270, 1170, 2070 etc. Consequently if all primary cranks (the real ones) are
rotated clockwise by 270 the new position of the central crank will be O3 at 450 from the
horizontal, as shown in figure 5 a. For every central crank position at 450 to the
horizontal i.e. 450, 1350, 2250 and 3150 there will be a maximum of unbalanced secondary
couple. (see figure 5. b )

When the central crank 3 is on horizontal at 00 and 1800, the maximum primary and
secondary couples will occur.

10
 o
secondary cranks M
144
1
54
Unbalanced secondary
2
couple = [(4,133) /4]x 62,83
M =4,079 kNm
28
8
2 5
o

- 1,944
288 1 - 0,9
72
3 4 2

+0
5
44

,97
No unbalanced + 1,9

2
1
secondary forces

4
3 (R x r)/n = 0,54 [kgm]

o
5 primary cranks
primary cranks
4
1
3 3
3'

27
45

4 o
18

3 o

3 3
5 2

a) b)

Fig. 5
Exercise 2 (Example 2 from the text book)

The six cylinder single acting two stroke Diesel engine are pitched 1 m apart and the
cranks are spaced at 60o intervals. The crank length is 300 mm; the connecting rod/crank
ratio is 4,5; the reciprocating mass per line is 1350 kg; the rotating mass is 1000 kg and
the crank speed is 200 rev/min. Show with regard to primary and secondary balance, that
the firing order 1 5 3 6 2 4 give unbalance in primary moment only and the
firing order 1 4 5 2 3 6 gives secondary moment unbalance only. Compare the
maximum values of these moments evaluating with respect to the central plane of the
engine.
Although the recommendation based on practical experience is that the Equivalent Mass
2
at crank pin to be = R 1 R in this exercise the Equivalent Mass at crank pin was
3
considered to be = (R + M), where the revolving mass R1 = M = 1000 kg and the
reciprocating mass R = 1350 kg

11
Also as the primary inertia force can be partially balanced by a rotating mass, the
rotating mass M is introduced only for the calculation of primary forces and couples

The partial balancing of the secondary inertia force can be achieved only if a balance
mass rotates at twice the crank speed (2). Due to practical constrains, usually for the
calculation of the secondary forces and couples the rotating mass is ignored.

Secondary Primary Secondary Primary

forces forces couples couples
Crank R M r Rr (R+M)r a Rra (R + M)ra
[kg] [kg] [m] [kgm] [kgm] [m] [kg m2] [kgm2]
1 1350 1000 0.3 405 705 -2.5 -1013.5 -1762.5
2 1350 1000 0.3 405 705 -1.5 -607.5 -1057.5
3 1350 1000 0.3 405 705 -0.5 -202.5 -352.5
4 1350 1000 0.3 405 705 +0.5 +202.5 +352.5
5 1350 1000 0.3 405 705 +1.5 +607.5 +1057.5
6 1350 1000 0.3 405 705 +2.5 +1013.5 +1762.5

Consider first the firing order 1 5 3 6 2 4

For a two stroke engine the angular displacement of the cranks will be 3600 / 6 = 600.
There are several possibilities of drawing the force and couples diagrams:
Crank 1 will be placed in the firing line direction (positive vertical). The rest of
the cranks arranged in firing order clockwise or counter-clockwise.
- Forces and Couples diagrams in numerical order (Fig. 6)
Crank 1 will be placed in the firing line direction (positive vertical). The rest of
the cranks arranged in numerical order clockwise or counter-clockwise.
- Forces and Couples diagrams in firing order (Fig. 7)
Crank 1 will be placed in the firing line direction (positive vertical). The rest of
the cranks arranged in firing order clockwise or counter-clockwise.
- Forces and Couples diagrams in firing order (Fig. 7)

Instructions

1. Compare the maximum values of these moments evaluating with respect to the
central plane of the engine using the firing orders given.

2. Draw the Force vs Crankshaft angle graph to indicate the profile of the
unbalanced forces on an individual cylinder. (To accomplish this, draw a graph
for primary, secondary and total forces as shown in Figure 3 using equation for
primary and secondary forces).

3. Discuss your findings for 1 and 2. Compile a report for this engine scenario, show
neatly the tables, calculations, diagrams and graphs.

12
 The recommended method is to place the cranks in firing order and draw the
diagrams in numerical order (see Fig. 6)
When the firing order is given Forces diagram Forces diagram
the cranks MUST be arranged in numerical order in firing order
in the firing order. 5
5
Primary cranks 1 3 1
in firing order 2
1 3
6 4
o o
6 4
5 4

Primary couples diagram 2

in numerical order Primary couples diagram
in firing order
o o
3 2
5

6 4 -3
-3
The forces and couples diagrams 5
-2
may be drawn in firing or numerical
order, once the cranks were drawn in
-1 -1

59
firing order.
59

4
6
-2

6
Fig. 6
primary forces diagram
primary cranks in numerical order in firing order
1 5

60 1 3
6 2

4 6
5 3

4
primary forces diagram
primary cranks in firing order in firing order
5
1

1 3
60
4 5

4 6

2 3

Fig. 7

13
Solution:

The students are required to solve the exercise as home work

Please be aware of the following:
360 0
The cranks will be at 60 0
6
When drawing the cranks position the firing order must be observed. In other words
for the firing order 1 5 3 6 2 4 first position crank number 1 on vertical
direction, next crank number 5 at 600 from crank no. 1 in clockwise direction etc. as
shown in figure 8.
For the firing order 1 4 5 2 3 6 first position crank number 1 on vertical
direction, next crank number 4 at 600 from crank no. 1 in clockwise direction etc. as
shown in figure 8.
The secondary cranks will be at 2 x 600 = 1200 from each other respecting the firing
order (see Fig. 8 for secondary cranks)
1 2 3 4 5

1m 1m 0,5m 0,5m 1m 1m

Firing order: 1 - 5 - 3 - 6 - 2 - 4
1 1, 6

60
4 5
120

2 3 3, 4 2,5

6
secondary cranks
primary cranks
Firing order: 1 - 4 - 5 - 2 - 3 - 6

1 1, 2

60 4
6
120

3 5 5, 6 4, 3

2
secondary cranks
primary cranks

Fig. 8

14
 Example 3

A five cylinder engine has its cylinders uniformly spaced at 100 mm centre distances.
The crank radius is 80 mm, the connecting rods are 240 mm long and N = 3200 rev/min.
The following data is available:

Crank R [kg] 1.1 Find the masses m2 and m4 and the missing angles for
o
1 1,2 0 complete primary balance;
2 m2 1.2 Find the unbalanced secondary couples.
3 1,2 288o
4 m4
5 1,2 216o
Solution:
Consider crank 1 coincident with the line of stroke on vertical position and assume a
counter-clockwise movement.
Crank R [kg] r [m] a [m] Rra [kgm2] Take plane
1 0 o
1,2 0,08 -0,1 -9,6 x 10 -3 1 2 3 4 5 of crank 2
2 m2 0,08 0 0 as reference
plane
3 288o 1,2 0,08 0,1 +9,6 x 10-3 -0,1 0,1
4 m4 0,08 0,2 + m4x16x10-3 0,2
5 216o 1,2 0,08 0,3 +28,8 x 10-3 0,3

1 4
The positive sense of the couple on crank
4 41
+39,7 4 is at 41o measured from crank 1,
41 counter-clockwise.
3
Q +28,8
5 0 3200
21
60 -9,6
3
335,1 rad / s
288 0 1 30
5 +9,6
Couple 39,7 10 3 335,12 4458 Nm
-3
step 1 01 = - 9,6 x 10
step 2 13 = 9,6 x 10 -3
step 3 45 = 28,8 x 10 -3
step 4 34 = 39,7 x 10 -3 (measured)
step 5 m4 = 39,7/16 = 2,48 kg

Crank R [kg] r [m] a [m] Rra [kgm2] Take plane

1 2 3 4 5
1 0o 1,2 0,08 -0,3 -28,8 x 10-3 of crank 4
2 m2 0,08 - 0,2 - m2 x 16 x 10-3 as reference
plane
3 288o 1,2 0,08 -0,1 -9,6 x 10-3 -0,1 0,1
4 m4 0,08 0 0 -0,2
5 216o 1,2 0,08 +0,1 +9,6 x 10-3 -0,3

15

The sense of vector 12 on the diagram is
-9,6 negative as shown in the values table,
1 therefore the positive sense of the couple
2
4 3 on crank 2 will be at 175o measured from
41 crank 1, counter-clockwise.
+9,6 0
3200
3 5
-39,7
335,1 rad / s
Q 30
175

-2 -28,8 Couple 39,7 10 3 335,12 4458 Nm

85

5 1

+2
-3
step 1 01 = - 28,8 x 10
step 2 35 = 9,6 x 10 -3
step 3 23 = - 9,6 x 10-3
-3
step 4 12 = - 39,7 x 10 (measured)
step 5 m2 = 39,7/16 = 2,48 kg
Secondary cranks

For the secondary cranks the angle will be 2 measured from crank 1, counter-clockwise.

Crank R [kg] The mass and position of cranks 2 and 4 are as calculated
1 1,2 0o
2 2,48 1750
3 1,2 288o
4 2,48 410
5 1,2 216o

Crank R [kg] r a [m] Rra [kgm2] Take plane of

[m] 1 2 3 4 5 crank 3 as
1 1,2 0,08 -0,2 -19,2 x 10-3 reference
2 2,48 0,08 -0,1 -19,84 x 10-3 plane
-0,1 0,1
3 1,2 0,08 0 0
4 2,48 0,08 0,1 + 19,84x10-3 -0,2 0,2
5 1,2 0,08 0,2 +19,2 x 10-3

16
 1 2 Crank 2: (175o x 2) = 350o measured from
crank 1 counter-clockwise.
10 Crank 3: (288o x 2) 360o = 216o measured
82 53 from crank 1 counter-clockwise.
72 Crank 4: 41o x 2 = 82o measured from crank
5
4 1 counter-clockwise.
Q Crank 5: (216o x 2) 360o = 72o measured
from crank 1 counter-clockwise.

36 3200 l 240
3
335,1 rad / s; n 3
30 r 80
0 2
balancing balancing couple 5,0
polygon n
side 335,12
50,56 - 19,2 50,56 10 3 1892,5 Nm
53 3
1
- 19,84
5
4
+ 19,2 2
+ 19,84

Example 4

A six cylinder four-stroke in-line engine has a firing order of 1 4 2 6 3 5. The

piston stroke is 120 mm and the length of the connecting rod is 180 mm. The centre lines
of the cylinders are spaced at 110 mm, 110 mm, 130 mm, 110 mm and 110 mm,
respectively from one another. If the reciprocating mass per cylinder is 0,8 kg and the
rotational speed of the engine is 2600 rev/min, determine:

4.1 The unbalanced primary and secondary couples abut a reference plane
situated mid-distance between cranks 3 and 4,
4.2 The unbalanced primary and secondary forces using the analytical method.

Solution:

Firing order 1 4 2 6 3 5
Four stroke engine = 7200 / 6 = 1200 between cranks
Piston stroke = 120 mm r = 120 / 2 = 60 mm
n = l / r = 180 / 60 = 3
2600
272 rad / s
30

17
 Crank R [kg] r [m] Rr [kgm] a [m] (R r a) x 10-3 [kg m2]
1 0,8 0,06 0,048 - 0,28 - 13,44
2 0,8 0,06 0,048 - 0,175 - 8,4
3 0,8 0,06 0,048 - 0,065 - 3,12
4 0,8 0,06 0,048 + 0,065 + 3,12
5 0,8 0,06 0,048 + 0,175 + 8,4
6 0,8 0,06 0,048 +0,285 + 13,44
1 2 3 4 5 6

0,110 0,110 0,130 0,110 0,110

-0,065 0,065
-0,175 0,175
-0,285 0,285

firing order: 1 - 4 - 2 - 6 - 3 - 5
1, 6 1;6
0 6 6 0
+13,44 -13,44
-13,44 +13,44
0
-3,12 +3,12
0
12

24
0

+3,12 3
-3,12 3
4 2 4
- 8,4 -8,4 2
3, 4 2,5 2;5 4;3
1
+8,4 +8,4
5 1 5
no unbalanced no unbalanced
primary cranks primary couple secondary cranks secondary couple

Fig. 8

When drawing the cranks position the firing order must be observed. In other words
for the given firing of 1 4 2 6 3 5, first position crank number 1 on vertical
direction, next crank number 4 at 1200 from crank no. 1 in counter-clockwise
direction etc. (see Fig. 8)

4.2 Acceleration of the reciprocating parts:

cos 2 l
f c 2 r cos 2 r where n
n r
The Force required to accelerate the reciprocating parts:
cos 2


F R 2 r cos R 2 r
n

primary inertia secondary inertia
force force

18
For the primary forces to be balanced Fprimary 0

F1 R 2 r cos 0,8 272,32 0,06 cos 0 3559 N
cos 120 cos 240 0,5
F2 3559 cos 240 1779,5 N
F3 3559 cos 120 1779,5 N
F4 3559 cos 120 1779,5 N
F5 3559 cos 240 1779,5 N
F6 3559 cos 360 3559 N
No unbalanced primary forces
For the secondary forces to be balanced Fsec ondary 0
cos 2 cos2 0
F1 R2 r 0,8 272,3 0,06
2
1186,33 N
n 3
cos2 120
F2 1186,33 593,167 N
3
cos2 240
F3 1186,33 593,167 N
3
cos2 240
F4 1186,33 593,167 N
3
cos2 120
F5 1186,33 593,167 N
3
cos2 360
F6 1186,33 1186,33 N
3
No unbalanced secondary forces

Example 4 a

Reconsider example 4 by changing the firing order from1 4 2 6 3 5,

to 1 4 2 3 6 5 i.e. cranks 6 and 3 are interchanged (see Fig. 9).

19
 1 2 3 4 5 6

0,110 0,110 0,130 0,110 0,110

0
-0,065 0,065
-0,175 0,175
-13,44
-0,285 0,285

firing order: 1 - 4 - 2 - 3 - 6 -5
1, 3 2
29 - 8,4
06 = 33 is the unbalanced -3,12 1
primary couple
+3,12 3
12
0

+8,4
5
4, 6 2,5

+13,44
primary cranks
6

0
1;3 06 = 33 is the unbalanced
secondary couple
31
0

-13,44
0
24

2
- 8,4
-3,12
1
2;5 4;6 3
4
+8,4
secondary cranks

+13,44

Fig. 9

20
Example 5
The centre line of a five cylinder reciprocating engine taken in order are 0,6 m; 0,8 m;
0,8 m and 0,6 m apart. The following data is available:

Cylinder Reciprocating Angular Piston connecting rods

mass displacement stroke
1 R1 1 0,4 m l = 4 x crank length
2 150 kg Angular
3 145 kg displacement
between cranks 2
and 3 is to be 700
4 156 kg 4
5 152 kg 5

For the data given above determine:

5.1 The reciprocating mass R1;
5.2 The angular position of all the cranks referred to crank 1, in order that the
primary forces and couples are balanced;
5.3 If the connecting rods length is four time the length of the crank, determine the
secondary unbalanced force when the engine rotates at 300 rev / min;
Solution:

1 2 3 4 5

0,6 m 0,8 m 0,8 m 0,6 m

R1 150 kg 145 kg 156 kg 152 kg

Crank 1 = reference plane

crank m r mr a mra
[kg] [m] [kgm] [m] [kgm2]

1 R1 0,2 0,2R1 0 0
2 150 0,2 30 0,6 18
3 145 0,2 29 1,4 40,6
4 156 0,2 31,2 2,2 68,64
5 152 0,2 30,4 2,8 85,12

First determine the position of the cranks 4 and 5:

Place crank 2 at 1800
Place crank 3 at 700 from crank 2 in counter-clockwise direction*

21
 * Crank 2 can be placed in any position and crank 3 clockwise or counter
clockwise at 700 from crank 2.

Use the mra values to determine the positions of cranks 4 and 5.

There are two possible positions 4 and 5 and 4 and 5 as can be seen in figure 10.

2
70

4' 140

40
3 2
5'

70

4

6
10

Couples diagram to establish

3
the position of cranks 4 and 5

5
14
4' 2 5' 0

76

18 5
40,6
2
R8

40
5,1
2
85,12
70

70 4
68,64
3
64
R68,

Fig. 10

Consider first the crank 4 and 5 positions.

From figure 11 the angular positions of cranks 4 and 5 are determined.
Use the mr values to determine the mass R1 and the angular position of crank
1 relative to crank 2 (see figure 12).
From the diagram in figure 12 the closing vector 4-5 is 29,95 kgm;

29,95 0,2 R1 ; R1 149,75 kg

22
 Couples diagram to establish
the position of cranks 4 and 5

2 18 0 5
5
14
40,6

R8

76
5,1
2
3 85,12
2
2

40
70

70
68,64

70 4
64
R68,

3 4
3

Fig. 11

"mr" diagram to find the mass R1 and

5 the position of crank 1
71
1
30

2 0
76

33
33

1
29
2 5
40

3
30,4
70

31,2
70 4 4

3
All cranks rotated to bring crank 1
All cranks rotated by 570 to bring crank 1
in horizontal position
in vertical position (line of stroke)
1 5

73 76
71 2
71

5 4
1
70
70
76

73

3 70
70
2 3
4
Fig. 12

23
 Consider the 4 and 5 cranks:

R8
5,1
2
Couples diagram to establish
the position of cranks 4' and 5'

4' 85,12 4'

5' 140

2 18 0
68

40
,64 40,6
2
5'

70
3

4

6
R68,64 10

2 30 0
4' 30,4 1
33,66
19
5'
31,2 29
3

The vector 51 is 33,66 kgm 33,66 0,2 R1 ; R1 168,3 kg

The preferred position are cranks 4 and 5 as cranks 4 and 5 need a higher value for the
mass R1.
To obtain any value for primary forces and couples, the values read from the diagrams
must be multiplied by 2 and for secondary forced and couples by 2/n.

N.B.
Inertia force m f
f 2 r
Inertia force m 2 r m r 2

Inertia couple Inertia force a m r 2 a m r a 2

24
Annexure

Differences between 2 stoke and 4 stroke engines

2 stoke engines used in scooters and 4 stroke engine used in cars, buses,
motorcycles trucks
It has one power stroke for each revolution It has one power stroke for every two
of the crankshaft revolutions of the crankshaft
Less thermal efficiency More thermal efficiency
It consumes more lubricating oil It consumes less lubricating oil
Lighter flywheel is required and engine Heavy flywheel is required and engine runs
runs balanced because turning moment is unbalanced because turning moment on the
more even due to one power stroke for each crankshaft is not even due to one power
revolution of the crankshaft stroke for every two revolutions of the
crankshaft
More wear and tear of moving parts Less wear and tear of moving parts
Engine consists of inlet and exhaust ports Engine consists of inlet and exhaust valve.
More noise is created by engine Less noise is created by engine
Simple lubricating system Complicated lubricating system
Engine requires less space Engine requires more space
More fuel consumption and fresh charge is Less fuel consumption and complete
mixed with exhaust gases burning of fuel
Engine is air cooled Engine is water cooled
Engine runs hotter Engine runs cooler
Less output due to mixing of fresh charge More output due to full fresh charge intake
with the hot burnt gases and full burnt gases exhaust
More mechanical efficiency due to less Less mechanical efficiency due to more
friction on a few parts friction on many parts
Less cost than 4 stroke More costly
Engine is light Engine is heavy
Engine design is simple due to absence of Engine design is complicated due to valve
valve mechanism mechanism

25