Modal balancing of flexible rotors with bow and distributed unbalance

Unbalance and bow are found to be one of the most common causes of synchronous machinery vibrations in rotating systems. Concentrated lumped mass models are adopted in most of the finite element approach for modeling unbalances and subsequent balancing in rotating systems. But this assumption may not be appropriate for long slender rotors with unbalances distributed along the length of the rotor. A polynomial curve for eccentricity distribution with finite element modeling is used to identify the distributed unbalance. The unbalance eccentricity distributions are estimated using the measured vibration responses at a speed below the balancing speed. Modal correction mass required to balance a rotor at its first bending critical speed, having both distributed unbalance and bow is computed knowing the amplification factor at critical speed. The rotor is balanced at its first bending critical speed using modal balancing method in a single trial run and using a single balancing plane. The method thus avoids multiple trial runs required for modal balancing of flexible rotors. This method is verified on an experimental rotor having both bow and unbalance. The concept of quantifying the distributed unbalance using ‘Norm’ of eccentricity polynomial function is also introduced for the first time.     

IDENTIFICATION OF SPEED-DEPENDENT BEARING PARAMETERS

Bearing dynamic characteristics have been a major unknown in the modelling and analysis of large turbo-generators. An identification algorithm for bearing dynamic characterization by using unbalance response measurements is developed for multi-degree-of-freedom (m.d.o.f.) flexible rotor-bearing systems. The algorithm identifies the bearing dynamic parameters, consisting of four effective stiffness and four damping coefficients for each bearing, utilizing frequency domain synchronous unbalance response measurements from the accelerometers attached to the bearing housings in the horizontal and vertical directions, for a minimum two different unbalance configurations. The procedure of identifying bearing dynamic coefficients by using the proposed algorithm is presented and demonstrated through a numerical example. Adding noise to the simulated signal checks the robustness of the algorithm against measurement noise. Combinations of regularization and the generalized singular value decomposition (SVD) are used to tackle an ill-posed problem due to the nearly circular orbit of the rotor at the bearings, as a special case for nearly isotropic bearings. It is demonstrated that by measuring noisy bearing responses with the direction of rotation of the rotor both in the clockwise and anticlockwise directions, the bearing estimation problem for circular orbit becomes well-conditioned. The regularization algorithm is tested for an experimental rotor-bearing rig. The response reproduction capabilities are excellent even in the presence of measurement noise.     

Whirl and whip instabilities in rotor-bearing system considering a nonlinear force model

Linear models and synchronous response are generally adequate to describe and analyze rotors supported by hydrodynamic bearings. Hence, stiffness and damping coefficients can provide a good model for a wide range of situations. However, in some cases, this approach does not suffice to describe the dynamic behavior of the rotor-bearing system. Moreover, unstable motion occurs due to precessional orbits in the rotor-bearing system. This instability is called “oil whirl” or “oil whip”. The oil whirl phenomenon occurs when the journal bearings are lightly loaded and the shaft is whirling at a frequency close to one-half of rotor angular speed. When the angular speed of the rotor reaches approximately twice the natural frequency (first critical speed), the oil whip phenomenon occurs and remains even if the rotor angular speed increases. Its frequency and vibration mode correspond to the first critical speed. The main purpose of this paper is to validate a complete nonlinear solution to simulate the fluid-induced instability during run-up and run-down. A flexible rotor with a central disk under unbalanced excitation is modeled. A nonlinear hydrodynamic model is considered for short bearing and laminar flow. The effects of unbalance, journal-bearing parameters and rotor arrangement (vertical or horizontal) on the instability threshold are verified. The model simulations are compared with measurements at a real vertical power plant and a horizontal test rig.     

Study on the structures of fluid flows in the annular space formed by a submerged tilting pad journal bearing

In this study, the Taylor vortices of the film flow in the bearing clearance and so-called cavity flow between pads in a submerged tilting pad journal bearing were visualized by means of a tracer method. The effects of pad arc extent and pad inclination (from leading to trailing edges) on fluid flows, especially on the structures of Taylor vortices and cavity flow were investigated. The critical Taylor number of the film flow increased with an increase in pad inclination slightly. The pitch of array of the Taylor vortex rings at the critical Taylor number was, however, scarcely influenced by the pad inclination. The pitch was likely fixed by the mean clearance over the pad. Two-dimensional cavity flow field (in the central section perpendicular to the rotation axis) between pads was measured by a Particle Image Velocimetry to investigate the interaction of film flow and cavity flow between pads. The Taylor vortices out of the preceding pad were almost carried over the cavity region into succeeding pad, and hardly mixed with the cavity flow. This phenomenon is important in relation to the oil exchange between the film and cavity flows.     

Unified modelling of passive homopolar and heteropolar electrodynamic bearings

A model of passive electrodynamic bearings based on the R–L dynamics of the eddy currents inside a conductor is presented. The model is derived from an analytical solution of the magnetic field in the air region surrounding the rotor for electrodynamic bearings having an even number of magnetic pole pairs. It allows homopolar and heteropolar electrodynamic bearings to be considered in a single unified way that accounts for the electromechanical interactions between the rotating conductor and the magnetic field of the stator. The model of the bearings is then coupled to a Jeffcott rotor model using complex coordinates in a state-space representation, allowing the dynamics of rotors supported by electrodynamic bearings to be studied. The number of magnetic pole pairs is found to influence rotordynamic stability, unbalance responses and frequency responses. The results demonstrate that homopolar electrodynamic bearings have a unique characteristic of passively filtering the transmission of forces due to residual unbalance of the rotor to the machine supports. The models are also used to perform a stability analysis of a case study presented in literature, and results from experimental observation are compared to those obtained analytically.     

Dynamic behavior analysis of cracked rotor

In the present study, the additional slope is used to consider the crack breathing, and is expressed explicitly in the equation of motion as one of the inputs to produce the bending moment at the crack position. Inversely, the additional slope is calculated by integrating on the crack region based on a fracture mechanics concept. The response of a cracked rotor is formulated based on the transfer matrix method. The transient behavior due to the crack breathing is considered by introducing a ‘moving’ Fourier-series expansion concept to the additional slope. The time-varying harmonic components of the additional slope are used to calculate the harmonic responses. The application considered is a general rotor model composed of multiple shafts, disks and cracks, and resilient bearings at both ends. Verification analysis is carried out for a simple rotor model similar to those found in the literature. Using the additional slope, the cracked rotor behavior is explained by the crack depth and rotation speed increase. It is shown that region on the crack front line having the dominant stress intensity factor value moves from the central area to both ends, as the crack depth increases. The result matches well with the crack propagation pattern shown in a bench mark test in the literature. Whirl orbits near the critical and sub-critical speed ranges of the rotor are discussed. It is shown that there exists some speed range near the critical speed, where the temporary whirl direction reversal and phase shift exist. When an unbalance is applied, the peculiar features, such as the whirl direction reversal and phase shift, disappear.     

Rotor drop and following thermal growth simulations using detailed auxiliary bearing and damper models

Catcher bearings (CBs) or auxiliary bearings provide mechanical backup protection in the events of magnetic bearing failure. This paper presents numerical analysis for a rotor drop on CBs and following thermal growths due to their mechanical rub using detailed CB and damper models. The detailed CB model is determined based on its material, geometry, speed and preload using the nonlinear Hertzian load–deflection formula, and the thermal growths of bearing components during the rotor drop are estimated using a 1D thermal model. A finite-element squeeze film damper provides the pressure profile of an annular oil film and the resulting viscous damping force. Numerical simulations of an energy storage flywheel with magnetic suspensions failed reveal that an optimal CB design using the detailed simulation models stabilizes the rotor drop dynamics and lowers the thermal growths while preventing the high-speed backward whirl. Furthermore, CB design guides based on the simulation results are presented.     

磁流变液阻尼器在转子振动控制中的应用

设计了一种转子振动控制用的剪切式磁流变液阻尼器,建立了磁流变液阻尼器－悬臂转子系统的分析模型,理论和实验研究了转子系统的不平衡响应特性。研究表明,随着施加磁场强度的增加,磁流变液阻尼和刚度增大,转子系统的临界振幅明显下降,系统的临界转速也明显提高。通过简单的开关控制,可抑止转子通过临界转速过程中的振动。     

ANALYSIS OF THE MULTIPLE-SOLUTION RESPONSE OF A FLEXIBLE ROTOR SUPPORTED ON NON-LINEAR SQUEEZE FILM DAMPERS

The multiple-solution response of rotors supported on squeeze film dampers is a typical non-linear phenomenon. The behaviour of the multiple-solution response in a flexible rotor supported on two identical squeeze film dampers with centralizing springs is studied by three methods: synchronous circular centred-orbit motion solution, numerical integration method and slow acceleration method using the assumption of a short bearing and cavitated oil film; the differences of computational results obtained by the three different methods are compared in this paper. It is shown that there are three basic forms for the multiple-solution response in the flexible rotor system supported on the squeeze film dampers, which are the resonant, isolated bifurcation and swallowtail bifurcation multiple solutions. In the multiple-solution speed regions, the rotor motion may be subsynchronous, super-subsynchronous, almost-periodic and even chaotic, besides synchronous circular centred, even if the gravity effect is not considered. The assumption of synchronous circular centred-orbit motion for the journal and rotor around the static deflection line can be used only in some special cases; the steady state numerical integration method is very useful, but time consuming. Using the slow acceleration method, not only can the multiple-solution speed regions be detected, but also the non-synchronous response regions.     

Swept sine testing of rotor-bearing system for damping estimation

Many types of rotating components commonly operate above the first or second critical speed and they are subjected to run-ups and shutdowns frequently. The present study focuses on developing FRF of rotor bearing systems for damping estimation from swept-sine excitation. The principle of active vibration control states that with increase in angular acceleration, the amplitude of vibration due to unbalance will reduce and the FRF envelope will shift towards the right (or higher frequency). The frequency response function (FRF) estimated by tracking filters or Co-Quad analyzers was proved to induce an error into the FRF estimate. Using Fast Fourier Transform (FFT) algorithm and stationary wavelet transform (SWT) decomposition FRF distortion can be reduced. To obtain a theoretical clarity, the shifting of FRF envelope phenomenon is incorporated into conventional FRF expressions and validation is performed with the FRF estimated using the Fourier Transform approach. The half-power bandwidth method is employed to extract damping ratios from the FRF estimates. While deriving half-power points for both types of responses (acceleration and displacement), damping ratio (ζ) is estimated with different approximations like classical definition (neglecting damping ratio of order higher than 2), third order (neglecting damping ratios with order higher than 4) and exact (no assumptions on damping ratio). The use of stationary wavelet transform to denoise the noise corrupted FRF data is explained. Finally, experiments are performed on a test rotor excited with different sweep rates to estimate the damping ratio.     

Vibration quenching in a large scale rotor-bearing system using journal bearings with variable geometry

In large scale rotating machinery the resonance amplitude during the passage through resonance is a matter of consideration because of its influence in the surrounding environment of the rotational system and foundation. In this paper, a variable geometry journal bearing (VGJB), recently patented, is applied for the mounting of a large scale rotor bearing system operating at the range of medium speed. The simulation of the rotor-bearing system incorporates a recent method for simulation of a multi-segment continuous rotor in combination with nonlinear bearing forces. The use of the current bearing gives results that encourage the use of such a bearing in rotating machinery since the vibration amplitude during the passage through the critical speed can be reduced up to 60–70%. In the presented study, the developed amplitude and the rotor stresses are severely reduced compared to those of the system with normal cylindrical journal bearings during a virtual start up of the system.     

Nonlinear dynamics of a support-excited flexible rotor with hydrodynamic journal bearings

The major purpose of this study is to predict the dynamic behavior of an on-board rotor mounted on hydrodynamic journal bearings in the presence of rigid support movements, the target application being turbochargers of vehicles or rotating machines subject to seismic excitation. The proposed on-board rotor model is based on Timoshenko beam finite elements. The dynamic modeling takes into account the geometric asymmetry of shaft and/or rigid disk as well as the six deterministic translations and rotations of the rotor rigid support. Depending on the type of analysis used for the bearing, the fluid film forces computed with the Reynolds equation are linear/nonlinear. Thus the application of Lagrange's equations yields the linear/nonlinear equations of motion of the rotating rotor in bending with respect to the moving rigid support which represents a non-inertial frame of reference. These equations are solved using the implicit Newmark time-step integration scheme. Due to the geometric asymmetry of the rotor and to the rotational motions of the support, the equations of motion include time-varying parametric terms which can lead to lateral dynamic instability. The influence of sinusoidal rotational or translational motions of the support, the accuracy of the linear 8-coefficient bearing model and the interest of the nonlinear model for a hydrodynamic journal bearing are examined and discussed by means of stability charts, orbits of the rotor, time history responses, fast Fourier transforms, bifurcation diagrams as well as Poincaré maps.     

Linear parameter varying control design for rotating systems supported by journal bearings

Linear parameter varying (LPV) control is a model-based control technique that takes into account time-varying parameters of the plant. In the case of rotating systems supported by lubricated bearings, the dynamic characteristics of the bearings change in time as a function of the rotating speed. Hence, LPV control can tackle the problem of run-up and run-down operational conditions when dynamic characteristics of the rotating system change significantly in time due to the bearings and high vibration levels occur. In this work, the LPV control design for a flexible shaft supported by plain journal bearings is presented. The model used in the LPV control design is updated from unbalance response experimental results and dynamic coefficients for the entire range of rotating speeds are obtained by numerical optimization. Experimental implementation of the designed LPV control resulted in strong reduction of vibration amplitudes when crossing the critical speed, without affecting system behavior in sub- or super-critical speeds.     

Balancing of machinery with a flexible variable-speed rotor

The balancing procedure of machines composed of a flexible rotating part (rotor) and a non-rotating part (stator) mounted on suspensions is presented. The rotating part runs at a variable speed of rotation and is mounted on bearings with variable-speed-dependent characteristics. Assuming that the unbalance masses are relatively well defined, such as in the case of a crank-shaft, the procedure is based on a numerical approach using rotordynamics theory coupled with the Finite Element and Influence Coefficient Methods. An academic rotor/stator model illustrates the procedure. Moreover, the industrial application concerns a refrigerant rotary compressor whose experimental investigation permits validating the model. Assuming that the balancing planes are located on the rotor, it is shown that reducing the vibration level of both rotor and stator requires a balancing procedure using target planes on the rotor and on the stator. In the case of the rotary compressor, this avoids rotor-to-stator rubs and minimizes vibration transmission through pipes and grommets.     

Theoretical and experimental research on a disk-type non-contact ultrasonic motor

We developed a disk-type non-contact ultrasonic motor based on B22 vibration mode. The rotors of SU-8 photoresist are fabricated by the UV-LIGA process to control their shapes and thicknesses. So the structures of them are optimized by the experiments. It is found that the revolution speed of disk-type non-contact ultrasonic motor not only depends on the vibration amplitude of the stator, but also the weight and construction of the rotors. The maximum revolution speed of the optimal rotor is 3569 rpm at the input voltage of 20 V and the driving frequency of 45.6 kHz. The exciting principle of traveling wave is presented with theoretical equations. The electric signals applied to the piezoelectric ceramic are designed by the principle. The natural frequency and corresponding vibration mode are calculated and analyzed using finite element method. It is shown that experimental results are in good agreement with simulation, which verifies the effectiveness of the finite element model. Moreover, the levitation distance between the stator and rotor is measured by a CCD laser displacement transducer.     

Rolling bearing vibrations—The effects of geometrical imperfections and wear

The geometrical shape and surface properties of the components of rolling bearings will always deviate to some extent from their theoretical design. For bearings of standard tolerances these deviations are large enough to cause measurable levels of vibrations when the bearing is in operation. The purpose of this paper is to show in some detail how these surface irregularities are related to the vibration characteristics of the bearing. The study is restricted to radial bearings, having a radial load and a positive clearance. The approximate methods used render the results useful mainly for lightly loaded bearings operating at low and moderate speeds. Attention has been focused on the effects of inner ring waviness and non-uniform diameters of the rolling elements. A mixed theoretical and experimental impedance approach has been used to treat the bearing when fitted in a simple machine structure, thereby showing how resulting vibrations of the bearing pedestal can be calculated, with account taken of the effects of bearing, rotor and foundation properties. During operation bearings undergo progressive surface and subsurface deterioration. These alterations of geometrical and surface properties of bearing components will always be accompanied by some degree of change of the vibrations characteristics of the bearing. Two common modes of surface deterioration—spalling fatigue and abrasive wear—have been studied, the practical objective being to highlight some possible methods of condition monitoring and prediction of impending bearing failure.     

Non-linear dynamics of flexible multi-bearing rotors

A general analysis has been developed to computer simulate steady state and transient vibration phenomena of complex rotor-bearing-support systems. A central feature of this analysis is a proper handling of various highly non-linear effects (most notably journal bearings) which dominate the dynamic phenoména encountered during large amplitude rotor-bearing vibrations. There are a number of potential causes of large amplitude rotor vibration, such as high rotor imbalance (e.g., loss of turbine blades at running speed), critical speed operation, journal bearing dynamic instability (oil whip), earthquakes, and shock. Failure mode analysis requires the evaluation and understanding of such potentially large dynamic forces and displacements. The paper presents development of the analysis, comparison with experiment and examples of its use in industrial applications.     

Optimum support characteristics for rotor-shaft system with preloaded rolling element bearings

Preloading of rolling element bearings is often used to avoid clearance in the bearings and achieve precise dynamic requirement. Preloading gives rise to an expression of the restoring force, which is a non-linear function of the deformation of the rolling elements. In this paper, frequency-dependent optimum support characteristics have been found out by simultaneously minimizing the unbalance response (UBR) of the rotor and maximizing the stability limit speed (SLS) of a flexible horizontal rotor-shaft system comprising an unsymmetrically placed rotor disc placed on an elastic shaft mounted on preloaded rolling element bearings at the ends supported on viscoelastic polymeric supports. A sensitivity study of the UBR and SLS with respect to the support characteristics has been presented to have an idea about the permissible deviation of the support characteristics from the respective optimum, at any frequency. Thus, the sensitivity study helps the quality control man as well as the manufacturer of such supports to estimate the permissible deviation in the most sensitive frequency zones. The results presented in this work are in terms of non-dimensional parameters of the system and are, therefore, valid for any system under consideration.     

Linear and non-linear control techniques applied to actively lubricated journal bearings

The main objectives of actively lubricated bearings are the simultaneous reduction of wear and vibration between rotating and stationary machinery parts. For reducing wear and dissipating vibration energy until certain limits, one can use the conventional hydrodynamic lubrication. For further reduction of shaft vibrations one can use the active lubrication action, which is based on injecting pressurized oil into the bearing gap through orifices machined in the bearing sliding surface. The design and efficiency of some linear (PD, PI and PID) and a non-linear controller, applied to a tilting-pad journal bearing, are analysed and discussed. Important conclusions about the application of integral controllers, responsible for changing the rotor-bearing equilibrium position and consequently the “passive” oil film damping coefficients, are achieved. Numerical results show an effective vibration reduction of unbalance response of a rigid rotor, where the PD and the non-linear P controllers show better performance for the frequency range of study (0-80 Hz). The feasibility of eliminating rotor-bearing instabilities (phenomena of whirl) by using active lubrication is also investigated, illustrating clearly one of its most promising applications.     

Dynamic behaviours of a full floating ring bearing supported turbocharger rotor with engine excitation

The rotor dynamic behaviour of turbochargers (TC) has been paid significant attention because of its importance in their healthy operation. Commonly, the TC is firmly mounted on engines and they will definitely suffer from the vibrations originated from engines in operation. However, only a limited number of papers have been published with consideration of this phenomenon. In this paper, a finite element model of a TC rotor supported by nonlinear floating ring bearings has been established. The nonlinear bearing forces have been calculated by a newly proposed analytical method. An efficient numerical integration approach has been employed to conduct the investigation including the traditional unbalance and the considered engine excitation effects in question. The results show that the unbalance will place considerable influence on the rotor response at a low working speed. At high speeds, the effect will be prevented by the dominant sub-synchronous vibrations, which also prohibit the appearance of a chaotic state. The novel investigation with the proposed model considering engine excitation reveals that the engine induced vibration will greatly affect the TC rotor response at relatively lower rotor speeds as well. At higher speed range, the dominant effect of sub-synchronous vibrations is still capable of keeping the same orbit shapes as that without engine excitation from a relative viewpoint.