An Unbalance Optimization Method for a Multi-Stage Rotor Based on an Assembly Error Propagation Model

Yue Chen,Xun Sun,Jiwen Cui

doi:10.3390/app11020887

Yue Chen, Xun Sun + Show 1 more

Open Access

https://doi.org/10.3390/app11020887

Copy DOI

Abstract

For the assembly of a multi-stage rotor, such as an aero-engine or gas turbine, the parts need to be assembled optimally to avoid excessive unbalance. We propose a method to optimize the unbalance of a multi-stage rotor during assembly. First, we developed an assembly error propagation model for a multi-stage rotor. The alignment process and distribution of the screw holes of the adjacent rotors was considered for the first time. Secondly, we propose a new assembly datum for unbalance optimization to ensure consistency with the actual conditions of a dynamic balance test. Finally, the unbalance optimization of a multi-stage rotor was achieved using a genetic algorithm, and the corresponding optimal assembly orientations of rotors at different stages were also identified. The results of the simulations showed that the assembly error propagation model had high accuracy and that the genetic optimization process had good convergence. The effect of unbalance optimization was also proven with experiments.

Highlights

Error Propagation Model.The core components of rotating machinery, such as the high-pressure compressor of an aero-engine, are typically assembled by several single-stage rotors [1,2,3]
There is an urgent need for an assembly optimization method that can predict the cumulative error of a multi-stage rotor after assembly and achieve optimal matching of the assembly orientations of rotors at different stages to improve the assembly efficiency and one-time assembly qualified rate of multi-stage rotors
Of the assembly mounting surfaces of rotors at different stages are propagated stage by In Figure 1, the bottom mounting surface of Rotor 1 is used as an XY plane, and the stage continuously, forming assembly cumulative errors

Summary

Introduction

Error Propagation Model.The core components of rotating machinery, such as the high-pressure compressor of an aero-engine, are typically assembled by several single-stage rotors [1,2,3]. The traditional way to eliminate unbalance is to measure the unbalance of the rotor with a dynamic balancing machine and grind the rotor on a pre-set balanced surface [6,7]. This often requires repeated test runs and repairs to ensure the rotor meets the vibration requirements. This method costs time and changes the initial unbalance of the single-stage rotor with the balanced surfaces. There is an urgent need for an assembly optimization method that can predict the cumulative error of a multi-stage rotor after assembly and achieve optimal matching of the assembly orientations of rotors at different stages to improve the assembly efficiency and one-time assembly qualified rate of multi-stage rotors

Methods

Results

Conclusion