Rod-fastening Rotor Research Articles

Dynamic model-based intelligent fault diagnosis method for fault detection in a rod fastening rotor

A complete fault sample database is of great significance for the intelligent fault diagnosis method of rod fastening rotor. However, the lack of fault samples makes the fault diagnosis results unbelievable. To solve this issue, the dynamic model-based intelligent fault diagnosis method is established for a rod fastening rotor, and the fault sample database is enriched by numerical simulations. First, the lumped parameter model of the rod fastening rotor system is constructed and further updated using Euclidean Distance between measurement and numerical simulation of the intact system. Second, mathematical models of various fault types are incorporate into the updated model to obtain numerical simulation fault samples. Thirdly, the utilization of numerical simulation fault samples is severed as training data to the artificial intelligence (AI) models and the unknown measurement test samples will be finally classified. In this paper, Support Vector Machine, Random Forest, Bayesian Network and Decision Tree are selected as the typical AI models. Subsequently, the feasibility of classification is validated by the test bench of the rod fastening rotor system, and the problem of insufficient fault samples can be solved.

Effect of relative phase of loose tie rods on nonlinear dynamic behavior of rod-fastening rotor-bearing-seal system

Loosening of multiple tie rods in a circumferential rod-fastening rotor caused by thermal deformation and centrifugal loads is very common in engineering. The relative position of loose tie rods in the circumferential direction will also have an important impact on rotor dynamics. The relevant research has not been done yet. In this paper, a contact model of the rough machined surface is firstly established by combining the probability functions describing rough surfaces and fractal contact theory of asperities, then the contact stiffness model between disks is established based on the contact model. Finally, the dynamic model of the circumferential rod-fastening rotor-bearing-seal system is established and solved. The effect of relative phase of loose tie rods on the nonlinear dynamic characteristics of rod-fastening rotor-bearing-sealing system is studied. It can be concluded that relative phase of the loose tie rod has an important influence on the frequency, bifurcation, and periodic motion of the rotor system. At lower speed, the anisotropy of contact stiffness caused by loose tie rods has little effect on the rotor trajectory, while the generalized bending moment has a greater influence on dynamics of the system. At higher speed, the anisotropy of contact stiffness has a great influence on the axis rail of the rod-fastening rotor.

Simulation data-driven attention fusion network with multi-similarity metric: A single-domain generalization diagnostic method for tie rod bolt loosening of a rod-fastening rotor system

The rod-fastening rotor system is the core rotating component of gas turbines and aero engines. The rod-disk joint structure of the rod-fastening rotor system is subjected to tie rod bolt loosening under complex operating conditions. Because of the uncertainty of fault occurrence, the model must possess diagnostic capability under unseen working conditions. Domain generalization methods are commonly employed to address such problems. They typically utilize multi-condition data or generate data from a single condition to train the model, enabling it to generalize to unknown operating conditions. However, difficulties in collecting complete multi-condition data and limitations in generating data, such as conflicting attributes and limited categories, make it challenging to ensure high-quality data for model training. To address these issues, this paper establishes a dynamic model of the rod-fastening rotor system to obtain high-fidelity simulation fault data, ensuring the physical accuracy, richness, and diversity of the source domain data. Meanwhile, a novel signal-domain generalization method called simulation data-driven attention fusion network with multi-similarity metric is proposed for tie rod bolt loosening in the rod-fastening rotor system. The attention feature fusion strategy is utilized to achieve the comprehensive representation of local and global features efficiently. Moreover, a multi-similarity loss based on deep metric learning is introduced to comprehensively consider the self-similarity and relative similarities between features, enabling class-level optimization of features. The proposed method is validated to have superior diagnostic performance in two cross-domain tasks compared with other methods. The proposed method can provide valuable insights into fault diagnosis in the rod-fastening rotor system.

Dynamic Modeling and Experimental Modal Analysis for the Central Rod-Fastened Rotor With Hirth Couplings Based on Fractal Contact Theory

Abstract The central rod-fastened rotor of gas turbine exhibits pronounced noncontinuous characteristics due to the large number of contact interfaces between the compressor and turbine disks. It is necessary to establish an accurate dynamic modeling method for the central rod-fastened rotor that fully considers the contact surface effect. In this work, the contact behavior of the rough surface is characterized by the fractal theory. The normal and tangential contact stiffness models are developed, and the influence of fractal parameters is discussed. Besides, the finite element model for the central rod-fastened rotor is established by developing an improved contact element considering the equivalent stiffness segment of Hirth couplings. Finally, the proposed model is verified by conducting the modal testing and measuring the first four modes of natural frequencies and modal shapes of the central rod-fastened rotor. The results show that the numerical results are in good agreement with the experimental ones, and the fractal contact model can effectively predict the connection stiffness of Hirth couplings, which in turn improves the simulation accuracy for the modal characteristics of the central rod-fastened rotor and provides a dynamic modeling approach with high efficiency and less computational complexity.

Multi-optimization of rod fastened rotor on the distribution of bending stiffness and unbalance

A rod fastened rotor (RFR), which contains serial disks, rods (or a rod), and a torque tube, is the main form of heavy duty gas turbines and light duty aero engines. The roughness of the interface is the main parameter affecting the bending stiffness of RFR, and the jumpiness of the disks is the intuitive representation of the unbalance of the rotor. In this paper, a multi-optimization algorithm, NSGA-Ⅱ, was used to improve the vibration behavior of the RFR-bearing system. First, the quantitative relation between the bending stiffness of the rotor and the roughness of the interface was set up by combining the Persson contact theory and the Greenwood–Williamson model, and the nondimensional bending stiffness (NS) was proposed as the optimization objective of roughness. Then, the optimization objective of the jumpiness of the disk, (A + B), was rendered based on the minimum unbalance force. Finally, the multi-optimization on the roughness and jumpiness of the RFR was carried out, and the vibration behavior was improved greatly. In addition, this multi-optimization method was applied to a practical RFR, and the experimental results showed that the vibration amplitude was reduced by about 82%. The work in this paper can provide the guidance for vibration reduction of the rotor system.

DDAGCN: an unsupervised cross-domain identification method for tie rod bolt loosening in a rod-fastening rotor system under different working conditions

The cross-domain diagnosis of tie rod bolt loosening is essential for guaranteeing the healthy operation of rod-fastening rotor (RFR) systems. The unsupervised domain adaptation (UDA) method effectively alleviates the impact of domain discrepancy and has been applied for cross-domain diagnosis. Traditional UDA methods mainly focus on the marginal and conditional distributions with fixed weights to adapt the domain distribution discrepancy. However, the fixed distribution combination cannot satisfy the requirement of feature domain alignment under different working conditions, and the relative importance of the two distributions cannot be evaluated quantitatively. This paper proposes an improved dynamic distribution adaptive graph convolutional network (DDAGCN) for the cross-domain diagnosis of tie rod bolt loosening under different working conditions. This method can quantitatively evaluate the relative significance of each distribution in representing the distribution discrepancy. First, it combines the convolutional neural network and the graph convolutional network to extract the features in the graph structure by using the connection relationship between nodes, and realizes the full extraction of neighbourhood information of nodes. Then, the dynamic distribution adaptive alignment strategy is introduced to construct the dynamic linear combination of marginal and conditional distributions, so as to measure the distribution discrepancy between domains. Meanwhile, the domain adversarial module is combined to further reduce the domain gap and finally realize feature alignment. The extracted domain invariant features can effectively enhance the generalization ability and fault identification ability of the model. The case of the public bearing dataset verifies that the effectiveness and generalization ability of the proposed method for cross-domain fault diagnosis under different working conditions is superior to other compared methods. In addition, the identification ability of the proposed method for the degree of tie rod bolt loosening is verified by the self-made bolt loosening dataset of the RFR system.

Task-Generalization-Based Graph Convolutional Network for Fault Diagnosis of Rod-Fastened Rotor System

Task-Generalization-Based Graph Convolutional Network for Fault Diagnosis of Rod-Fastened Rotor System

Dynamic characteristics of a rod-fastening rotor system with tie rod bolt loosening

Dynamic characteristics of a rod-fastening rotor system with tie rod bolt loosening

Numerical and experimental study of the preload induced period-1 and chaotic vibration of a rotor system considering contact effects

Contact effects are one of the primary nonlinear sources of vibrations in the gas turbine rotor systems. Specifically, the nonlinear stiffness between the disk interface from the contact effects has an important influence on the vibration characteristics. In this study, a contact model that accounts for the elastoplastic deformation of asperity is established based on the contact theory. To improve the macroscopic contact model of the bolted structure, we integrate the tested morphology results and modified the skewed distribution function. Subsequently, a dynamic model of the rod fastened rotor-bearing system that incorporates the nonlinear oil film force is established. The influence of the preload on the vibration characteristics of the rotor bearing system is analyzed. The results demonstrate that the improved contact model accurately describes the distribution of asperities on rough surface. The contact effects weaken the rotor lateral stiffness to a certain extent. According to the numerical results and experimental results, it can be found that changes in preload significantly affects the occurrence conditions from periodic vibration to chaotic vibration, a higher preload is conducive to maintaining the stable period-1 motion state at high speed. Additionally, as the preload is decreased, the speed range with obvious periodic-doubling frequencies gradually increases and the amplitude of vibration response decreases. This work provides a practical guidance for the dynamic design and preload adjustment of gas turbine rod-fastened rotor considering contact effects.

Dynamic Characteristics Analysis of a Rod Fastening Rotor System Considering Contact Roughness

A rod fastening rotor is the core component of gas turbines, which affects the working stability and service life of the whole machine. The characterization of the contact mechanism of a joint’s interface is a key problem in dynamic prediction. The aim of this paper is to gain insight into the influence of the joint’s interface on the dynamic characteristics of the rod fastening rotor system. According to the equivalent bending stiffness of the joint’s interface, the natural frequency of the system is obtained by the analytical method, where the normal contact stiffness of the joint’s interface related to the frequency index is established on the theory of fractal contact analysis. After that, the effects of key parameters on the contact stiffness are discussed in detail. Finally, the variations in the vibration frequency are further revealed as well.

Nonlinear dynamic response on multi-fault rod fastening rotor with variable parameters

A multi-fault nonlinear model of rod fastening rotor is proposed considering the structural properties of rod fastening and the integration of multiple factors. The nonlinear analysis is performed to present the nonlinear characteristics of gas turbine rotor system with multi faults. The fault dynamics of rod fastening rotor is exposed for interaction and failure mechanism of multiple faults. The variable parameter analysis reveals the impact of system parameters variation on vibration response in multi-fault rod fastening rotor system. Analysis results reflect that multi faults enhances the nonlinearity of the system and makes dynamic characteristics more complicated. Complex nonlinear characteristics of the dynamical system are presented under different system parameters. The multi-fault nonlinear dynamic model and the nonlinear analysis of variable parameter contribute to the fault identification and stability research in the rod fastening rotor of gas turbine, which will provide the reference for the design and application of rod fastening rotor system.

Study on the bistable vibration behaviour of a rod-fastened rotor-bearing system.

Gas turbine generator sets are widely used in IGCC system, gas-steam combine cycle, distributed energy system et al. for its advantages of low pollution, high efficiency, quick start and stop. The structure of gas turbine rotor can be divided into integral rotor and rod-fastened rotor. Experimental study shows that the vibration signal, especially the displacement signal, of the rod-fastened rotor will increase/decrease greatly in a small interval of rotating speed. The reason for this phenomenon is the unique structure of the rod-fastened rotor, namely the interfaces between discs. In this paper, based on the Lagrange equation, the equation of motion of a rod-fastened rotor-bearing system considering the damping of the contact interface is established. The bistable behaviour and hysteretic cycle, also called the jumping phenomenon in engineering, are revealed. In addition, a test bench of the rod-fastened rotor-bearing system is built. The bistable behaviour and hysteretic cycle are experimentally proven, and the effect of the eccentric distance of the rotor on the bistable behaviour is experimentally explored.

Investigation on dynamic characteristics of a rod fastening rotor-bearing coupling system with fixed-point rubbing

The aim of this paper is to gain insight into the nonlinear vibration feature of a dynamic model of a gas turbine. First, a rod fastening rotor-bearing coupling model with fixed-point rubbing is proposed, where the fractal theory and the finite element method are utilized. For contact analysis, a novel contact force model is introduced in this paper. Meanwhile, the Coulomb model is adopted to expound the friction characteristics. Second, the governing equations of motion of the rotor system are numerically solved, and the nonlinear dynamic characteristics are analyzed in terms of the bifurcation diagram, Poincaré map, and time history. Third, the potential effects provided by contact degree of joint interface, distribution position, and amount of contact layer are discussed in detail. Finally, the contrast analysis between the integral rotor and the rod fastening rotor is conducted under the condition of fixed-point rubbing.

Nonlinear Dynamic Characteristics of Multidisk Rod Fastening Rotor with Axial Unbalance Mass Distribution

During long-term operation, the blades of rod fastening rotor are very prone to fault and may cause uneven axial mass distribution. The dynamic characteristics of a multidisk rod fastening rotor with axial unbalance mass distribution are studied. A four-disk rod fastening rotor model was established by the lumped mass method. The mass unbalance on different disks was used to simulate blade faults in different parts, and nonlinear factors such as oil film force and disk contact effect were considered. The fourth-order Runge-Kutta method was used to solve the model, and the spectrum and axis trajectory curves were obtained. The influence of fault location and rotating speed on rotor dynamic characteristics was analysed when there were blade faults on two disks. The results show that a large, unbalanced mass will bring strong nonlinear characteristics. The rod fastening rotor may be in different motion states at different rotating speeds. When the fault position of two disks changes, the changes of bearing spectrum, axis trajectory, and phase difference have regularity. The results can provide a theoretical basis for condition monitoring and fault diagnosis of rod fastening rotor.

Nonlinear Dynamic Characteristics of Rod Fastening Rotor with Preload Relaxation

Compared to ordinary rotor, rod fastening rotor has the advantages of lighter weight, higher strength and easier installation, so it is widely used in gas turbine. However, in the process of a long-term operation, the rod may be deformed due to the influence of alternating load, high temperature and other uncertain factors. In serious cases, it can even lead to a major accident. The discontinuous characteristic of rod fastening rotor leads to great differences in dynamic characteristics compared to ordinary rotor. Based on the Herz contact theory and GW contact model, the contact effect between two discs was studied, and the relationship among the contact load, the distance between two disks and the equivalent bending stiffness was obtained. Findings show the bending stiffness to decrease nonlinearly with the decrease in contact load. The lumped mass method was used to establish the rotor model. The contact effect was considered and the Runge–Kutta method was used to solve the model. Combined with the bifurcation diagram, time domain diagram and spectrum diagram, the influence of contact stiffness on rotor dynamic characteristics was analyzed. The results show that the dynamic characteristics of the rod fastening rotor are rich due to the influence of nonlinear factors. In the case of uniform relaxation, the contact stiffness has different effects on the response state and frequency doubling amplitude of the system at different speeds, which is mainly related to the motion state of the system. In the case of non-uniform relaxation, the degree of relaxation does not affect the motion state of the system, but only changes the amplitude of vibration. The results provide theoretical support for condition monitoring and fault diagnosis of rod fastening rotor.

Dynamic analysis of composite rod fastening rotor system considering multiple parameter influence

Dynamic performances of composite rod fastening rotor system are analyzed considering the integration of multiple parameters. A dynamic modeling method of multi-disk rod fastening rotor system is proposed based on the composite rotor structure and the influences of multiple parameters. The interaction of system parameters and fault features are revealed in the composite rod fastening rotor system. The dynamic analysis discloses the influence of fault degree and multiple parameters on the nonlinear behaviors. The results show that the dynamic characteristics of the rod fastening rotor system alter under the crack fault. The evolution of nonlinear performances is displayed in the analysis of multiple parameters. The analysis results contribute to the identification of dynamic characteristics for rod fastening rotor system and fault detection of gas turbine rotor system.

Dynamics Investigation on Axial-Groove Gas Bearing-Rotor System with Rod-Fastened Structure

This research report discusses the dynamic behaviors of an axial-groove gas bearings-rotor system with rod-fastened structure. The time-based dependency-compressible Reynolds equation in the gas bearing nonlinear system is solved by the differential transformation method, and the continuous gas film forces of a three-axial-groove gas bearing are obtained. A dynamic mathematical model of the rotor system with rod-fastened structure supported in two- and three-axial-groove gas bearings with eight degrees of freedom is established. The dynamic motion equation of the rod-fastened rotor system is solved by the modified Newmark-β method based on disturbance compensation, which can reduce the computing error and improve computing stability. The dynamic characteristics of the rod-fastened rotor-gas bearing system are analyzed efficiently by the diversiform unbalance responses. The influence of the position angle of the pad on the nonlinear characteristics of the rod-fastened rotor system is also studied.

Nonlinear dynamic response and stability of a rod fastening rotor with internal damping effect

Nonlinear dynamic response and stability of a rod fastening rotor with internal damping effect

Normal fractal contact stiffness model among three disks of rod-fastening rotor system with considering friction and the asperities interaction

PurposeThe purpose of this study is to develop a normal contact stiffness (NCS) model among three disks of the assembled rotor system, which systematically considers the friction coefficient, the asperities interaction and the elastoplastic contact regime.Design/methodology/approachBased on the revised fractal theory, considering the friction effect, the elastoplastic contact regime and the asperities interaction in a simple way, the total NCS among three disks of the rod-fastening rotor bearing system is established. Effects of fractal dimension and roughness, friction coefficient, asperities interaction and material properties on the normal stiffness are investigated by simulations and the relevant comparisons are given for examining the reasonability of the proposed model.FindingsNCS will decrease when asperities interaction and friction are included. As the load increases, the influences of asperities interaction and friction on stiffness become serious. NCS will be enhanced when the elastoplastic regime is considered.Originality/valueA comprehensive NCS model is developed. It provides a theoretical basis for the modeling of the NCS for multi-interfaces.

Establishment of a contact stiffness matrix and its effect on the dynamic behavior of rod-fastening rotor bearing system

Establishment of a contact stiffness matrix and its effect on the dynamic behavior of rod-fastening rotor bearing system