Rotor Speed Research Articles

Demodulation algorithm of low coherent heterodyne interference signal for axial clearance measurement of rotating machinery

The time-domain low coherent heterodyne interference axial clearance measurement method has the challenges of small range and low precision in the clearance measurement of rotating machinery. An axial clearance demodulation algorithm based on the windowed power spectrum density transform (WPSD) is proposed. Based on the characteristics of low coherent heterodyne interference signal, the relationship model between window width and rotating structure motion parameters (amplitude of axial clearance change, rotor speed) is constructed, and the optimal window width mathematical model is obtained. The axial clearance measurement experiments are completed under different axial clearance measurement distances based on an experimental clearance platform, different rotor speeds and different axial clearance variation amplitudes. The experimental results show that the absolute error of the axial clearance reconstruction signal is less than 17 μm and the relative error is less than 4.8 % when the axial clearance measurement distance is 2.1 mm ∼ 11.3 mm, the rotor speed is in the range of 6000 rad/min ∼ 12000 rad/min, and the variation of axial clearance is in the range of 150 μm ∼ 350 μm. The experimental and simulation results are basically consistent.

Modeling the critical rotation speed of a bladed rotor with bent blades in a circulation mixer of feed mixtures

The purpose of the research is to substantiate the critical rotation speed of a rotor with bent blades based on force analysis and modeling the movement of mixture particles in a horizontal loader of a circulation mixer. The research method[1]ology included the substantiation of the highest rotation frequency of the loader blade rotor based on a force analysis of moving particles of forces when they were moved by the bent blades of the loader and compliance with the conditions for the entry of flying particles into the tray. The numerical analysis performed on the basis of the obtained expressions using the Mathcad mathematical package made it possible to establish the critical values of the rotation speed of the rotor-loader with bent blades based on the condition of the material coming off the blade and the condition of the flight of particles from the blade into the receiving tray. With radial blades, the limitation is the entry of particles into the receiving tray at a critical frequency of 43 min-1 , then for a blade bend of 30° – about 60 min-1 , for a blade bend of 45° – about 70 min-1, for a blade bend of 60° – about 80 min-1. The lowest critical values of the rotor-loader rotation frequency from the condition of particle movement along the blade correspond to the blade bend angle of 27–60° and are determined by the friction coefficient of the material, amounting to 83–78 min-1. With an increase in material friction, the critical values of the rotor rotation speed from the condition of material coming off the blade decrease slightly, and the bend angle for the rotation speed extremum increases. The highest rotation speed of the rotor - loader with a radius of 0.12 m is limited to 78 min-1 at a blade bending angle of the order of 30–60°, determined by the friction of the material on the blade.

A LESO Based Backstepping Controller Considering Coal Seam Hardness for Rotary Speed in Coal Mine Tunnel Drilling Process

A LESO Based Backstepping Controller Considering Coal Seam Hardness for Rotary Speed in Coal Mine Tunnel Drilling Process

Data-driven control of wind turbine under online power strategy via deep learning and reinforcement learning

This study proposes a data-driven wind turbine (WT) model predictive control (MPC) enhanced by a deep-learning (DL) radial basis function network (RBFN) and a reinforcement-learning (RL) deep Q-learning network (DQN). The RBFN provides comprehensive aerodynamic predictions, including thrust, torque, and power. Besides, the MPC linearization relies on the RBFN prediction to estimate force sensitivities. The DQN achieves an online power strategy (OPS) that solves the 2-degree-of-freedom (2-DOF) optimization of rotor speed and pitch angle, which can actively adjust power capture to meet different power requirements. The DQN adopts a novel bisection algorithm with a first-in-first-out (FIFO) queue for high-precision 2-DOF results. The MPC coordinates the permanent magnet synchronous generator (PMSG) and pitch servo, considering shaft rotation and tower movement. Compared with the maximum power point tracking (MPPT) and power reference point tracking (PRPT) based controls, the proposed RBFN-DQN-MPC reduces power fluctuation and ensures constant output. This study also compares the DQN with the categorical DQN (C51), which indicates that the DQN is more effective in the 2-DOF optimization. Hence, WTs enhanced by the DL-RL-MPC are intelligent and reliable for flexible wind generation.

Research of Bubble Breakup and Influencing Factors in Flotation Machine

As the core factor of flotation, bubbles have an important effect on flotation. The rotor speed, initial gas parameters and impeller structure of the flotation machine will affect the formation and movement of bubbles. It is very important to study the influence mechanism of operating parameters of flotation machine on the bubble breakup process for flotation machine design and structure optimization. This paper takes KYF-0.2m<sup>3</sup> flotation machine as the research object, establishes a single bubble analysis model, adopts the VOF (Volume of Fluid) method to analyze the influence of different initial positions of bubbles on the bubble breakup behavior, and studies the influence of impeller speed and initial position of bubbles on the bubble breakup. Result show that the breakup of bubbles mainly occurs near the stator region. With the increase of rotational speed of the impeller, the centrifugal force and the disturbance of the convection field will become greater, the time of the bubble breakup become shorter, more bubbles breakup and generate more smaller ones. With the bubble position is closer to the rotating axis of the impeller, the impact of reflow becomes stronger and the bubble breakup effect will be better, and if the bubble initial position closer to the impeller cover, the influence of impeller on the bubbles become greater and the distribution of bubbles will be more uniform.

Innovative centrifugal airflow upgrading for coal gasification fine slag based on experiment and CFD-DEM approach

In this work, an innovative process combining centrifugal airflow upgrading and sieving was proposed to achieve enrichment of residual carbon. The separation mechanism and macroscopic flow behavior in centrifugal air classifier were explained and predicted by constructing a coupled CFD-DEM model considering particle contact parameters. Compared the grinding, dry sieving pre-treatment had a better promotion effect on the enrichment of residual carbon. The general flow pattern was composed of an upward swirling flow and a horizontal rotation flow, facilitating dispersion and secondary elution of carbon. However, the tangential inlet and horizontally mounted rotor cage were the main cause of secondary vortex formation, leading to severe particle entrainment. Increasing inlet gas velocity at appropriate rotor speed was conducive to obtaining higher carbon content and carbon yield. By regulating the inlet gas velocity and rotor speed, higher carbon content and yield could be achieved at particle size fractions of 78–160 μm.

Research on an inlet-engine hybrid integrated modelling method with pressure dynamic self-tuning

With aircraft flying faster and higher, the interaction between the inlet and engine cannot be ignored. The inlet engine integration characteristics must be considered in engine design and performance evaluation. The total pressure between the inlet and compressor is a critical parameter that directly affects the accuracy of engine performance evaluation. The traditional solution to inlet-engine integrated modelling is to add an external balance equation to the component-level model (CLM), which may reduce real-time performance. In this study, an inlet-engine hybrid integrated modelling (IEHIM) method is proposed to solve this problem, which combines the advantages of the volume effect model and the CLM method. The proposed IEHIM method consists of an engine model, characteristics of the inlet component, and a pressure dynamic self-tuning (PDST) algorithm. The PDST algorithm coefficients were optimised to enhance the performance of the IEHIM method. Finally, the effectiveness of the IEHIM was verified through simulations and ground experiments. The method was also verified on an actual controller (operating frequency: 132 MHz), which exhibited a mass-flow matching error below 0.2 % and an average time consumption of 5.191 ms in each control cycle. The results were also compared with the actual experimental data, where the errors in the compressor entry total pressure and rotor speed were below 1.1520 % and 1.2195 %, respectively.

Effect of melt‐processing conditions on the electrical conductivity and microwave absorbing properties of composites based on clean scrap poly(vinylidene fluoride/ethylene vinyl acetate copolymer and graphene nanoplatelets

AbstractClean scrap polyvinylidene fluoride (rPVDF) from industrial reject was compounded with ethylene vinyl acetate (EVA) copolymer and graphene nanoplatelets (GNP) to produce low cost and scalable conductive composites. The effect of the melt processing conditions (temperature, time, and rotor speed) on the electrical conductivity and microwave absorbing (MWA) properties was investigated. All systems presented co‐continuous morphology indicated by scanning electron microscopy (SEM) and selective extraction experiments. The preferential localization of GNP in the EVA phase was evidenced by selective extraction and thermogravimetric analysis (TGA). Higher conductivity value was observed for the composite processed at 210°C for 3 min at a rotor speed of 200 rpm. The MWA performance of monolayer and bilayer composite structures with 2 mm thickness was investigated in terms of minimum reflection loss (RL) and effective absorption bandwidth (EAB). The bilayer system provided the best MWA response with RL = − 43.1 dB (>99.99% of EM attenuation) when prepared at 190°C for 3 min at a rotor speed of 200 rpm. The ecological and environmental importance of finding new applications for plastic waste, and the low cost of the materials and processing make this composite an interesting candidate for MWA purpose.Highlights Promising application of clean scrap polyvinylidene fluoride (PVDF) in microwave absorbing materials; Conductivity and absorbing performance are affected by processing conditions; Co‐continuous structure of rPVDF/EVA blend influenced by graphene nanoplatelets (GNP); Selective localization of GNP in EVA phase; Outstanding microwave absorption properties achieved with bi‐layer structure.

Drilling performance analysis of a polycrystalline diamond compact bit via finite element and experimental investigations

The significance of improving the drilling productivity and reducing the cost and non-productive time of drilling process, substantially relies on the efficiency of drilling performance. This paper provides a comprehensive understanding of drilling process, aiming to predict drilling performance and investigate drilling parameters using a validated finite element (FE) model. Experimental validation of the FE model was achieved through testing on a laboratory drilling rig, ensuring the accuracy and reliability of the numerical simulations. To accurately capture the nonlinear characteristics of bit-rock interaction, the Riedel–Hiermaier–Thoma model was adopted as a material model, and its parameters were identified through a series of carefully conducted experimental tests. The numerical results obtained from the FE rock failure model during the compressive and tensile tests demonstrated a robust correlation with the experimental data. The verified material model was then employed into another FE drilling model to simulate rock breaking in an actual drilling scenario. This analysis sheds light on the impact of drill-bit interaction with the rock formation, providing valuable insights into its behaviour during drilling operations. The FE drilling model was further utilised in a parametric study to predict the effects of critical drilling parameters, like loading rate and rotary speed, on the weight on the bit, torque on the bit, and rate of penetration. Both the FE drilling and experimental results provided a significant consistency when the drilling parameters were compared, and nonlinear dynamic phenomena, such as stick–slip and bit-bouncing, were observed. By investigating these effects, this study contributes to optimising drilling operations, enabling better control of premature vibrations and enhancing drilling efficiency.

Research on hammering characteristics of hammer mill based on discrete element method

In hammer mill crushing, the speed change of the rotor hammer head will have an effect on the efficiency of crushing, and so on. This paper takes the hammer mill rotor as the research object and carries out a simulation study, establishes the material particle crushing model, and verifies the validity of the model. The discrete element method (DEM) is used to simulate the movement of the material inside the hammer mill after crushing, revealing that the working principle of the hammer mill is based on the form of particle movement, and to study the law of the particle collision fracture bond energy, compressive stress and particle collision impact energy of the hammer mill. Through comparison, the final working condition of the hammer mill is that at the rotor speed of 1600 r min−1, the working efficiency of the whole equipment is the highest.

ОБЕРТАЛЬНИЙ МОМЕНТ БЕЗПАЗОВОГО МОМЕНТНОГО ДВИГУНА З ПОСТІЙНИМИ МАГНІТАМИ ТА МАСИВНИМ МАГНІТОПРОВОДОМ СТАТОРА

The properties of the solid magnetic core of the stator of a slotless torque motor with permanent magnets are considered. It is noted that the solid stator under the conditions of low rotation speed has some advantages over the traditional laminated magnetic circuit. These advantages consist in the cost reduction of the design, its compactness and the low time of production preparation. The mathematical model's assumptions and the input data's limitations are formulated. A model of a static magnetic field with a moving electrically conductive medium is chosen. The two-dimensional model is implemented in the "Magnetic fields" interface of the "COMSOL Multiphysics" software. The maximum torque values were obtained and the optimal number of pole pairs was found. The method of calculating the torque based on eddy current losses in the magnetic medium is used. The decrease in torque with increasing rotor speed is calculated. The correction coefficients of the maximum moment were obtained to correct the results of two-dimensional modelling using a three-dimensional model. References 5, figures 6, tables 1.

Study on the Effect of Thermal Characteristics of Grease-Lubricated High-Speed Silicon Nitride Full Ceramic Ball Bearings in Motorized Spindles

Grease lubrication is cost-effective and low-maintenance for motorized spindles, but standard steel bearings can fail at high speeds. This study focuses on high-speed full ceramic ball bearings lubricated with grease. The coefficient of friction torque in the empirical formula is corrected by establishing the heat generation model of full ceramic ball bearing and combining it with experiments. A simulation model of grease flow is established to study the influence of grease filling amount on grease distribution. The simulation model of the temperature field of a full ceramic ball bearing is established to analyze the influence of rotating speed on bearing heat generation, and experiments verify the calculation results of the theoretical model. The results show that an optimal grease filling amount of 15~25% ensures even distribution without accumulation. Additionally, when the amount of grease is constant, the outer ring temperature increases with higher rotating speeds. The test results show that when the grease filling is 0.9~1.2 g, it accounts for about 9~12% of the volume of the bearing cavity, and the temperature of the outer ring is the lowest. At a rotation speed of 24,000 rpm, the outer ring temperature of the grease-lubricated bearing is 50.1 °C, indicating a reasonable range for use in motorized spindles. It provides a theoretical basis for the optimization design of macro-structural parameters of full ceramic ball bearings in the future, which can minimize heat generation and maximize bearing capacity.

Hydrodynamic performance evaluation of pump-jet propulsion based on the toroidal propeller

Pump jet propulsion (PJP) is a widely used propulsion method for underwater vehicles. Compared with traditional propeller propulsions, it has the characteristics of higher propulsion efficiency, lower noise, and better performance. A novel propeller with annular blades, named as ‘the toroidal propeller’, is designed and discussed with its characteristic parameters. Then the novel propeller is installed to the PJP and Suboff submarine to evaluate its performance with Computational Fluid Dynamics (CFD) simulations. The high-speed range of modified submarine with the toroidal propeller is also predicted and analyzed through propulsion parameters. The results indicate that when the toroidal propeller is applied to the PJP of underwater vehicle, its propulsion efficiency can reach 0.88 at the speed coefficient of 1.2. When the rotator speed is 5000 RPM, the pump jet thruster with toroidal propellers can continue to provide effective thrust, which will easily cause the speed of submarine to exceed 60 kn.

Pitch Actuator Fault-Tolerant Control of Wind Turbines via an L1 Adaptive Sliding Mode Control (SMC) Scheme

Effective fault identification and management are critical for efficient wind turbine operation. This research presents a novel L1 adaptive-SMC system designed to enhance fault tolerance in wind turbines, specifically addressing common issues such as pump wear, hydraulic leakage, and excessive air content in the oil. By combining SMC with L1 adaptive control, the proposed technique effectively controls rotor speed and power, ensuring reliable performance under various conditions. The controller employs an adjustable gain and an integrated sliding surface to maintain robustness. We validate the controller’s performance in the FAST (Fatigue, Aerodynamics, Structures, and Turbulence) simulation environment using a 5-megawatt wind turbine under high wind speeds. Simulation results demonstrate that the proposed L1 adaptive-SMC outperforms traditional adaptive-SMC and adaptive control schemes, particularly in the presence of faults, unknown disturbances, and turbulent wind fields. This research highlights the controller’s potential to significantly improve the reliability and efficiency of wind turbine operations.

Design and Parameter Optimization of a Combined Rotor and Lining Plate Crushing Organic Fertilizer Spreader

To address the inefficient crushing of fertilizer during the mechanized spreading process caused by the caking of high-humidity organic fertilizer, a fertilizer spreader with a combined rotor and lining plate crushing mechanism was proposed in this paper. With the introduction of the basic structure and working principle of the spreader, a particle group model for an organic fertilizer consisting of both caked and bulk fertilizer was built, based on the Hertz–Mindlin model with bonding and the Hertz–Mindlin model with JKR contact, in EDEM to construct an organic fertilizer-crushing-and-spreading model. With the rotor speed, the axial distance of the hammer, and the number of circumferential hammer groups as the experimental factors and the maximum broken bond rate of the caked organic fertilizer and the minimum coefficient of variation of spreading uniformity as the experimental indices, the Box–Behnken test method was employed to establish regression equations for response surface analysis and multi-objective optimization of the test results. The results indicated that, when the rotor speed was 6.47 Hz, the axial distance of the hammer was 90.30 mm, the number of circumferential hammer groups was five, the broken bond rate reached 90.86%, and the coefficient of variation was 21.45%. Verification tests under these conditions showed a broken bond rate of 90.03% and a coefficient of variation of 22.12%, which were consistent with the optimization results. Therefore, our research provides a reference for the structural design of an organic fertilizer spreader and the optimization of its working parameters.

Wind Tunnel Investigation of the Icing of a Drone Rotor in Forward Flight

The Bell Textron APT70 is a UAV concept developed for last mile delivery and other usual applications. It performs vertical takeoff and transition into aircraft mode for forward flight. It includes four rotor each with four rotating blades. A test campaign has been performed to study the effects of ice accretion on rotor performance through a parametric study of different parameters, namely MVD, LWC, rotor speed, and pitch angle. This paper presents the last experimentations of this campaign for the drone rotor operating in forward flight under simulated icing conditions in a refrigerated, closed-loop wind tunnel. Results demonstrated that the different parameters studied greatly impacted the collection efficiency of the blades and thus, the resulting ice accretion. Smaller droplets were more easily influenced by the streamlines around the rotating blades, resulting in less droplets impacting the surface and thus slower ice accumulations. Higher rotation speeds and pitch angles generated more energetic streamlines, which again transported more droplets around the airfoils instead of them impacting on the surface, which also led to slower accumulation. Slower ice accumulation resulted in slower thrust losses, since the loss in performances can be directly linked to the amount of ice accreted. This research has not only allowed the obtainment of very insightful results on the effect of each test parameter on the ice accumulation, but it has also conducted the development of a unique test bench for UAV propellers. The new circular test sections along with the new instrumentation installed in and around the tunnel will allow the laboratory to be able to generate icing on various type of UAV in forward flight under representative atmospheric conditions.

Optimized structure design for binary particle mixing in rotating drums using a combined DEM and gaussian process-based model

Particle mixing is a crucial operation in various industrial production processes. However, phenomena like segregation or local accumulation can arise, especially when particles differ in properties like radius and density. Numerical simulation of particles using Discrete Element Method (DEM) allows for the manipulation of control variables in batches, generating a large amount of data and facilitating quantitative research. In this study, the mixing behaviors of binary particles in rotating drums are systematically investigated. The DEM model is first validated with experimental data and then rotating drums with varying obstacles, rotation speeds, particle radii, and densities are simulated. Moreover, a Gaussian process-based optimization is conducted by correlating Lacey mixing index (MI) and parameterized shape of obstacle to find the optimized mixing condition. Experimental validations are further performed on the optimized condition to verify the design. It is shown that this integrated approach holds significant potential for enhancing the efficiency, effectiveness of industrial mixing processes and the consideration of energy consumption when balancing the mixing efficiency and optimal rotating speed.

Composite failure analysis of an aero-engine inter-shaft bearing inner ring

The inter-shaft bearing is a critical component in dual rotors aero-engine. Due to the complex and severe loads caused by the interactive excitation of HP and LP rotors during operation, the inter-shaft bearing is prone to damage accumulation and failure. Focusing on a typical failure of inter-shaft bearing inner ring fragmentation and cannot be spliced together completely in high thrust-weight ratio turbofan engine, this paper conducted morphological investigation, fractographic analysis, vibration signal processing, finite element numerical simulation, and fully studied the failure mechanism of this failure.The results indicated that: there exists an uncoordinated resonance speed of the HP rotor in close proximity to the operating speed. This puts the rotor in non-synchronous procession state, accompanied by the uncoordinated angular displacement of the inner and outer rings, which resulting in a lager rolling dynamic load in bearing inner ring. This further leads to high tangential impact load at the root fillet of the anti-rotation pin, causing significant stress concentration, and eventually leads to the generation of initial cracks. These cracks persist and propagate into fatigue oblique fracture over time. After oblique fracture, the modal frequencies of the inner ring become more dispersed. Under the rolling dynamic load (traveling wave load), nodal diameter vibration occurs, causing high stress vibration fatigue damage, and ultimately leading to multiple-point simultaneous fragmentation.The investigation suggests that reducing the stress levels at the root fillet of the anti-rotation pin of the inner ring is an effective approach to prevent bearing failure. This can be achieved through two methods: one is optimizing the rotor structure to decrease the rolling dynamic load on the inner ring, the other is eliminating the anti-rotation pin and appropriately reducing the tightening torque of the compression nut and the interference between the bearing inner ring and the HP turbine rear journal.

Numerical investigation into rotating instability and the vortex structure near the tip in a transonic compressor rotor

An unsteady simulation with a full-annular computed domain was conducted to explore the flow unsteadiness near the tip region and the mechanism of rotating instability (RI) in the transonic rotor. The numerical static pressure signals were monitored at the tip region. RI was identified by a frequency hump in the spectrum of the static pressure signal in a small mass flow coefficient with a narrow range of 0.9510–0.9174. The cross-power spectrum of two static pressure signals obtained in adjacent passages showed that the circumferential propagation speed of RI decreased with the decrease in the mass flow coefficient. The relative circumferential propagation speed of RI of the prominent mode order was −0.65 to −0.61 times the rotor speed. Details of the flow field near the tip showed that a new vortex structure was induced by the interaction of the tip leakage vortex and the shock wave, which was called as tip secondary vortex (TSV). The TSV was the key parameter to the formation of RI. The impact of the TSV on the pressure side surface generated a low-pressure area and changed the tip load of the adjacent blade. RI is result of the propagation of the interaction between the TSV and the tip load.

Nonlinear vibrations of variable speed rotating graphene platelets reinforced blades subjected to combined parametric and forced excitation

It is generally acknowledged that the disturbance of rotating speed will cause parametric resonance for blades, and the presence of rotor displacement also can make the blade vibrate transversely. However, the coupled resonance mechanism of blades under the combined action of rotating speed disturbance and rotor displacement is not yet clear. To answer this question, this article investigates the nonlinear coupled resonance behavior of rotating blades in two cases: typical tuned (the frequency ratio of parametric and forced excitations equals 2:1) and frequency ratio detuned. A nonlinear vibration equation for rotating blades is established based on Euler beam theory in conjunction with geometric nonlinearity. The mixing rule and modified Halpin-Tsai model are used to calculate the effective properties of GPLRMF materials. Subsequently, using the method of varying amplitudes (MVA), an approximate analytical solution of the coupled resonance response is derived, the Jacobian matrix is used to determine the stability of non-trivial solutions, and the accuracy of the analytical results is verified with the aid of numerical solutions. Finally, the steady-state response of typical tuned and detuned coupled resonance is analyzed, and the influence mechanism of factors such as excitation amplitude, excitation phase angle and other parameters on coupled resonance is studied in detail. The results indicate that the supercritical coupled resonance curve exhibits double resonance peaks and jumps. Meanwhile, the steady-state response of coupled resonance highly depends on the excitation phase angle.