Rotor Structure Research Articles

Multi-Objective Optimization of Three-Stage Turbomachine Rotor Based on Complex Transfer Matrix Method

This study presents the complex transfer matrix method (CTMM) as an advanced mathematical model, providing significant advantages over the finite element method (FEM) by yielding rapid solutions for complex optimization problems. In order to design a more efficient structure of a three-stage turbomachine rotor, we integrated this method with various optimization algorithms, including genetic algorithm (GA), differential evolution (DE), simulated annealing (SA), gravitational search algorithm (GSA), black hole (BH), particle swarm optimization (PSO), Harris hawk optimization (HHO), artificial bee colony (ABC), and non-metaheuristic pattern search (PS). Thus, the best rotor geometry can be obtained fast with minimum bearing forces and disk deflections within design limits. In the results, the efficiency of the CTMM for achieving optimized designs is demonstrated. The CTMM outperformed the FEM in both speed and applicability for complex rotordynamic problems. The CTMM was found to deliver results of comparable quality much faster than the FEM, especially with higher element quality. The use of the CTMM in the iterative optimization process is shown to be highly advantageous. Furthermore, it is noted that among the different optimization algorithms, ABC provided the best results for this multi-objective optimization problem.

A unified Jacobi-Ritz-spectral BEM for vibro-acoustic behavior of spherical shell

In order to solve the vibration and acoustic characteristics of spherical shell in light fluid environment, based on Jacobi-Ritz-spectral BEM, a unified analysis formula for acoustic vibration of spherical shell under arbitrary boundary conditions is established. Based on the First-order shear deformation theory (FSDT) and domain decomposition method (DDM), the theoretical model of spherical shell structure is established. The improved Jacobi polynomial is innovatively used to construct the displacement tolerance function of the spherical shell. Based on the spectral Kirchhoff-Helmholtz integral formula, the theoretical model of the acoustic fluid outside the spherical shell is established. The special form of Jacobi polynomial Chebyshev polynomial is used to describe the excitation sound pressure on the spherical shell segment, so as to ensure that the generalized coordinates of the structure can be perfectly matched with the acoustic boundary element nodes. In addition, the integration along the meridian of the shell is used to control the movement of the fluid, which simplifies the surface integration. The CHIEF method is used to solve the problem of non-unique solution of acoustic variables of rotary structure. Compared with the published literature, numerical simulation results and experimental results, the proposed method has higher calculation accuracy. In addition, based on this method, the influence of boundary conditions, geometric dimensions and other factors on the acoustic and vibration characteristics of spherical shells is discussed, which accumulates data for analyzing the acoustic and vibration behavior of spherical shells.

Analysis of Vibration Characteristics for Rotating Braided Fiber-Reinforced Composite Annular Plates with Perforations

In the current study, a comprehensive numerical model for analyzing the vibrational characteristics of braided fiber-reinforced composite (BFRC) rotating annular plate with perforations under diverse boundary constraints was introduced. This model employs the differential quadrature finite element method (DQFEM), which was developed based on the first-order shear deformation theory (FSDT) and coordinate transformation approach. The BFRC material, specifically a two-dimensional biaxial orthogonal fabric, was utilized to fabricate the annular plate with two distinct types of holes: circular and sector-shaped. The model’s convergence, accuracy, numerical stability, and reliability were confirmed through comparative assessments utilizing data from the literature, from ABAQUS software, and from experimental findings. The analysis focuses on studying the influences of structural properties, material parameters, and boundary restraints on the frequencies of vibration for BFRC rotating annular plates with holes. This theoretical model helps provide scientific basis and technical guidance for the stability and lightweight design of rotating annular plates, such as rotor structures in aircraft engines.

General Analytical Model for Electromagnetic-Thermal Bi- Directional Coupling of IPM Motors in Electric Vehicles Considering Different Rotor Structures

General Analytical Model for Electromagnetic-Thermal Bi- Directional Coupling of IPM Motors in Electric Vehicles Considering Different Rotor Structures

ANCF-based modelling of rigid-flexible coupling of helicopter flexible rotor blades

Abstract A high-precision rotor structure dynamic model applicable to a variety of helicopter blade hub structures is established considering rotor blade flexible deformation. The absolute nodal coordinate method is applied to the traditional rotor blade rigid-flexible coupling dynamics model, making the new model applicable to both fully articulated rotor blades and other advanced blade hub structures. No small-volume assumptions were made in the modelling process. Both Green’s strain expression under finite deformation and the geometrical relation of elastic deformation motion based on the absolute nodal coordinate method are used to derive the blade strain energy, kinetic energy, and the external load virtual work. The rotation angle at the articulation constraint at the root of the blade coupled with the elastic deformation degrees of freedom of the blade in three independent rigid body degrees of freedom, respectively. The rotor blade rigid-flexible coupling dynamics equations were established according to the Hamilton action principle. The time-domain simulation is carried out under a free single pendulum and fixed rotational speed/fixed torque for the established flexible blade model, which verifies the validity and high accuracy of the rigid-flexible coupling articulation model of the flexible rotor blade and the blade hub.

Dynamic Rare-Earth Metal-Organic Frameworks Based on Molecular Rotor Linkers with Efficient Emissions and Ultrasensitive Optical Sensing Performance.

4,4',4″-Triphenylamine tricarboxylate (TPA-COOH) with a distinct molecular rotor structure was reacted with rare-earth (RE) metal ions to obtain seven dynamic RE-based luminescent MOFs (RE-LMOFs) (i.e., emission colors in the blue, yellow-green, red, and near-infrared regions and emission peak wavelengths between 400 and 1600 nm) via the effective transfer of absorbed energy from TPA-COOH to the RE metal ions through the antenna effect. Due to the large energy level difference between RE ions, it was rare in the early days to use the same ligand to construct energy-level matching RE-LMOF homologues with multiple RE metal centers. The uncoordinated oxygen atoms on the molecular rotor linkers in RE-LMOFs provide active sites that can specifically capture highly toxic metal ions and strong oxidative pollutants. The limit of detection (LOD) of RE-LMOF for Al(III) ions is far below the maximum concentration of Al(III) ions in drinking water stipulated by the U.S. Environmental Protection Agency (USEPA) and that for H2O2 is much lower than the H2O2 content in cancer cells, showing excellent application potential for diagnosing early cell cancelation.

The effects of load conditions and structural parameters on fretting wear of annular flat in heavy-duty gas turbine

Heavy-duty gas turbine is the core equipment in energy and electricity systems. In the compressor of a heavy-duty gas turbine, the forces and torques are usually transmitted by the friction force of the annular flat contact interfaces between two adjacent discs. Aimed at the annular flat connection structure of the combined rotor in heavy-duty gas turbine, the distribution of fretting characteristics on the annular flat is analyzed. The wear depth was calculated on the contact interface based on the modified Archard's wear theory and finite element method. On the annular flat, the time-varying distributions of fretting characteristics with the progress of wear are investigated. The increase of fretting cycles increases the wear depth of the annular flat. Moreover, the effects of load conditions and disc geometrical parameters on the fretting characteristics are studied. The increase of tie rod preload force and transmitted torque will intensify the fretting wear on the annular flat. In addition, the decrease of the distance between the tie rod and the annular flat and the decrease of the width of the annular flat will exacerbate the fretting wear on the annular flat. A fretting wear experiment is conducted to verify the finite element model. The experimental results show the fitting curve of wear depth decreases from the inner radius to the outer radius, which aligns with the results obtained from the finite element simulation. Ultimately, the research of this paper will provide a reference for the design and engineering application of the annular flat contact interfaces.

Electromagnetic-thermal-mechanical performance of novel interior permanent magnet motor

To mitigate the challenges of magnetic leakage and iron loss in the rotor of interior permanent magnet (IPM) motors, this article proposes a novel rotor structure that eliminates the bilateral bridge, relying solely on a central bridge to maintain rotor strength. This design reduces the overall bridge width of the rotor, thereby decreasing magnetic leakage and improving torque. The novel rotor features a distinctive design that combines high silicon steel sheets and low silicon steel sheets. High silicon steel sheets are used on the rotor's surface to minimize iron loss, while low silicon steel sheets are used internally to ensure rotor strength. This design takes advantage of the high silicon steel's low iron loss while mitigating its brittleness and saturation issues. The article describes the method for producing this combined rotor. Mechanical and electromagnetic property tests are conducted on both high and low silicon steel sheets, resulting in stress-strain curves, B-H curves, and iron loss characteristics. Finally, the rotor stress is calculated. The analysis indicates that this novel motor can reduce magnetic leakage, increase torque by 7.5 %, improve efficiency by 0.18 %, decrease rotor iron loss by 36.2 %, and lower rotor temperature by 3.9 % compared to the original motor.

Wake Structures and Performance of Wind Turbine Rotor With Harmonic Surging Motions Under Laminar and Turbulent Inflows

ABSTRACTThis study presents a comprehensive numerical analysis of a full‐scale horizontal‐axis floating offshore wind turbine (FOWT) rotor subjected to harmonic surging motions under both laminar and turbulent inflow conditions. Utilizing high‐fidelity computational fluid dynamics (CFD) simulations, namely, large eddy simulation (LES) with actuator line model (ALM), this research investigates the rotor performance, wake characteristics, and wake structures of a surging FOWT in detail. The study delves into the influence of varying inflow turbulence intensities, surging settings, and their interplay on the aerodynamic performance and the wake aerodynamics of a FOWT rotor. The results show that, through employing the phase‐averaging technique, surge‐induced periodic coherent structures (SIPeCS) can be identified in the wake of all the surging cases studied, irrespective of the inflow conditions and the surging settings. Additionally, the findings show that the faster wake recovery observed in the surging cases is not caused by enhancing the instability‐induced turbulence level, a previously accepted hypothesis. Instead, the results indicate that it is due to the enhanced advection process resulting from the induction fields of SIPeCS that causes the wake to recover faster. The analysis of rotor performance shows that the time‐averaged rotor performances are affected by the intricate aerodynamics arising from the surging motions. With certain surging settings, the time‐averaged thrust and the time‐averaged power of a surging rotor are found to be simultaneously lower and higher compared with those of a fixed rotor. Furthermore, the study underscores the importance of considering both the magnitude of surging and the rate of surging simultaneously to fully characterize the hysteresis load on a surging rotor.

An improved finite set model predictive control of SRM drive based on a voltage vectors strategy for low torque ripple

The robust rotor structure and fault-tolerance characteristics of the Switched Reluctance Motors (SRMs) are the best choice for next-generation Electric Vehicle (EV) applications. This machine has few restraints like high torque and flux ripples. However, the existing Model Predictive Control (MPC) using multiple control objectives and maximum sectors in the switching table results in high torque ripples due to the improper sector partition, Voltage Vectors (VVs) and weight factor (K1) selection. This paper proposes a Finite Set-Model Predictive Control (FS-MPC) for an analytical model of a non-linearity SRM machine to analyze the torque ripple performance. The proposed VVs are derived using sector partition based on the rotor position. The control is designed as a single cost function with the weighting factor contributing to smooth torque by selecting optimal control signals. Simulation studies and experiments with a four-phase 8/6 SRM drive verifies the enhanced FS-MPC for real-time implementation. The dynamic speed and ripple values of SRM Drives are measured using a mixed signal oscilloscope and the sensor probes. The laboratory outcomes calculate the analytical equations to validate the findings. The calculated value of torque ripple is 9 % through this FS-MPC. The study reveals that the proposed method is well suited for torque ripple reduction than flux ripples.

A Fluorogenic Chemogenetic pH Sensor for Imaging Protein Exocytosis.

Fluorescent protein-based pH biosensors enable the tracking of pH changes during protein trafficking and, in particular, exocytosis. The recent development of chemogenetic reporters combining synthetic fluorophores with self-labeling protein tags offers a versatile alternative to fluorescent proteins that combines the diversity of chemical probes and indicators with the selectivity of the genetic encoding. However, this hybrid protein labeling strategy does not avoid common drawbacks of organic fluorophores such as the risk of off-target signal due to unbound molecules. Here, we describe a novel fluorogenic and chemogenetic pH sensor based on a cell-permeable molecular pH indicator called pHluo-Halo-1, whose fluorescence can be locally activated in cells by reaction with HaloTag, ensuring excellent signal selectivity in wash-free imaging experiments. pHluo-Halo-1 was selected out of a series of four fluorogenic molecular rotor structures based on protein chromophore analogues. It displays good pH sensitivity with a pKa of 6.3 well-suited to monitor pH variations during exocytosis and an excellent labeling selectivity in cells. It was applied to follow the secretion of CD63-HaloTag fusion proteins using TIRF microscopy. We anticipate that this strategy based on the combination of a tunable and chemically accessible fluorogenic probe with a well-established protein tag will open new possibilities for the development of versatile alternatives to fluorescent proteins for elucidating the dynamics and regulatory mechanisms of proteins in living cells.

PMSM Design for Elevators: Determination of the Basic Topology Affecting Performance

In recent years, with the increase in high-rise building construction, there has been a rise in demand for elevators. This demand has spurred mutual growth between the vertical transportation sector and high-rise building construction. Both sectors are improving technology, security, and comfort standards. Traditional elevator traction machines typically employ asynchronous motors coupled with geared reducers, despite their low energy efficiency and requirement for large machine rooms. However, with the proliferation of rare-earth magnet materials and advancements in driver technologies, the use of Permanent Magnet Synchronous Motors (PMSMs) in elevator traction machines has increased. PMSMs operate with direct drive, eliminating the need for reducers. High efficiency and passenger comfort are crucial parameters for elevator traction machines. This study focuses on identifying the fundamental topology that could influence the performance of PMSMs for gearless elevator machines. Factors such as stator materials, rotor structures, permanent magnets, winding configurations, slot/pole combinations, cogging torque and torque ripple have been examined to select suitable design topologies for elevator motors. Important topics such as the magnetic properties of grain-oriented silicon steel sheets used in stator construction, B-H curves, lamination forming and stacking factors have been addressed. Two different rotor topologies and magnet arrangements, namely internal and external, have been investigated in PMSM designs. Additionally, the use of four different magnet materials, namely AlNiCo, Ferrite, NdFeB, and SmCo have been compared for PMSM traction motors in elevators. Single-layer and double-layer winding configurations, distributed and concentrated winding configurations have been compared. Fractional slot/pole combinations, which directly affect the performance and comfort of PMSMs, have also been examined based on information obtained from the literature. Particularly, structures with high winding factors, such as 12/10, 12/14, 18/16, 18/20, 24/22, and 24/26 have been identified. Finally, studies on skewing to reduce cogging torque and torque ripple have been addressed.

Solar photovoltaic fed synchronous reluctance motor with optimized rotor flux barriers: Design and performance optimization

This paper focuses on enhancing the design of a synchronous reluctance motor (SyRM) specifically tailored for solar photovoltaic (PV) water pumping applications. With growing adoption of green technologies and renewable energy sources, particularly solar power, there is a need to boost the motor's efficiency to meet the demands of such applications. Utilizing renewable energy for water pumping offers significant advantages in terms of sustainability, scalability, and environmentally friendly energy generation. Achieving optimal efficiency and reliability is paramount, as it reduces overall system cost and enhances reliability. SyRM design methodology in this study integrates both analytical and finite element (FE) procedures. Unlike other motor types, the rotor structure of the SyRM does not include any cages, magnets, or windings, resulting in a robust, reliable, and cost-effective manufacturing process. In SyRM, the rotor is constructed solely with barriers, which significantly impact torque shaping, torque ripple content, and power factor. This paper primarily examines the influence of various air-barrier shapes on different motor performance parameters, such as average torque, torque ripple, saturation, cross-section, and saliency ratio. The selected motor configuration for this investigation is a 4-pole, 100 Hz synchronous reluctance motor with 24 stator slots. The accuracy of the FE analysis findings is validated through a prototype of designed SyRM, followed by comprehensive performance evaluations conducted in a controlled laboratory environment. Additionally, this paper addresses an improved control strategy for a SyRM-based photovoltaic (PV) water pumping system. It eliminates the need for a speed controller in the position sensor-less field-oriented control (FOC) of SyRM. The solar water pump drive involves two stages of power conversion.

Optimal Design of an Interior Permanent Magnet Synchronous Motor for Electric Vehicle Applications Using a Machine Learning-Based Surrogate Model

This paper presents an innovative design for an interior permanent magnet synchronous motor (IPMSM), targeting enhanced performance for electric vehicle (EV) applications. The proposed motor features a double V-shaped rotor structure with irregular ferrite magnets embedded in the slots between the permanent magnets. This design significantly enhances torque performance. Furthermore, a machine learning-based surrogate model is developed by integrating fine and coarse mesh data. Optimized using the Non-dominated Sorting Genetic Algorithm II (NSGA-II), this surrogate model effectively reduces computational time compared to traditional finite element analysis (FEA).

Study on the Structural Characteristics of Bulb Tubular Pumps Based on Fluid–Structure Interaction

As a special type of through-flow device, bulb turbine pumps have been widely used in the Eastern Route of the South-to-North Water Diversion Project due to their compact structure, flexible installation process, easy maintenance, high efficiency, and strong adaptability. Therefore, structural improvements to enhance their safety and stability through fluid–structure interaction analysis have significant engineering value. This paper conducts static and transient fluid–structure interaction analyses of the bulb turbine pump structure. The results show that the rotor structure experiences the greatest deformation under low-flow conditions, with maximum deformation (2.13 mm) occurring at the leading edge of the impeller inlet and decreasing radially along a gradient distribution. The damping effect of water changes the mode shapes of the rotor structure, and although the vibration modes under wet conditions are similar to those in the air, the frequencies decrease to varying degrees. In transient analyses under different conditions, the total deformation of the rotor system is greater than in static analyses, showing significant regularity. Under low-flow conditions, the deformation of the pressure surface at the inlet and outlet of the blade tip is greater than that of the suction surface, with a maximum total deformation of 3.656 mm. The maximum total deformation under design flow is 3.337 mm; under high flow, it is 2.646 mm. The total deformation of the casing mainly occurs on both sides of the internal bulb body bottom support, with a maximum deformation of 2.0355 mm and an equivalent stress maximum of 44.848 MPa. The equivalent stress and total deformation distribution of the support structure are similar, located at the top support and trailing edge, with a maximum value of 22.94 MPa at the trailing edge. The research results provide technical references and theoretical foundations for the structural optimization of bulb turbine pumps.

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.

Effects of air gap eccentricity on different rotor structures for PMSM in electric vehicles

In addition to research related to static eccentricity and dynamic eccentricity examining fault and diagnostic methods in various types of motors, there are also studies conducted for motors with non-uniform air gaps similar to the condition. In these studies, improvements and changes in motor performance for such types of motors can be observed. In this study, the effects of the rotor structures determined in the study and the air gap shape, which is effective by changing the eccentricity ratio, on the motor performance of the interior permanent magnet synchronous motor designed for electric vehicle applications are examined. Besides the elliptical rotor structure, which is widely researched in dynamic eccentricity studies, these eccentric motor structures also include novel rectangular and polygonal eccentric rotor structures. Motor models with non-uniform air gap structures are designed in two dimensions and subjected to simulation and analysis studies using the finite element method. At the end of the study, along with the parameters identified for motor performance, the harmonic components of the stator current, radial air gap flux density and the output torque obtained through Fast Fourier Transform analysis have been provided.

Vibration Performance Analysis of a Yokeless Stator Axial Flux PM Motor with Distributed Winding for Electric Vehicle Application

This article presents a detailed analysis of the electromagnetic force and vibration behavior of a new axial flux permanent magnet (AFPM) machine with a yokeless stator and interior PM rotor. Firstly, the configuration of an AFPM machine with a dual rotor and a sandwiched stator is introduced, including the structural design, fixation of the yokeless stator and segmented skew rotor structure. Then, the influence of anisotropic material and a fixed structure on stator modes is analyzed, including elastic modulus, shear model, the skew angle of slot and the thickness of stator yoke. Furthermore, a new non-equally segmented skew rotor structure is proposed and calculated for the reduction in vibration based on the multiphysics model. Three different segmented skew rotor schemes are compared to illustrate the influence of reducing vibration and noise. The predicted results show that the effect of the non-equally segmented skew rotor on reducing vibration is better than the other two schemes. Finally, a 120 kW AFPM motor is experimented with and the result matches well with the predicted data. The vibration performance of the AFPM motor with a dual rotor and sandwiched yokeless stator is revealed comprehensively.

Resonant peak reduction of a rotor system based on gradually variable stiffness of supports with shape memory alloy springs

A novel method for reducing the resonant peak of a flexible rotor at critical speeds based on control of the gradual variable stiffness of supports (GVSS) using shape memory alloy (SMA) springs is presented in this paper. The resonance peaks of a rotor structure can be attenuated through the design of GVSS law. Firstly, the impact of GVSS on the rotor's critical speeds was analyzed, and the mechanical mechanism of vibration reduction based on GVSS was identified. Secondly, a rotor system with a single critical speed was used for simulation analysis and it was founded that the starting time to change support stiffness and the change rate were two critical factors that affect vibration reduction. Then, a further simulation was undertaken on a test rig designed with dynamic similarity of an aeroengine rotor having multiple supports and multiple critical speeds. The range of the variable stiffness with SMA springs’ supports and the control strategy of GVSS were investigated. Afterwards, the test rig was manufactured and assembled for testing and validation. To achieve rapid temperature changes for variation of the support stiffness, an innovative design utilizing the carbon fiber heating tubes and the liquid nitrogen sprays for heating and cooling of shape memory alloy springs was carried out. The test results indicate that using gradually variable stiffness of supports with SMA Springs can effectively reduce the multiple resonance peaks of a rotor, with a maximum suppression rate of 52.3 %. This verifies the feasibility of the method. It also indicates the potential for further engineering applications.

Electromagnetic Optimization of a High-Speed Interior Permanent Magnet Motor Considering Rotor Stress

High-speed interior permanent magnet (IPM) motors require highly reliable rotors. Some measures must be adopted to improve rotor safety, but its electromagnetic performance is seriously affected. It is a challenge to achieve excellent electromagnetic characteristics while satisfying mechanical strength. This paper presents an electromagnetic optimization design of high-speed IPM motors considering rotor stress. Firstly, the permanent magnet (PM) is segmented by adding stiffeners to improve stress distribution. The effects of the bridge and stiffener thickness on the rotor stress and electromagnetic performance are analyzed. Secondly, an electromagnetic optimization model is built based on a three-segment PM rotor structure, aiming for maximum efficiency and minimum rotor core losses. Then, the initial design and optimized scheme are compared, the results show that the efficiency, safety and temperature performance of the motor are improved. Finally, a 140 kW, 18,000 rpm prototype is manufactured and tested. The above analysis provides a valuable reference for the design and widespread application of high-speed IPM motors.