A Novel Blade Vibration Monitoring Experimental System Based on Blade Tip Sensing
(This article belongs to the Section Manufacturing Processes and Systems)
Abstract
:1. Introduction
2. Materials and Methods
2.1. Principle of BTT Measurement
2.2. Identification of Blade Vibration Parameters
3. Design of the Test Rig
- shaft rotation speed that can be smoothly adjusted in the range of 1000–12,000 rpm;
- rapid measurement and adjustment of the alignment of the rotor system;
- easy replacement of different blade disks to carry out different kinds of crack fault experiments.
- probes that can be installed in the continuous 180° range of the casing, and the installation of each probe being achievable;
- at least four nozzles for gas excitation that can be installed uniformly on the casing circumference, the installation of each nozzle being achievable.
4. Data Acquisition System
- The OPR sensor installed near the shaft receives the reflected laser from the shaft at any time. The optical signal is converted into an electrical signal through the photoelectric conversion preamplifier. When the keyway on the shaft passes the sensor, a speed pulse is generated.
- Using the same principle, a blade pulse is generated when a rotating blade passes through the optical probe installed on the casing.
- The speed pulse and blade pulse outputs of the preamplifier are analog signals, which are converted into digital signals by the signal conditioning module.
- Digital signals enter the high-frequency counter, and the arrival time of each pulse is recorded.
- The acquisition card stores the recorded TOAs in the cache of each channel, and then packages and sends them to the upper computer, which converts them into vibration signals.
5. Experimental Investigation
- The blades of the disk were numbered and the specific results of the blades were recorded. A revolution was considered to begin when a keyway on the shaft passed through the OPR sensor and recorded a speed pulse. The first blade passing through the Number1 probe was deemed to be the reference blade, denoted as Blade 1. In this investigation, Blade 3 was selected as the test blade with cracking, shown in Figure 15. The crack was introduced at that location, which was the stress concentration position (refer to Table 1 and Table 4);
- The resonant frequencies in the range of motor speed were determined in advance using the Campbell diagram obtained by FEM analysis. Four nozzles were installed in the circumferential direction of the casing, so that the blades could be excited periodically during rotation to facilitate synchronous resonance;
- The rotational speed was set from 2000 to 5500 rpm to pass through the resonant frequencies of the blade. The acceleration of the speed was set at 0.5 rpm/s, which was slow enough to allow the blade resonance time to be sufficiently long for analysis;
- TOPR and TOAs of each blade tip were recorded by probes near the shaft and probes near the blade tip, respectively. The amplitude, phase, and natural frequency of the blade vibration could be obtained by analyzing the TOAs (discussed in Section 4);
- The experimental BTT tests were repeated six times under the same conditions. The repetition of the experiment was designed to determine the robustness of the selected BTT method.
5.1. FEM Analysis
5.2. BTT Analysis
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Project | Symbol/Unit | Value |
---|---|---|
Number of Blades | Nb | 8 |
Length of Blades | Lb/mm | 48 |
Width of Blades | Hb/mm | 20 |
Thick of Blades | Tb/mm | 1 |
Diameter of Blade Tip | Db/mm | 136 |
Mode | Frequency /Hz | Ration Effctive Mass to Total Mass/% | |||||
---|---|---|---|---|---|---|---|
X | Y | Z | ROT X | ROT Y | ROT Z | ||
1 | 367.9 | 24.15 | 0.02 | 0.00 | 0.01 | 13.11 | 58.85 |
2 | 398.4 | 0.00 | 0.00 | 23.58 | 46.96 | 0.00 | 0.00 |
3 | 865.6 | 0.00 | 0.01 | 0.31 | 0.32 | 6.47 | 0.00 |
4 | 965.3 | 0.14 | 23.50 | 0.00 | 9.18 | 0.08 | 0.22 |
5 | 1495.6 | 0.00 | 0.00 | 9.88 | 5.52 | 0.16 | 0.00 |
Rotation Speed /rpm | Sensor Position | Peak-to-Peak Value /g | Root-Mean-Square Value /g |
---|---|---|---|
2000 | motor output end | 0.43 | 0.0064 |
bearing pedestal | 0.11 | 0.0010 | |
connecting seat of probe | 0.23 | 0.0013 | |
4000 | motor output end | 0.67 | 0.0072 |
bearing pedestal | 0.15 | 0.0005 | |
connecting seat of probe | 0.3 | 0.0010 | |
8000 | motor output end | 1.06 | 0.0650 |
bearing pedestal | 0.37 | 0.0281 | |
connecting seat of probe | 0.64 | 0.0391 |
Project | Symbol/Unit | Value |
---|---|---|
Length of the crack | Lc/mm | 2.2 |
Width of the crack | Hc/mm | 0.5 |
Length of root-to-crack | c/mm | 3.5 |
Material Mark | Density/kgm−3 | Young’s Modulus/GPa | Poisson’s Ratio |
---|---|---|---|
Al 6061 | 2750 | 71 | 0.33 |
Damage Increment | Crack Size/mm | Position/% |
---|---|---|
1 | 2 | 5 |
2 | 4 | 5 |
3 | 8 | 5 |
4 | 2 | 20 |
5 | 4 | 20 |
6 | 8 | 20 |
7 | 2 | 50 |
8 | 4 | 50 |
9 | 8 | 50 |
Damage Increment | Frequency/Hz | ||
---|---|---|---|
Mode 1 | Mode 2 | Mode 3 | |
1 | 332.8 | 1788.7 | 2218.3 |
2 | 322.3 | 1764.8 | 2207 |
3 | 290.4 | 1548 | 2100.5 |
4 | 335.6 | 1797.7 | 2266.4 |
5 | 325.7 | 1775 | 2255 |
6 | 311.2 | 1586.9 | 2210.5 |
7 | 340.5 | 1795.6 | 2249.2 |
8 | 339.2 | 1770.2 | 2134.7 |
9 | 336 | 1589.7 | 1954.8 |
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Li, H.; Tian, S.; Yang, Z. A Novel Blade Vibration Monitoring Experimental System Based on Blade Tip Sensing. Materials 2022, 15, 6987. https://doi.org/10.3390/ma15196987
Li H, Tian S, Yang Z. A Novel Blade Vibration Monitoring Experimental System Based on Blade Tip Sensing. Materials. 2022; 15(19):6987. https://doi.org/10.3390/ma15196987
Chicago/Turabian StyleLi, Haoqi, Shaohua Tian, and Zhibo Yang. 2022. "A Novel Blade Vibration Monitoring Experimental System Based on Blade Tip Sensing" Materials 15, no. 19: 6987. https://doi.org/10.3390/ma15196987
APA StyleLi, H., Tian, S., & Yang, Z. (2022). A Novel Blade Vibration Monitoring Experimental System Based on Blade Tip Sensing. Materials, 15(19), 6987. https://doi.org/10.3390/ma15196987