Search Results (70)

The global response characteristics of rotor/stator rubbing systems are critical for the optimal design and safe operation of rotating machinery. Based on the mathematical model, numerical simulation and theoretical analysis have been widely carried out to study the regions of different responses, which have not been globally explored and evaluated by experiments with the unified parameters of a mathematical and physical model. Thus, the existence conditions of the global responses of a rubbing rotor are experimentally investigated and then quantitatively compared with theoretical solutions and dynamic simulation results. With the equivalent stiffness and the kinetic dry friction identified by the aid of a new voltage divider, the rubbing rotors are accurately tested by the new experimental technique and dynamically simulated by rigid-flexible coupling technique. From the comparison results of orbit and full spectrum, it is shown that the response characteristics of no rub motion, synchronous full annular rub, partial rub, and dry friction backward whirl obtained by experiment and dynamic simulation are in good agreement with theoretical solutions. Then, it is also concluded that all boundaries of the existence/co-existence regions of the whirling motions are proved to be valid. Moreover, stick-slip oscillation is detected in the rotor/stator testing system. Full article

This work analyzes high-power wind turbines (WTs) from the Oravita region, Romania. These WTs are based on slip ring induction generator with wound rotor and we propose a modified architecture with two power converters on both the stator and on the rotor, functioning at variable wind speeds spanning a large interval. Investigations developed around a realistic WT model with doubly fed induction generator show how WT control enables variable wind speed operations at optimal mechanical angular speed (MAS), guaranteeing maximal power point (MPP), but only up to a critical wind speed value, after which the electrical power must saturate for reliable operation. In this reliable operating region, blade pitch angle control must be enforced. Variable wind speed acts as a time-varying parameter disturbance but also imposes the MPP operation setpoint in one of the two analyzed regions. To achieve null tracking errors, a double integrator must appear within the MAS controller when the wind speed disturbance is realistically modeled as a ramp-like input; however, inspecting the linearized model reveals several difficulties as described in the paper, together with the proposed solution tradeoff. The study developed around the Fuhrlander-FL-MD-70 1.5[MW] WT model shows that several competitive controllers are designed and tested in the identified operating regions of interest, as they validate the reliable and performant functioning specifications. Full article

External-rotor dual-armature flux-switching PM (ER-DA-FSPM) machines have high torque density and decent fault tolerance, making them promising candidates for in-wheel machine applications in electric vehicles. The torque output and optimal design parameters of ER-DA-FSPM machines are affected by the stator/rotor torque ratio, which is the focus of this paper. Firstly, this paper analyzes airgap flux density harmonics of ER-DA-FSPM to provide a clear insight into the torque-generation mechanism. Then, this paper investigates the influence of torque ratio on average torque under the same copper loss. It is found that the average torque decreases with torque ratio increasing due to the reduction of the positive torque component generated by the sixth airgap field harmonics and the rise in the negative torque component from the eighth harmonics. Moreover, this paper also provides the optimal parameter recommendation to guide the machine design. The split ratio should increase, and the arc of PMs should decrease for a larger torque ratio, whilst the other parameters are hardly influenced. Next, this paper makes a comparison among the ER-DA-FSPM machine, external rotor flux-switching PM (ER-FSPM) machine, and surface-mounted PM (ER-SPM) machines. It shows that the ER-DA-FSPM machine, with the torque ratio being 2, can lead to a much larger total torque. In addition, in the event of rotor winding failure, which is more possible due to the existence of slip rings than stator winding failure, the stator can still provide an average torque larger than that of ER-SPM machine and 92.0% that of the ER-FSPM machine, respectively. Finally, the theoretical analysis is verified by the experiments. Full article

In rotating machinery, aerodynamic forces and oil film forces often lead to cross-coupling stiffness. This paper is aimed at studying the stick-slip whirling vibrations induced by the piecewise smooth rotor/stator frictions in a modified flexible rotor subjected to cross-coupling stiffness. Governing equations determining the sliding region and boundaries of piecewise discontinuous friction are defined. This analytical study was conducted to discuss the complex vibrations and bifurcations. Various types of sliding motions (continuous pure rolling, continuous crossing, and grazing–sliding) were observed in this research. Further, as for discussing the impacts of the parameters on nonlinear sliding vibrations, a parametric study was conducted. The obtained results reveal that with an increase in the cross-coupling stiffness coefficient, continuous pure rolling occurs earlier, and the disk vibration time around the contact regime becomes shorter. For studying the self-excited backward whirling vibration of stick–slip nonlinear motions, analytical formulations are established. Detailed vibration amplitude and frequency studies of friction-induced backward whirling vibrations were carried out. Numerical simulations were performed to compare them with the analytical solutions and to validate the results as well. The proposed theory and results provide fresh perspectives for predicting friction-induced whirlings and creating proper designs for turbo machinery. Full article

Integrating wind power generators, whose frequency varies in a wide range due to varying wind speeds, into a grid is a formidable problem. At present, the use of permanent magnet synchronous generators (PMSG) and doubly fed induction generators (DFIG) as wind generators with suitable control is the best possible solution. However, a dual-field excited synchronous generator (DESG), which has two windings on the rotor, can also be used for the same purpose with appropriate control. A new control strategy, which essentially employs the d-axis and q-axis components of the alternator terminal voltage, is suggested here. This strategy essentially results in exciting the two field windings with a slip frequency. This eventually holds the stator frequency constant, irrespective of the rotor speed of the wind generator. The difference between the required frequency and the natural frequency, analogous to the rotor speed of the wind power generator, is the slip frequency. The ring modulator automatically adjusts the slip frequency depending on the actual speed of the generator’s rotor. This paper uses the ANSYS MAXWELL 2022 R1 software to design a DESG and uses a ring modulator as the control function generator for feedback with ANSYS TWIN BUILDER 2022 R1. Simulations are carried out using transient–transient co-simulation by combining both of these software tools for cases of both a constant-speed input and of a variable-speed input to the rotor of the machine. Moreover, a mathematical model of the DESG as a wind generator with the proposed controlled strategy is used to perform the stability analysis of a nine-bus three-machine system, and the results are compared with those of conventional wind generators. Full article

Flexible support cylindrical gas film seals (CGFSs) adapt well to rotor whirling and have a good gas lubrication effect during thermal deformation. However, when a CGFS operates under the “three high” (high interface slip speed, high-pressure differential, and high ambient temperature) operating conditions, the complex deformation of the support structure is a crucial factor affecting the stability of the CGFS. A thorough and systematic analysis of the micro gap flow field characteristics of flexible support CGFSs is a fundamental problem when we study the deformation of the support structure under multiple physical field conditions. This study uses a cylindrical gas film high-speed rotor test rig to study and compare the sealing characteristics of experiments and numerical simulations and then optimizes and verifies the accuracy and effectiveness of the simulation model. A cross-scale gas film grid model is used to analyze the flow field characteristics and seal ability of different groove models and compare the mechanical characteristics and sealing performance. We also analyze the gas film pressure distribution in micro gaps and explore the impact of dynamic pressure groove microstructure on flow field characteristics. Results show that micro gaps are the primary conditions for generating hydrodynamic effects, and high rotational speed, high-pressure differential, and large eccentricity have a significant effect on improving hydrodynamic effects and enhancing gas film stability. However, an increase in these parameters can cause an increase in leakage rate. A single flow channel makes it easier to improve the hydrodynamic effect, gas film load-bearing ability, and gas film stability while reducing leakage rate. The analyses in this study supplement and improve the theory of the flow field characteristics of cylindrical annular micro gaps and provide a theoretical basis for exploring the relation between the support structural parameters of the CGFS and the mechanical characteristics of the micro gap flow field. This study provides important guidance to the establishment of a quantitative design theory of supporting structures. Full article

The contactless transmission between the conductor rotor and the permanent magnet (PM) rotor of an adjustable permanent magnet coupler (APMC) provides the device with significant tolerance for alignment errors, making the performance estimation complicated and inaccurate. The first proposal of an edge coefficient in this paper helps to describe the edge effect with better accuracy. Accurate equivalent magnetic circuit (EMC) models of the APMC are established for each region. Models of magnetic flux, magnetic resistance, and eddy current density are established by defining the equivalent dimensional parameters of the eddy current circuit. Furthermore, the concept of magnetic inductance is proposed for the first time, parameterizing eddy currents that are difficult to describe with physical models and achieving the modeling of the dynamic eddy current circuit. The magnetic resistance is subdivided into two parts corresponding to the output and slip according to the power relationship. Furthermore, eddy current loss and dynamic torque models are further derived. The method proposed in this paper enables the APMC to be modeled and calculated in a completely new way. The correctness and accuracy of the model have been fully demonstrated using finite element simulation and an experimental prototype. In addition, the limitations of the proposed method and the reasons are fully discussed and investigated. Full article

This paper presents the performance analysis of a three-phase squirrel cage induction motor (SCIM) with a double–triple-layer (DTL) stator winding configuration operating with broken rotor bar (BRB) faults. The effects of BRB faults on the performance of specific parameters are analyzed under a steady-state regime. The SCIM is modeled using the two-dimensional finite element method (FEM) to study electromagnetic performance under healthy and BRB faulty conditions. To validate the finite element analysis (FEA) results, a prototype of an SCIM with a DTL stator winding configuration is tested for performance evaluation under healthy and BRB faulty conditions. The FEA and experimental (EXP) results of the SCIM with a DTL stator winding arrangement are compared with the results of the SCIM with a conventional double-layer (CDL) stator winding configuration. FEA and EXP results evidenced that the SCIM with a DTL stator winding configuration mitigates some of the adverse effects introduced by the BRB faults compared to the SCIM with a CDL stator winding of the exact specifications. Under loaded conditions, the SCIM with a DTL stator winding configuration reduced the magnitudes of the twice slip frequency sidebands caused by BRB faults from ±1.2 Hz for the SCIM with a CDL stator winding arrangement down to ±0.2 Hz and ±0.36 Hz when operating with 3BRB and 6BRB faults, respectively. The results also indicate that the SCIM with a DTL stator winding configuration has reduced the decibel sideband magnitude by 7.5 dB and 8 dB for unloaded and loaded conditions, respectively. This premise has positioned the SCIM with a DTL stator winding configuration as a strong candidate in applications where BRB faults are frequent, and the motor may be required to continue operating with a BRB fault until scheduled maintenance is in effect. Full article

Brushless synchronous machines (BSMs) are replacing conventional synchronous machines with static excitation in generation facilities due to the absence of sparking and lower maintenance. However, this excitation system makes measuring electric parameters in the rotor challenging. It is highly difficult to detect ground faults, which are the most common type of electrical fault in electric machines. In this paper, a ground fault detection method for BSMs is proposed. It is based on an inductive AC/DC rotating current sensor installed in the shaft. In the case of a ground fault in the rotating parts of the BSM, a fault current will flow through the rotor’s sensor, inducing voltage in its stator. By analyzing the frequency components of the induced voltage, the detection of a ground fault in the rotating elements is possible. The ground faults detection method proposed covers the whole rotor and discerns between DC and AC sides. This method does not need any additional power source, slip ring, or brush, which is an important advantage in comparison with the existing methods. To corroborate the detection method, experimental tests have been performed using a prototype of this sensor connected to laboratory synchronous machines, achieving satisfactory results. Full article

Contemporary aero-engines aim for enhanced efficiency and weight reduction. They are designed to increase rotor operational speed while reducing rotor bending stiffness. This may result in bending deformation in rotor systems within the operational speed range. Such deformation can change the relative positions of rotor components, potentially causing increased mass asymmetry or unbalance. Traditional rotor dynamic models typically assume a constant rotor state. They approximate unbalance using constant mass eccentricities at certain rotor cross-sections. However, this approach has its limitations. This paper focuses on a high-speed jointed rotor system. A distributed rotational inertia load excitation model is proposed. This model explicitly considers the rotor’s variable unbalance state at different operational speeds. The study involves both simulations and experimental investigations. The results show that at high speeds, bending deformation causes the unbalance and rotational inertia load to shift from a concentrated to a distributed state. Notably, the localized rotational inertia moment from thin-disk components like turbine disks becomes significant at high speeds. This results in a rapid increase in bearing load with rotational speed. It also profoundly affects the rotor’s joints, causing interfacial slip and sudden changes in rotor vibration characteristics. Full article

To overcome the problems existing in the practical application of traditional in-wheel motors used for electric vehicles, an integrated double rotor in-wheel motor was proposed, which can realize three drive modes to meet variable operating condition requirements of the vehicle. The process of switching between different drive modes affects the ride comfort of a vehicle. Taking the mode switching from a single inner motor drive to a dual-motor coupling drive as a research object, a dynamic modeling method of drive mode switching based on the switching system was proposed. According to the critical conditions of each state transition, the switching rules expressed by the segmental constant function were designed. At the engagement stage of electromagnetic clutch II, the torque coordination control strategy based on model predictive control (MPC) and control allocation was proposed. The simulation results show that the proposed strategy can effectively reduce the impact degree of a vehicle and the slipping-friction work of the clutch on the premise of ensuring the fast response of mode switching and the steady increase in vehicle speed. The switching quality of the mode-switching process is effectively improved. In addition, the drive mode switching control of the double rotor in-wheel motor prototype was tested, which proves its ability to operate in multi-drive mode. Full article

This review paper targets the corrosion-stiction phenomenon that can occur in automotive braking systems under static conditions in aggressive environments. The corrosion of gray cast iron discs can lead to a strong adhesion of the brake pad at the pad/disc interface that can impair the reliability and performance of the braking system. The main constituents of friction materials are initially reviewed in order to highlight the complexity of a brake pad. Corrosion-related phenomena, including stiction and stick-slip, are considered in detail to discuss the complex effect of the chemical and physical properties of friction materials on these phenomena. In addition, testing methods to evaluate the susceptibility to corrosion stiction are reviewed in this work. Electrochemical methods, including potentiodynamic polarization and electrochemical impedance spectroscopy, are useful tools for a better understanding of corrosion stiction. The development of friction materials with low susceptibility to stiction should follow a complementary approach targeting an accurate selection of the constituents, control of local conditions at the pad–disc interface, and the use of specific additives or surface treatments to reduce the corrosion susceptibility of gray cast-iron rotors. Full article

The present study deals with the harmful torsional resonance vibrations of textile rotor bearings, the amplitudes of which are reduced mainly by the use of high-capacity damping materials, characterized by an internal hierarchical structure and macroshape, added into the machine mechanical system. The additional materials are polymer matrix composites reinforced either by carbon nanofibers or carbon chopped microfibers and either aramid or carbon continuous fibers. The macroshape is based on a honeycomb with internal cavities. Torsional vibrations arise in mechanical systems as a result of fluctuations in the low-level pressing load of the flat belt driving the rotor-bearing pin and the changing of kinematic conditions within it, which, in the resonance area, leads to cage slip and unwanted impulsive torsional vibrations. Moreover, this occurs during high-frequency performance at around 2100 Hz, i.e., 126,000 min⁻¹. The condition, before the redesign, was characterized by significantly reduced textile rotor-bearing life due to significant impulse torsional vibrations in the resonance area. The study showed a significant reduction in average and maximum torsional amplitudes in the resonance area by 33% and 43%, respectively. Furthermore, the paper provides visualization of the propagation of a stress wave at the microscale obtained by the explicit finite element method to show the dispersion of the wave and the fibers as one of the sources of high damping. Full article

This paper presents an optimization strategy for a brushless doubly fed motor (BDFM) to achieve the maximum torque per ampere (MTPA). This method resolves the issue of high stator currents in slip frequency vector feedback linearization control (SFV-FLC) during both no-load and light-load conditions. Firstly, the paper establishes a reduced-order state-space (SS) model of the BDFM in arbitrary rotating reference coordinates. Secondly, the expression of BDFM is obtained after the control motor rotor field orientation. To ensure a minimal stator current at a specific torque, this paper constructs an auxiliary function based on Lagrange’s theorem, which forces the control motor stator current derivative to be zero, resulting in the MTPA criterion. Finally, the superiority of the MTPA optimization algorithm proposed in the paper is validated through simulation experiments. Full article

Speed feedback is indispensable not only for closed-loop controlled induction motors (IM) but also for the state monitoring systems of open-loop controlled IMs. Replacing speed sensors with speed estimations has many advantages including, e.g., hardware complexity reduction, sensor cabling elimination, and reduction of IM drive costs. From the various methods for IM speed estimation proposed in the literature, the model reference adaptive system (MRAS)-based speed estimator stands out because of its straightforward synthesis technique and lower computational complexity. On the other hand, this estimator is inherently sensitive to mismatching of IM equivalent circuit parameters. During transients, when the slip frequency cannot be temporarily controlled over the assumed operating point, rotor impedance varies with the slip frequency changes. This phenomenon is even more significant for open-loop controlled high-slip IMs (NEMA design D IMs), which operate under the cycling load like in, e.g., oil well pumps. The rate and the range of rotor impedance variability are related to the rate and the range of the slip frequency changes. Therefore, a speed estimator capable of modelling the slip frequency dependent variability of the rotor impedance may be required, particularly for the state monitoring systems of open-loop controlled IMs. This paper presents an MRAS-based speed estimator developed on the IM space vector model with the rotor impedance variability modelled by the parallel connected branches of the series rotor equivalent resistance and leakage inductance. The experimental test results confirm the precise speed estimation of the tested IMs achieved by the devised MRAS-based speed estimator in the considered slip frequency range and indicate its potential industrial application. Full article