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The presence of cracks in rotors is one of the most dangerous defects of rotating machinery. This can lead to catastrophic failure of the shaft and long out-of-service periods. The occurrence of a crack in a rotating shaft introduces changes in flexibilities which alters the dynamics during operation. This research deals with detecting damage in rotors by means of constantly monitoring the variation in the rotor’s dynamics during normal operating conditions. This project entails a computer finite element section as well as an experimental investigation. The flexibility in the region of the crack is different from an uncracked section. A finite element model of a shaft is built and investigated. The damaged model is the same except that the nodes in the location of the crack are not equivalenced in order to represent the crack. A simple constant cross-sectional shaft with semi-circular transverse surface cracks varying in size have been modelled on the Patran finite element software and a normal modes analysis was done using the Nastran solver. The results revealed a change in the natural frequencies due to the variation in the size of the crack. The experimental investigation involved creating sample shafts with damage positioned in them that would closely resemble what one may find in actual real-life situations and the dynamics during rotation with various torsional loadings are investigated and monitored using three methods. A fibre-optical sensor, Digital image correlation system and telemetry strain gauges were used. Undersampling techniques were used for the DIC system. Results showed that the fibre-optic sensor is by far the most favourable as it is able to detect damage under constant operation. The finite element model was updated by re-modelling the geometry, damage and material properties. The solution of the analysis matched the experimental results closely and model verification was achieved. / Dissertation (MEng)--University of Pretoria, 2013. / Mechanical and Aeronautical Engineering / unrestricted

Diante do expressivo aumento do número de refinarias de petróleo, bem como, com a crescente modernização das tecnologias de processo, englobando também o ramo petroquímico e de fertilizantes, notou-se que o consumo de energia de compressores centrífugos e suas eficiências tornaram-se de suma importância. Uma consequência desta nova realidade, está na necessidade de melhoria dos métodos estimativos para pré-dimensionamento e performance destas máquinas, o que necessariamente implica em uma previsão precisa de sua eficiência politrópica. Além disso, tais métodos devem também estimar as dimensões básicas de cada seção de compressão. A maior parte da literatura atual, versando sobre compressores centrífugos, tipo multiestágio, não está atualizada no que diz respeito à estimativa de eficiências politrópicas, quando comparadas com as eficiências alcançadas por compressores de fornecimento recente. Sendo assim, o principal objetivo da presente dissertação foi estimar um compressor centrífugo multiestágio, utilizando métodos adequados de cálculo. Isto implicou em comparar três métodos de estimativas, refletindo três procedimentos clássicos de cálculo, normalmente utilizados. Após pesquisa foram identificados três métodos, dois otimizados recentemente e um terceiro de abordagem mais antiga, proveniente de alguns fornecedores de compressores. Os métodos em análise são: Método das relações de Semelhança Otimizado por Sandberg (2016), Método de Lüdtke (2004), com correções propostas por Busaid e Pilidis (2016) e finalmente o Método dos Expoentes Politrópicos (N-Method), apresentado por Gresh (2001) e editado novamente em Gresh (2018). Os dois métodos mais recentes, embora baseados em diferentes critérios, apresentam estimativas de desempenho, dentro de uma precisão razoável, quando comparada aos dados reais de teste, enquanto que o método mais antigo, apresenta desvios significativos. Nesta dissertação, serão estimados seis casos reais de compressores, cujos resultados serão comparados aos estimados pelos três métodos de cálculo. Analisando os métodos, à luz dos desvios indicados nas tabelas para os seis casos, pode-se afirmar que o Método Simplificado e Corrigido de Lüdtke foi o que apresentou melhores resultados. O desvio relativo máximo apresentado foi na potência de eixo, cujo valor foi de 5,1%. Considerando o Método de Sandberg, verifica-se a partir dos desvios listados nas tabelas, que não cumpriu com o limite de aceitabilidade no tocante à potência no eixo para dois dos casos estudados. Entretanto, com exceção a estes dois casos, o método mostrou-se bastante satisfatório. Finalmente, analisando o Método dos Expoentes Politrópicos, citado por Gresh (2018), pode-se dizer que este método só foi aceitável para dois casos. Para os demais, segundo os desvios indicados nas tabelas, o método mostrou-se inadequado devido a desvios significativos na sua eficiência politrópica. / With the crescent number of modern fertilizer plants and hydrocracking process units in oil refineries, the consumption of energy and consequently the efficiency of centrifugal compressors were made of paramount importance in present day. A consequence of this new reality is the necessity of improvement of the methods that estimate the polytropic efficiency of these compressors. Furthermore, new methods also need to predict the basic geometric parameters of each machine. On the other side, most of the literature, which deals with polytropic efficiencies, is not up to date with the values performed by modern compressors. The main scope of present work is to provide background information and present a comparison between two up to date methods and a third classical old method, based on different approach, but capable to predict the performance and sizing of multistage centrifugal compressors. The methods under analysis are: Sandberg (2016) Optimized Similarity Method, Lüdtke\'s Method (2004), with corrections proposed by Busaid and Pilidis (2016) and finally the Politropic Exponent Method (N-Method), presented by Gresh (2001) and edited again in Gresh (2018). Both the newer methods present good agreement with the values performed by several compressors, as demonstrated when these methods are adopted, whilst the old method presents some deviations, mainly in the gas power. In this paper, six real cases will be estimated by the three methods and compared against supplier data; the results will be justified. Analyzing the methods, in respect of the deviations indicated in the tables for the six cases, it can be stated that the Simplified and Corrected Method of Lüdtke was the one that presented the best results. The maximum relative deviation presented was in the brake horsepower, whose value was of 5.1%. Considering the Sandberg Method, it can be verified from the deviations listed in the tables, that it did not meet the limit of acceptability regarding power on the axis for two of the cases studied. However, with the exception of these two cases, the method was quite satisfactory. Finally, analyzing the Politropic Exponents Method, quoted by Gresh (2018), it can be said that this method was only acceptable for two cases. For the others, according to the deviations indicated in the tables, the method proved to be inadequate, due to significant deviations in its polytropic efficiency.

Este trabalho versa sobre a análise teórica do desempenho da regulação sincronizada aplicada na redução de vibrações de rotores utilizando mancais magnéticos. Originalmente apresentado na dissertação \\Regulação sincronizada de distúrbios senoidais\", de Vaydia I. C. Segura, o regulador teve o seu módulo de regulação modificado para trabalhar com múltiplas entradas e saídas, além de permitir a estimação em tempo real da matriz de influência. O desempenho e a robustez do regulador foram analisados em função de seus parâmetros. A regulação sincronizada foi aplicada a um modelo teórico de rotor desenvolvido pelo método dos elementos finitos e simulado em computador. / This work discusses about the theoretical analysis of the performance of synchronized regulation applied in reduction of rotor vibrations using magnetic bearings. Originally presented in the dissertation \\Synchronized regulation of sinoidal disturbing\", of Vaydia I. C. Segura, the regulator had its regulation module changed to work with multiple inputs and outputs, in addition to enabling real-time estimation of the influence matrix. The performance and robustness of the regulator were analyzed as a function of the parameters. The synchronized regulation was applied to the theoretical model developed by the finite elements method and simulated in a computer.

Vibration-based fault diagnosis (FD) with a simple spectrum can be complex, especially when considering FD of rotating machinery with multiple bearings like a multi-stage turbine. Various studies have sought to better interpret fault spectra, but the process remains equivocal. Consequently, it has been accepted that the simple spectra requires support from additional techniques, such as orbit analysis. But even orbit analysis can be inconclusive. Though promising, attempts at developing viable methods that rival the failure coverage of spectrum analysis without gaining computational complexity remain protracted. Interestingly, few researchers have developed FD methods for transient machine operation, however, these have proven to be involved. Current practices limit vibration data to a single machine, which usually requires a large unique data history. However, if sharing of data between similar machines with different foundations was possible, the need for unique histories would be mitigated. From readily available works, this has not been encountered. Therefore, a simple but robust vibration-based approach is warranted. In light of this, a novel on-bearing vibration response integration approach for condition monitoring of shaft-related faults irrespective of speed and foundation type is proposed in the present study. Vibration data are acquired at different speeds for: a baseline, unbalance, bow, crack, looseness, misalignment, and rub conditions on three laboratory rigs with dynamically different foundations, namely: rigid, flexible support 1 (FS1) and flexible support 2 (FS2). Testing is done on the rigid rig set up first, then FS1, and afterwards FS2. Common vibration features are computed from the measured data to be input to the proposed approach for further processing. First, the proposed approach is developed through its application to a machine at a steady speed in a novel Single-speed FD technique which exploits a single vibration sensor per bearing and fusion of features from different bearings for FD. Initially, vibration features are supplemented with bearing temperature readings with improved classification compared to vibration features alone. However, it is observed that temperature readings are insensitive to faults on the FS1 and FS2 rigs, when compared to vibration features, which are standardised for consistent classification on the different rigs tested. Thus, temperature is not included as a final feature. The observed fault classifications on the different rigs at different speeds with the standardised vibration features are encouraging. Thereafter, a novel Unified Multi-speed FD technique that is based on the initial proposed approach and which works by fusion of vibration features from different bearings at different speeds in a single analysis step for FD is proposed. Experiments on the different rigs repeatedly show the novel Multi-speed technique to be suitable for transient machine operation. Then, a novel generic Multi-foundation Technique (also based on the proposed approach) that allows sharing of vibration data of a wide range of fault conditions between two similarly configured machines with similar speed operation but different foundations is implemented to further mitigate data requirements in the FD process. Observations made with the rigs during steady and transient speed tests show this technique is applicable in situations where data history is available on one machine but lacking on the other. Comparison of experimental results with results obtained from theoretical simulations indicates the approach is consistent. Thus, the proposed approach has the potential for practical considerations.

Este trabalho versa sobre a análise teórica do desempenho da regulação sincronizada aplicada na redução de vibrações de rotores utilizando mancais magnéticos. Originalmente apresentado na dissertação \\Regulação sincronizada de distúrbios senoidais\", de Vaydia I. C. Segura, o regulador teve o seu módulo de regulação modificado para trabalhar com múltiplas entradas e saídas, além de permitir a estimação em tempo real da matriz de influência. O desempenho e a robustez do regulador foram analisados em função de seus parâmetros. A regulação sincronizada foi aplicada a um modelo teórico de rotor desenvolvido pelo método dos elementos finitos e simulado em computador. / This work discusses about the theoretical analysis of the performance of synchronized regulation applied in reduction of rotor vibrations using magnetic bearings. Originally presented in the dissertation \\Synchronized regulation of sinoidal disturbing\", of Vaydia I. C. Segura, the regulator had its regulation module changed to work with multiple inputs and outputs, in addition to enabling real-time estimation of the influence matrix. The performance and robustness of the regulator were analyzed as a function of the parameters. The synchronized regulation was applied to the theoretical model developed by the finite elements method and simulated in a computer.

Orientadores: Katia Lucchesi Cavalca, Rainer Nordmann / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-12T14:22:54Z (GMT). No. of bitstreams: 1 Furtado_RogerioMendonca_D.pdf: 2160863 bytes, checksum: 4c54a9ce5fcded113554dc24287e591a (MD5) Previous issue date: 2008 / Resumo: Um atuador magnético como fonte de excitação em sistemas rotativos é desenvolvido para emprego na análise modal e em outros estudos, envolvendo a excitação sem contato. Embora os sistemas magnéticos para aplicação de forças em máquinas rotativas sejam empregados com alto desempenho (como por exemplo os mancais magnéticos), o desenvolvimento de um sistema simples, para aplicações laboratoriais, se apresenta como uma contribuição experimental útil, para ser empregado numa bancada de testes utilizada no desenvolvimento de projetos de máquinas rotativas. O conceito apresentado é simples, mas permite a excitação externa sem contatos ou mesmo o controle das amplitudes de vibração, quando associado a um sistema de controle. Contudo, a calibração e o estudo do desempenho dinâmico do sistema não são análises simples. Neste sentido, o trabalho apresenta uma experiência prática e discussões sobre o desenvolvimento do atuador magnético utilizado para testes em máquinas rotativas. A influência da corrente elétrica, entreferro, superfície do pólo do atuador e também da freqüência de excitação, são apresentadas. A força magnética é estimada, baseando-se na medida da densidade de fluxo magnético, medida por sensores hall. / Abstract: A magnetic actuator as excitation source in rotating systems is developed, in order to accomplish modal analysis and other studies involving contacless excitation. Although the use of magnetic systems to apply forces onto rotating machinery has been carried out with high performance level (for example, magnetic bearings), the development of a conveniently easy and simples device for laboratory application presents interesting contribution to experimental methods used in test rigs based on similarity design to rotating machinery. The initial concept of the magnetic actuator proposed here is simple, but enables either the external excitation without contact or the vibration control when associated with a controller system. However, the performance characteristics tunning to attend the dynamic demand of the system is not so trivial. Following this focus, the work brings practical experience and discussion about the development and performance analysis of a magnetic actuator used for rotating machinery tests. The influence of the electrical current in the actuator coils, the air-gap between actuator and rotative system, thetype of surface of the actuator poles (flat or curved) as well as excitation frequency was verified. Force estimation was based on the magnetic flux density, measured by hall sensors. / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

This student thesis aims to analyze the unbalance on rotating machinery by simulation and experimental. The machinery flywheel rotation is modelled as a Single Degree of Freedom (SDOF) and Multi Degree of Freedom (MDOF) system. The model rotation unbalance is simulated by MATLAB. Then the vibration measurement is taken by experimental. In addition, the tachometer is used to determine the flywheel speed calibration. Finally, the rotating unbalance reduction simulation is performed with different parameter value to determine an optimum level of machinery rotation vibration. Unbalance on rotating machinery causes a harmful influence on the environment and machinery. The root cause of rotating unbalance is determined by the simulation and experimental analysis. The analysis result is used as an indicator for predicting machinery breakdown and estimating the correct predictive maintenance action for the machinery. In this project, the simulation and experimental analysis were carried out on a rotating component of the KICKR Snap Bike Trainer. The simulation and numerical analysis are performed by MATLAB programme. On the experimental part, the vibration measurement method and results were discussed. The suggestion of unbalance reduction were recommended base on measurement and vibration analysis results.