This work treats dual-plane automatic ball balancing of elastically-mounted cylindrical rotors. The application is primarily to systems with a vertically-oriented single-bearing support, but extension is also made to horizontally-oriented single-bearing support as typically found in a vehicle wheel. The rotor elastic mounting includes three translational degrees of freedom for the body geometric center and three rotational degrees of freedom. Damping is included for each of these six degrees of freedom. The model for the automatic ball balancer consists of up to two arbitrarily-located hollow circumferential races, each of which contains up to two sliding particles. The friction model for the particles includes both viscous and Coulomb friction forces. Of considerable complexity is the logic path for the individual particles being either in motion or stationary relative to the rotor. The exact equations of motion for the overall system are derived via a Newtonian approach. Numerical-integration results show that the balancer performance depends strongly on the friction levels as well as the operating speed of the body. Simulations conducted with a pure static imbalance show that ideal automatic balancing is possible only for vertical-axis rotors that have zero Coulomb friction levels between the balancing particles and the races. Simulations with a horizontal-axis statically-imbalanced rotor show that an automatic balancer can improve performance for certain operating speeds and non-zero Coulomb friction levels in the presence of gravitational forces. Simulations conducted with a pure dynamic imbalance show that there is no inherent mechanism to counteract rotational displacements of the rotor about its geometric center. As a result, the balancing particles exhibit several phenomena described in previous works such as synchronous motion and oscillatory behaviors within their respective races. Simulations for an arbitrarily located imbalance show that rotor performance can be improved using dual-plane balancing techniques for certain operating speeds and Coulomb friction levels. Due to the inherent complexity in eliminating an arbitrarily located mass imbalance, the system is generally unable to reach a perfectly balanced configuration, but performance can be improved for carefully-selected initial conditions. / Ph. D.

Typical aero-engine assemblies have at least two nested rotors mounted within a flexible casing via squeeze-film damper (SFD) bearings. As a result, the flexible casing structures become highly sensitive to the vibration excitation arising from the High and Low pressure rotors. Lowering vibrations at the aircraft engine casing can reduce harmful effects on the aircraft engine. Inverse problem techniques provide a means toward solving the unbalance identification problem for a rotordynamic system supported by nonlinear SFD bearings, requiring prior knowledge of the structure and measurements of vibrations at the casing. This thesis presents two inverse solution techniques for the nonlinear rotordynamic inverse problem, which are focused on applications where the rotor is inaccessible under operating conditions, e.g. high pressure rotors. Numerical and experimental validations under hitherto unconsidered conditions have been conducted to test the robustness of each technique. The main contributions of this thesis are:• The development of a non-invasive inverse procedure for unbalance identification and balancing of a nonlinear SFD rotordynamic system. This method requires at least a linear connection to ensure a well-conditioned explicit relationship between the casing vibration and the rotor unbalance via frequency response functions. The method makes no simplifying assumptions made in previous research e.g. neglect of gyroscopic effects; assumption of structural isotropy; restriction to one SFD; circular centred orbits (CCOs) of the SFD. • The identification and validation of the inverse dynamic model of the nonlinear SFD element, based on recurrent neural networks (RNNs) that are trained to reproduce the Cartesian displacements of the journal relative to the bearing housing, when presented with given input time histories of the Cartesian SFD bearing forces.• The empirical validation of an entirely novel approach towards the solution of a nonlinear inverse rotor-bearing problem, one involving an identified empirical inverse SFD bearing model. This method is suitable for applications where there is no adequate linear connection between rotor and casing. Both inverse solutions are formulated using the Receptance Harmonic Balance Method (RHBM) as the underpinning theory. The first inverse solution uses the RHBM to generate the backwards operator, where a linear connection is required to guarantee an explicit inverse solution. A least-squares solution yields the equivalent unbalance distribution in prescribed planes of the rotor, which is consequently used to balance it. This method is successfully validated on distinct rotordynamic systems, using simulated data considering different practical scenarios of error sources, such as noisy data, model uncertainty and balancing errors. Focus is then shifted to the second inverse solution, which is experimentally-based. In contrast to the explicit inverse solution, the second alternative uses the inverse SFD model as an implicit inverse solution. Details of the SFD test rig and its set up for empirical identification are presented. The empirical RNN training process for the inverse function of an SFD is presented and validated as a part of a nonlinear inverse problem. Finally, it is proved that the RNN could thus serve as reliable virtual instrumentation for use within an inverse rotor-bearing problem.

The balancing of a wind turbine rotor is a crucial step affecting the machine’s performance, reliability, and safety, as it directly impacts the dynamic loads on the entire structure. A rotor can be balanced either statically or dynamically. A method of rotor balancing was developed that achieves both the simplicity of static balancing and the accuracy of dynamic balancing. This method is best suited, but not limited, to hollow composite blades of any size. The method starts by quantifying the mass and center of gravity of each blade. A dynamic calculation is performed to determine the theoretical shaking force on the rotor shaft at the design operating speed. This force is converted to a net counterbalance mass required for each blade. Despite the most careful methodology, there may still be large errors associated with these measurements and calculations. Therefore, this new method includes a physical verification of each blade’s individual balance against all other blades on the rotor, with the ability to quantify the discrepancy between blades, and make all balance adjustments in situ. The balance weights are aluminum plugs of varying lengths inserted into the root of each blade with a threaded steel rod running through the middle. The balance adjustment is thus not visible from outside. The weight of the plug and rod represent the coarse counterbalance of each blade, based on the dynamic calculations. The threaded steel rod acts as a fine adjustment on the blades’ mass moment when traveled along the plug. A dedicated blade-balance apparatus, designed and constructed in-house, is used to verify and fine-tune each individual blade and compare it to all other blades on the rotor. The resulting blade assembly is verified on a full rotor static balancing apparatus. The full rotor apparatus measures the steady state tilt of the rotor when balanced on a point. Next, the rotors' tilt is related to its overall level of imbalance with quantifiable error. Most error comes from the fact that the hub, comparable in mass to the blades, creates a false righting moment of the assembly not present in operation. The fully assembled rotor is tested, pre and post balance, in operation on the turbine at a series of predetermined speeds. This is accomplished with a 3-axis accelerometer mounted on the main turbine shaft bearing and a control system which regulates and records turbine speed at 100 Hz

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