On-line vibration monitoring is significant for high-speed rotating blades, and blade tip-timing (BTT) is generally regarded as a promising solution. BTT methods must assume that rotating speeds are constant. This assumption is impractical, and blade damages are always formed and accumulated during variable operational conditions. Thus, how to carry out BTT vibration monitoring under variable rotation speed (VRS) is a big challenge. Angular sampling-based order analyses have been widely used for vibration signals in rotating machinery with variable speeds. However, BTT vibration signals are well under-sampled, and Shannon’s sampling theorem is not satisfied so that existing order analysis methods will not work well. To overcome this problem, a reconstructed order analysis-based BTT vibration monitoring method is proposed in this paper. First, the effects of VRS on BTT vibration monitoring are analyzed, and the basic structure of angular sampling-based BTT vibration monitoring under VRS is presented. Then a band-pass sampling-based engine order (EO) reconstruction algorithm is proposed for uniform BTT sensor configuration so that few BTT sensors can be used to extract high EOs. In addition, a periodically non-uniform sampling-based EO reconstruction algorithm is proposed for non-uniform BTT sensor configuration. Next, numerical simulations are done to validate the two reconstruction algorithms. In the end, an experimental set-up is built. Both uniform and non-uniform BTT vibration signals are collected, and reconstructed order analysis are carried out. Simulation and experimental results testify that the proposed algorithms can accurately capture characteristic high EOs of synchronous and asynchronous vibrations under VRS by using few BTT sensors. The significance of this paper is to overcome the limitation of conventional BTT methods of dealing with variable blade rotating speeds.
Blade tip-timing (BTT) is a promising method of online monitoring rotating blade vibrations. Since BTT-based vibration signals are typically undersampled, how to reconstruct characteristic vibrations from BTT signals is a big challenge. Existing reconstruction methods are mainly based on the assumption of constant rotation speeds. However, rotating speed fluctuation is inevitable in many engineering applications. In this case, the BTT sampling process should be nonuniform, which will cause existing reconstruction methods to be unavailable. In order to solve this problem, this paper proposes a new reconstruction method based on nonlinear time transformation (NTT). Firstly, the effects of rotating speed fluctuation on BTT vibration reconstruction are analyzed. Next, the NTT of BTT sampling times under rotating speed fluctuation is presented. Then, two NTT-based reconstruction algorithms are derived for uniform and nonuniform BTT sensor configurations, respectively. Also several evaluation metrics of BTT vibration reconstruction under rotating speed fluctuation are defined. Finally, numerical simulations are done to verify the proposed algorithms. The results testify that the proposed NTT-based reconstruction method can reduce effectively the influence of rotating speed fluctuation and decrease the reconstruction error. In addition, rotating speed fluctuation has more bad effects on the reconstruction method under nonuniform sensor configuration than under uniform sensor configuration. For nonuniform BTT signal reconstruction under rotating speed fluctuation, more attentions should be paid on selecting proper angles between BTT sensors. In summary, the proposed method will benefit for detecting early blade damages by reducing frequency aliasing.
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