The steady-state response and breathing mechanism of a cracked rotor supported by flexible bearings are investigated in this paper. The generalized and efficient method proposed in this paper can be used to study the dynamics of complicated cracked structures without much modification. First, a three-dimensional finite element model of the cracked rotor-bearing system is established in the rotating frame and a general contact model for modeling the breathing crack is proposed. A component mode synthesis is used to form a reduced-order model. Then, a procedure combining multi-harmonic balance method with arc-length method is used to search the response solution. To accelerate the calculation, the analytical formulations for calculating the tangent stiffness matrix are used. Finally, the gravity induced response and breathing mechanism of a cracked rotor-bearing system are obtained. Interesting result is that the rotational speed and the crack depth will influence the breathing mechanism even if the load remains unchanged.
A generalized and efficient technique of reduced-order model (ROM) is proposed in this paper for stability and steady-state response analysis of an asymmetric rotor based on three-dimensional (3D) finite element model. The equations of motion of the asymmetric rotor-bearing system are established in the rotating frame. Therefore, the periodic time-variant coefficients only exist at a tiny minority of degrees-of-freedom (DOFs) of bearings. During the model reduction process, the asymmetric rotor-bearing system is divided into rotor and bearings. Only the rotor was reduced. And the physical coordinates of bearings are kept in the reduced model during reduction. Then, the relationship between the rotor and bearings is established by inserting periodic time-variant stiffness and damping matrix of bearings into the reduced model of rotor. There is no reduction to the matrices of bearings, which guarantees the accuracy of the calculation. This technique combined with fixed-interface component mode synthesis (CMS) and free-interface CMS is compared with other existing modal reduction method on an off-center asymmetric rotor and shows good performance.
Crack is a common fault of rotor systems. The research on crack fault detection methods is mainly divided into numerical and experimental studies. In numerical research, the current fault detection algorithms based on deep learning are mostly applied to bearings and gearboxes, and there are few studies on rotor fault diagnosis. In experimental research, the rotors used in an experiment are mostly single-span rotors. However, there are complex structures such as multi-span rotor systems in the actual industrial field. Thus, the fault detection algorithms that have been successfully applied on single-span rotors have not been verified on complex rotor systems. To obtain a fault signal close to the actual asymmetric shaft system of an asymmetric rotor system and validate the fault detection method, the crack fault detection platform is designed and built independently. We measure the vibration signals of three channels under five working conditions and establish an intelligent detection method for crack location based on a residual network. The factors that influence fault detection performance are analyzed, and the influence laws are discussed. Results show that the accuracy and anti-noise performance of the proposed method are higher than those of the commonly used machine learning. The average accuracy is 100% when SNR (signal-to-noise ratio) is greater than or equal to −2 dB, and the average accuracy is 98.2% when SNR is −4 dB.
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