大型旋转机械稳定运行机理及智能诊断研究

项目来源

国家自然科学基金(NSFC)

项目主持人

闻邦椿

项目受资助机构

东北大学

项目编号

U1708257

立项年度

2017

立项时间

未公开

项目级别

国家级

研究期限

未知 / 未知

受资助金额

250.00万元

学科

工程与材料科学-机械设计与制造-机械动力学

学科代码

E-E05-E0503

基金类别

联合基金项目-重点支持项目-NSFC-辽宁联合基金

关键词

运行稳定性 ; 转子系统 ; 故障诊断 ; 运行失稳 ; 非线性动力学 ; operation stability ; rotor system ; losting operation stability ; nonlinear dyanmics ; fault diagnosis

参与者

马辉;杨树华;冯坤;王平;孟继纲;姚红良;张学良;周世华;孙赵宁

参与机构

沈阳透平机械股份有限公司;北京化工大学

项目标书摘要:目前国产大型旋转机械存在运行稳定性差、智能诊断技术不足等问题,导致该类装备出现一些“该停车时不停,不该停车时停车”的现象,因此项目提出进行大型旋转机械运行稳定性和智能故障诊断的研究。.项目拟以大型离心压缩机机组为研究对象,结合非线性动力学理论和转子动力学理论,研究大型旋转机械多机组转子系统同步运行稳定性机理,以及典型故障和耦合故障下的失稳规律;结合模糊数学理论和系统评价理论,研究该类装备运行失稳的预测方法,以及提高同步运行稳定性的抑制方法问题;结合现代数字信号处理和模式识别方法,研究大型旋转机械失稳早期征兆辨识,以及失稳故障的准确智能诊断方法;结合专家系统理论,建立该类装备监控、预测、诊断、决策一体化软件框架,并编制出软件。.项目的成功,预计将减少大型旋转机械的停机次数,及时准确诊断出其早期故障,提高其运行稳定性,从而可以提升企业产品的竞争力和创新能力,为东北老工业基地的振兴做出贡献。

Application Abstract: The domestic large-scale rotating machinery has the problem of“can’t stop when must to stop,stop when not necessary to stop”sometime due to insufficient in intelligent fault diagnosis.To solve this problem,the project is proposed to study the operation stability mechanism and the intelligent fault diagnosis of the large-scale rotating machinery..The project will take the large-scale compressor sets as research objects.The multi-unit rotor system synchronization on operation stability and the principles of the stability losing under typical faults or multi-faults of the multi-unit rotor system will be studied based on nonlinear dynamics and rotor dynamics.The forecasting method of the multi-unit rotor operation stability of the large scale rotating machinery will also be studied based on fuzzy logic theory and system evaluation theory.The early signs identification and diagnosis method of the stability losing method and the precise intelligent diagnosis of early fault for the large-scale rotating machinery will be studied based on advanced digital signal processing methods and pattern recognition method.The software and framework of the platform which combining monitor,forecasting,diagnosis and decision-making together will be built by combining expert system theory..The success of the project can reduce the shutting down of the large-scale rotating machinery,precisely and intelligently diagnosis the rapidly processing faults,improve the operation stability and finally promote the technical innovations of enterprises and awaken the old northeast industrial base.

项目受资助省

辽宁省

项目结题报告(全文)

针对目前国产大型旋转机械存在运行稳定性差、智能诊断技术不足等问题,导致该类装备出现一些“该停车时不停,不该停车时停车”的现象,进行大型旋转机械运行稳定性和智能故障诊断的研究。项目的主要研究内容和结果如下:第一、结合非线性动力学理论和转子动力学理论,研究了以旋转件松动故障为代表的结构场失稳机理;以转静件摩擦故障为代表的结构场和热场耦合失稳机理;以气流激振故障为代表的流体场失稳机理,掌握了大型旋转机械多机组转子系统失稳机理。第二、建立了转子系统振动特征—运行稳定性的映射关系,实现单机组和多机组的稳定裕度描述。提出了基于改进AHP确定主观权重法和神经网络算法的多机组稳定性裕度评价体系,并研究了基于线性和非线性吸振器的转子系统稳定性在线提高方法。第三、针对大型旋转机械早期故障发展迅速,导致机组稳定裕度迅速下降的问题,研究微故障的智能诊断技术,提出了基于样本密度自适应的早期失稳故障信号采集方法、早期失稳故障微弱信号特征提取方法、基于案例数据学习早期失稳故障智能诊断方法、变工况条件早期失稳故障报警阈值自学习方法等。第四、编制了大型旋转机械运行稳定性分析软件、早期故障诊断软件等,提出了该类装备监控、诊断、评估决策一体化软件框架。将成果在实际工程的诊断和决策中加以应用,解决了工程实际问题。项目的成果对于掌握大型旋转机械的运行稳定性机理,减少大型旋转机械停机次数具有重要意义。项目成果已经应用于国产大型旋转机械的故障诊断和运行维护,及时准确诊断出了早期故障,提高其运行稳定性,减少了“该停车时不停,不该停车时停车”现象。项目的成果可以提升企业产品的竞争力和创新能力,为东北老工业基地的振兴做出贡献。

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  • 1.Structural vibrations and acoustic radiation of blade–shafting–shell coupled system

    • 关键词:
    • Acoustic radiators;Acoustic wave propagation;Radiation effects;Acoustic wave transmission;Sailing vessels;Frequency doublers;Acoustic emissions;Shells (structures);Structural dynamics;Acoustic radiation;Blade;Shafting;Shell;Vibration
    • Liu, Yang;Han, Jiyuan;Xue, Zengyuan;Zhang, Ye;Yang, Qiang
    • 《Journal of Sound and Vibration》
    • 2019年
    • 463卷
    • 期刊

    Structural vibrations and radiation noise are common problems in the blade–shafting–shell coupled system. To research this problem, a coupled system consisting of a five-leaf blade, shaft, bearing, and shell was established using a dynamic equilibrium equation. To describe the dynamic behaviour, a blade excitation force model consisting of transverse and vertical excitation forces generated by the blade was established using a quasi-steady method. It was found that the transverse excitation force resulted in more complex frequency components than the vertical excitation force. The frequency components of the blade frequency doubling (2.5fr) and the blade frequency (5fr) in the spectrogram were mainly produced by the transverse excitation force (where fr is the rotational frequency of the shafting). In addition, in the acoustic analysis section of this paper, a finite element model of the coupled system was established. Blade excitation forces were applied to the model, and the vibrational response data of the coupling model's nodes were obtained. Using the acoustic boundary element method, the coupled system's acoustic response was calculated from the surface node vibration velocity data of the coupling model. The effects of the transverse and vertical excitation forces on the acoustic radiation of the coupled system were considered. Finally, dynamic and acoustic experiments of the blade–shafting–shell coupled system were conducted. The results verified the accuracy of the simulation model. © 2019 Elsevier Ltd

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  • 2.AEFNet: a real-time network for detecting prohibited items in x-ray images across complex scenarios

    • 关键词:
    • prohibited items; dynamic convolution; feature pyramid; lightweight head
    • Zhu, Kaiyuan;Chang, Xinyu;Zhang, Qing
    • 《MEASUREMENT SCIENCE AND TECHNOLOGY》
    • 2025年
    • 36卷
    • 3期
    • 期刊

    Accurate identification of prohibited items in x-ray security images is essential for ensuring public safety. However, current methodologies struggle to simultaneously address irregular deformation, multi-scale features, and background occlusion of prohibited items, leading to inadequate detection accuracy. To address these challenges, we propose an adaptive efficient focusing network (AEFNet) designed to target regions, thereby enhancing the automatic detection of prohibited items. Specifically, to accommodate the irregular deformation of target regions, we introduce the DACSP module, which dynamically adjusts sampling positions to enhance the network's adaptability and focus on occluded targets. To address detail loss and managing multi-scale features, we propose a multi-scale focus feature module and a focusing diffusion pyramid network (FDPN), which enable the fusion of semantic and perceptual features, improving the use of contextual information at different detection scales. Additionally, detail-enhanced convolution improves the efficacy of feature utilization at different scales, while facilitating a lightweight network design. Finally, we employ the PIoUv2 function to optimize localization loss, resulting in significant performance enhancement. Experimental results show that AEFNet performs effectively across various x-ray security image datasets (PIDray, CLCXray, OPIXray) achieving 74.7%, 61.3%, and 89.2% mAP respectively, and AEFNet also demonstrates strong generalization capabilities on the PASCAL VOC dataset in non-prohibited item detection scenarios.

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  • 3.Research on Automatic Balance Control of Active Magnetic Bearing-Rigid Rotor System

    • Liu, Yang;Ming, Shuaishuai;Zhao, Siyao;Han, Jiyuan;Ma, Yaxin
    • 《SHOCK AND VIBRATION》
    • 2019年
    • 2019卷
    • 期刊

    In this paper, in order to solve the problem of unbalance vibration of rigid rotor system supported by the active magnetic bearing (AMB), automatic balancing method is applied to suppress the unbalance vibration of the rotor system. Firstly, considering the dynamic and static imbalance of the rotor, the detailed dynamic equations of the AMB-rigid rotor system are established according to Newton's second law. Then, in order to rotate the rotor around the inertia axis, the notch filter with phase compensation is used to eliminate the synchronous control current. Finally, the variable-step fourth-order Runge-Kutta iteration method is used to solve the unbalanced vibration response of the rotor system in MATLAB simulation. The effects of the rotational speed and phase compensation angle on the unbalanced vibration control are analysed in detail. It is found that the synchronous control currents would increase rapidly with the increase of rotational speed if the unbalance vibration cannot be controlled. When the notch filter with phase shift is used to balance the rotor system automatically, the control current is reduced significantly. It avoids the saturation of the power amplifier and reduces the vibration response of the rotor system. The rotor system can be stabilized over the entire operating speed range by adjusting the compensation phase of the notch filter. The method in the paper is easy to implement, and the research result can provide theoretical support for the unbalance vibration control of AMB-rotor systems.

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  • 4.Feature extraction method based on NOFRFs and its application in faulty rotor system with slight misalignment

    • 关键词:
    • Alignment;Fault detection;Feature extraction;Extraction;Harmonic analysis;Feature enhancement;Feature extraction methods;Misalignment fault;NOFRFs;Non-linear output frequency response function;Nonlinear features;Slight misalignment;Variable weighted
    • Liu, Yang;Zhao, Yulai;Li, Jintao;Lu, Huanhuan;Ma, Hui
    • 《Nonlinear Dynamics》
    • 2020年
    • 99卷
    • 2期
    • 期刊

    Fault features extraction method for slight misalignment of rotor systems is researched in this paper. When a rotor system with faults is excited by harmonic inputs, system response will contain higher harmonic components. Phenomenon of these higher harmonics implies the presence of nonlinear features in a rotor system. When extracting these nonlinear features, traditional methods have certain limitations, and it is easy to ignore weak features of a rotor system. Nonlinear output frequency response functions (NOFRFs) can extract effectively nonlinear features of a rotor system from noise-containing vibration signals and are used in many fault diagnosis fields. However, as for weak damage to structures and in the early stages of a system faults, fault features reflected by high-order NOFRFs are not still obvious enough. Therefore, a new method, named variable weighted contribution rate of NOFRFs, is proposed in this paper. This method enhances the ratio of high-order output frequency response to total output response of a rotor system. Based on this method, a new index MR is proposed to detect the faults of a rotor system. In addition, lumped mass model is used in this paper to simulate misaligned rotor system with slight misalignment, and the sensitivities of the traditional methods and new index for slight misalignment fault features extraction are compared. The results indicate that the new index is more sensitive for the slight misalignment rotor system. Additionally, the rotor system with misalignment fault experiment table is built, and the effectiveness of this new index for detecting the slight misalignment fault of the rotor system is verified.
    © 2019, Springer Nature B.V.

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  • 5.Dynamic Modelling Considering Nonlinear Factors of Coupled Spur Gear System and Its Experimental Research

    • 关键词:
    • Spur gear transmission; precise modeling; friction coefficient;experiment validation;MESH STIFFNESS CALCULATION; CRACK DETECTION; FRICTION; PAIR
    • Zhao, Yulai;Liu, Yang;Xin, Xicheng;Yu, Shuanghe;Ma, Hui;Han, Qingkai
    • 《IEEE ACCESS》
    • 2020年
    • 8卷
    • 期刊

    For the nonlinear vibration problem of spur gear transmission system caused by friction and gear backlash, the dynamic model of gearbox with 16-degree-of-freedom (16-DOF) considering timevarying meshing stiffness is established by Lagrange equation. The dynamic equations of the gear system are solved by the Newmark-beta method. The effects of friction coefficient, error fluctuation and meshing stiffness on the vibration response are investigated. In order to verify the validity of the model, a spur gear transmission rotor test bench was built by simulating the actual working conditions. The root mean square (RMS) is used to verify the accuracy of the model at multiple speeds, and makes up for the shortcomings of many researches without experimental argumentation. The experimental research can provide a reference for the research of gear transmission system.

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  • 6.Study on the Dynamic Problems of Double-Disk Rotor System Supported by Deep Groove Ball Bearing

    • 关键词:
    • VIBRATION; MODEL
    • Liu, Yang;Han, Jiyuan;Zhao, Siyao;Meng, Qingyu;Shi, Tuo;Ma, Hui
    • 《SHOCK AND VIBRATION》
    • 2019年
    • 2019卷
    • 期刊

    Aiming at the analysis of the dynamic characteristics of the rotor system supported by deep groove ball bearings, the dynamic model of the double-disk rotor system supported by deep groove ball bearings was established. In this paper, the nonlinear finite element method is used combined with the structural characteristics of deep groove ball bearings. Based on the nonlinear Hertz contact theory, the mechanical model of deep groove ball bearings is obtained. The excitation response results of the rotor system nodes are solved by using the Newmark- numerical solution method combined with the Newton-Raphson iterative method. The vibration characteristics of the rotor system supported by deep groove ball bearings are studied deeply. In addition, the effect of varying compliance vibration (VC vibration) caused by the change in bearing support stiffness on the dynamics of the system is considered. The time domain and frequency domain characteristics of the rotor system at different speeds, as well as the influence of bearing clearance and bearing inner ring's acceleration on the dynamics of the rotor system are analyzed. The research shows that the VC vibration of the bearing has a great influence on the motion of the rotor system when the rotational speed is low. Moreover, reasonable control of bearing clearance can reduce the mutual impact between the bearing rolling element and the inner or outer rings of the bearing and reduce the influence of unstable bearing motion on the vibration characteristics of the rotor system. The results can provide theoretical basis for the subsequent study of the nonlinear vibration characteristics of the deep groove ball bearing rotor system.

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  • 7.Application of weighted contribution rate of nonlinear output frequency response functions to rotor rub-impact

    • 关键词:
    • Function evaluation;Fault detection;Frequency response;Signal detection;Characteristic signal;Contribution rate;High application value;New evaluation methods;NOFRFs;Non-linear output frequency response function;Rub impact;Vibration signal
    • Liu, Y.;Zhao, Y.L.;Li, J.T.;Ma, H.;Yang, Q.;Yan, X.X.
    • 《Mechanical Systems and Signal Processing》
    • 2020年
    • 136卷
    • 期刊

    The rub-impact between a rotor and a stator is a common fault of the rotor system. Various methods are available to detect the rub impact using vibration signals. However, the noise in vibration signals causes inconvenience when extracting characteristic signals. Nonlinear output frequency response functions (NOFRFs) comprise an effective method for using input and output signals to detect damage of a structure or system. A new evaluation method named the NOFRFs weighted contribution rate has been proposed in this paper. This method is an extension of traditional NOFRFs-based indexes and attempt to obtain a new index with higher recognition of faults. As a new index extracted by this method, the second-order optimal weighted contribution rate of the NOFRFs optimally amplify the extracted fault features. The characteristic signal after amplification is significantly enhanced. The new index is applied to the evaluation of a rub-impact fault. The simulation and experimental results demonstrate the sensitivity of the new index to rub-impact faults. Especially in the initial stage of the occurrence of rub-impact, the new index shows better superiority. The findings demonstrated that the second order optimal weighted contribution rate has a high application value in the fault diagnosis of rub-impact. © 2019 Elsevier Ltd

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  • 8.Research on fault feature extraction method based on NOFRFs and its application in rotor faults

    • 关键词:
    • Feature extraction;Damage detection;Frequency response;Clenshaw-Curtis quadrature;Fault characteristics;Fault feature extractions;Guiding significances;Non-linear output frequency response function;Non-linear phenomena;Nonlinear characteristics;Weighted coefficients
    • Liu, Yang;Zhao, Yulai;Li, Jintao;Xi, Fangquan;Yu, Shuanghe;Zhang, Ye
    • 《Shock and Vibration》
    • 2019年
    • 2019卷
    • 期刊

    Rub-impact between the rotating and static parts is a more common fault. The occurrence of faults is often accompanied by the generation of nonlinear phenomena. However, it is difficult to find out because the nonlinear characteristics are not obvious at the beginning of the fault. As a new frequency domain-based method, nonlinear output frequency response functions (NOFRFs) use the vibration response to extract the nonlinear characteristics of the system. This method has a better recognition rate for fault detection. Also, it has been applied in structural damages detection, but the high-order NOFRFs have the characteristics that the signals are weak and the features are difficult to extract. On this basis, the concept of the weighted contribution rate of the NOFRFs is proposed in this paper. The variable weighted coefficients with orders are used to amplify the influence of high-order NOFRFs on the nonlinearity of the system so as to extract its fault characteristics. The new index RI is proposed based on Clenshaw-Curtis quadrature formula to eliminate the effect of artificially selected weighted coefficients on sensitivity. Especially in the early stage of the fault, the new index varies greatly with the deepening of the fault. Both simulation and experimental results verify the validity and practicability of the new index. The new index has certain guiding significance in the detection of mechanical system faults. © 2019 Yang Liu et al.

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  • 9.Effects of Substrate Roughness on Microstructure and Fatigue Behavior of Plasma Electrolytic Oxidation-Coated Ti-6Al-4V Alloy

    • 关键词:
    • roughness; microstructure; fatigue behavior; fatigue behavior; stressconcentration;MICROARC OXIDATION; SURFACE-ROUGHNESS; CORROSION-RESISTANCE;RESIDUAL-STRESS; CURRENT-DENSITY; COATINGS; LAYER; LIFE; TI; PERFORMANCE
    • Xi, Fangquan;Huang, Yong;Zhao, Yahui;Liu, Yang;Dai, Weibing;Tian, Yanzhong
    • 《MATERIALS》
    • 2022年
    • 15卷
    • 12期
    • 期刊

    Ceramic coatings were prepared by plasma electrolytic oxidation (PEO) on four different surface roughness' of Ti-6Al-4V alloys. The effects of substrate roughness on the microstructure and fatigue behavior were investigated. Microstructural characterization was carried out by scanning electron microscopy (SEM) and a laser scanning confocal microscope. In addition, an X-ray diffractometer (XRD) and a U-X360 stress meter were used to analyze the phase composition and residual stress properties of the coatings. The microstructure of coatings revealed the growth mechanism of the coatings. The larger and deeper grooves of the substrate promoted the nucleation and growth of the PEO coating, but the defects (cracks and pores) of the oxide layer became more serious. The fatigue test indicated a significant influence of substrate roughness on the fatigue life under low cyclic stress. The fatigue damage of PEO coatings decreases as the surface roughness of substrates decreases because of the synergistic effect of the coating surface defects and coating/substrate interface roughness. Substrate roughness influences the quality and fatigue performance of the oxide layer.

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  • 10.A novel fault diagnosis method for rotor rub-impact based on nonlinear output frequency response functions and stochastic resonance

    • 关键词:
    • Failure analysis;Fault detection;Numerical methods;Stochastic systems;Circuit resonance;Magnetic resonance;Frequency response;Contribution rate;Fault diagnosis method;Frequency domains;High order harmonics;Non-linear output frequency response function;Non-linear phenomena;Nonlinear problems;Stochastic resonances
    • Liu, Y.;Li, J.T.;Feng, K.P.;Zhao, Y.L.;Yan, X.X.;Ma, H.
    • 《Journal of Sound and Vibration》
    • 2020年
    • 481卷
    • 期刊

    The rub-impact fault of the rotor system is the research object in this paper, and the system is modeled by the finite element method. In the process of the study, the high-order harmonic components appear in the output response of the rotor system, which imply that the rotor system is nonlinear. Nonlinear output frequency response functions (NOFRFs) solve nonlinear problems in the frequency domain and explain these nonlinear phenomena. Based on NOFRFs, a method named weighted contribution rate of NOFRFs (WNOFRFs) is used to improve the weak high-order harmonic components proposed by the authors. In this paper, the multi-parameter optimized genetic algorithm is used to calculate the obstacle parameters of the stochastic resonance (SR) which is used to enhance weak signal components. In view of the fact that both WNOFRFs and SR can improve the weak signal components, a new method of weighted contribution rate of NOFRFs incorporating stochastic resonance (WNS) algorithm is proposed in this paper. Based on the algorithm, the variations of index WS show a trend of approximately linear growth, which indicates that index WS has certain advantages for the fault diagnosis of the rotor rub-impact. © 2020 Elsevier Ltd

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