转子—支承系统典型故障非线性动力特性分析与实验研究
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摘要
旋转机械在国民经济各部门中发挥着非常重要的作用。随着对旋转机械更高转速、更高效率的追求,其核心部分转子系统的工作环境越来越严峻,因此,转子故障时常发生。这就需要对故障转子的动力学特性、振动特征以及诊断技术进行深入研究,以期为工程设计和故障诊断提供充分的指导。本文采用有限元方法,进行故障转子动力学特性与故障诊断技术研究,主要研究内容如下：
1.对滑动轴承—转子系统动力特性进行研究,分析系统参数对其动力特性的影响。结果表明：偏心量、润滑油动力粘度、轴承长径比以及轴承间隙对系统均有较大影响；提高润滑油动力粘度和减小滑动轴承间隙可提高系统稳定性。
2.建立考虑弹性静子的碰摩系统动力学模型,研究弹性静子与非弹性静子碰摩的异同。结果表明：静子质量越大、碰摩刚度越大,转静耦合作用越明显。当静子质量远大于转子质量时,转静碰摩可简化为非弹性静子状态；若静子质量与转子质量相近,在研究转静碰摩时必须考虑两者之间的耦合作用。
3.对裂纹转子系统动力特性进行研究,分析系统参数对其动力特性的影响。结果表明：裂纹在转轴中心或在低转速、小偏心量的情况下,更容易被识别,裂纹的产生对系统失稳转速和失稳类型影响不大。
4.对碰摩、裂纹转子进行故障诊断研究,提出将时域波形、FFT频谱图及Hilbert-Huang时频谱应用于转子故障诊断中。系统地研究裂纹转子、碰摩转子以及两故障耦合转子在不同转速下的振动特征,得出：裂纹转子在临界转速的1/5、1/3和1/2运行时,频谱图中会出现明显的5X、3X和2X谐波共振；Hilbert-Huang时频谱能更准确有效地辨别碰摩,甚至是频谱分析无法诊断的轻微碰摩。
5.对故障转子进行实验研究,实验结果很好地验证了数值方法得出的结论,并为转子的故障诊断提供参考依据。
6.对高速离心压气机实验中出现的转静碰摩故障进行分析,找出故障原因,并提出改进方案；改进后,实验件顺利推到全转速运行,成功验证故障分析及改进方案的合理性。
Rotating machinery plays a very important role in many sectors of national economy. With the pursuit of higher speed and higher efficiency of the rotating machinery, the rotor system as the core component operates in harsher environment, so it often breaks down. Therefore, the dynamic characteristic, vibration feature and diagnostic technology of rotor with faults are required to be researched deeply for the guidance of engineering design and fault diagnosis. In this paper, the dynamic characteristic and fault diagnosis of rotor with faults are numerically investigated by finite element method. The main contents are as follows:
1. The dynamic characteristics of the rotor-bearing system supported by oil film are investigated, and the effects of all kinds of system parameters are also discussed. The results indicate that unbalance, dynamic viscosity, bearing aspect ratio and bearing clearance have great influence on rotor system. And increasing the dynamic viscosity and decreasing the bearing clearance properly can improve the stability of the system.
2. A dynamic model of rotor-bearing system with rub-impact fault is established, taking the stator elasticity into account. The characteristics of the rub-impact system with elastic or inelastic stator are compared and discussed. The results indicate that the bigger stator mass and rubbing stiffness is, the greater coupling effects will happen on the rotor and stator. If the mass of the stator is much heavier than that of the rotor, rub-impact with elastic stator can be simplified as that with inelastic stator. Otherwise, rotor-stator coupling must be taken into account.
3. The dynamic characteristics of the cracked rotor are investigated, and the effects of all kinds of system parameters are also discussed. The results indicate that the crack can be more easily identified in a low speed, small eccentricity rotor system or when the crack exists in the middle of the rotor. And the existence of the crack has little influence on the system unstable speed and unstable pattern.
4. The crack and rub-impact fault signals are analyzed by the method of waveform, FFT spectrum and Hilbert-Huang spectrum. The vibration features of crack fault, rub-impact fault and their coupling fault are investigated systematically, and the conclutions are gotten:the displacement response of the rotor containing5X,3X and2X components reaches its maximum amplitude when its speed is at1/5,1/3and1/2of the critical speed. Hilbert-Huang spectrum identifies rub-impact more accurately and efficiently, even the slight ones that cannot be identified by FFT spectrum.
5. The experimental investigation of rotor with fault is performed. The results validate the conclusions of the numerical method and provide a basis for diagnosing rub-impact fault and crack in practice exactly.
6. By analyzing the rub-impact fault in the high-speed centrifugal compressor experiment, the renovation projects are submitted to avoid this failure in the next time. In the subsequent operation, the compressor can operate well at full working speed, which shows the rationality of fault analysis and the renovation projects.
1.对滑动轴承—转子系统动力特性进行研究,分析系统参数对其动力特性的影响。结果表明：偏心量、润滑油动力粘度、轴承长径比以及轴承间隙对系统均有较大影响；提高润滑油动力粘度和减小滑动轴承间隙可提高系统稳定性。
2.建立考虑弹性静子的碰摩系统动力学模型,研究弹性静子与非弹性静子碰摩的异同。结果表明：静子质量越大、碰摩刚度越大,转静耦合作用越明显。当静子质量远大于转子质量时,转静碰摩可简化为非弹性静子状态；若静子质量与转子质量相近,在研究转静碰摩时必须考虑两者之间的耦合作用。
3.对裂纹转子系统动力特性进行研究,分析系统参数对其动力特性的影响。结果表明：裂纹在转轴中心或在低转速、小偏心量的情况下,更容易被识别,裂纹的产生对系统失稳转速和失稳类型影响不大。
4.对碰摩、裂纹转子进行故障诊断研究,提出将时域波形、FFT频谱图及Hilbert-Huang时频谱应用于转子故障诊断中。系统地研究裂纹转子、碰摩转子以及两故障耦合转子在不同转速下的振动特征,得出：裂纹转子在临界转速的1/5、1/3和1/2运行时,频谱图中会出现明显的5X、3X和2X谐波共振；Hilbert-Huang时频谱能更准确有效地辨别碰摩,甚至是频谱分析无法诊断的轻微碰摩。
5.对故障转子进行实验研究,实验结果很好地验证了数值方法得出的结论,并为转子的故障诊断提供参考依据。
6.对高速离心压气机实验中出现的转静碰摩故障进行分析,找出故障原因,并提出改进方案；改进后,实验件顺利推到全转速运行,成功验证故障分析及改进方案的合理性。
Rotating machinery plays a very important role in many sectors of national economy. With the pursuit of higher speed and higher efficiency of the rotating machinery, the rotor system as the core component operates in harsher environment, so it often breaks down. Therefore, the dynamic characteristic, vibration feature and diagnostic technology of rotor with faults are required to be researched deeply for the guidance of engineering design and fault diagnosis. In this paper, the dynamic characteristic and fault diagnosis of rotor with faults are numerically investigated by finite element method. The main contents are as follows:
1. The dynamic characteristics of the rotor-bearing system supported by oil film are investigated, and the effects of all kinds of system parameters are also discussed. The results indicate that unbalance, dynamic viscosity, bearing aspect ratio and bearing clearance have great influence on rotor system. And increasing the dynamic viscosity and decreasing the bearing clearance properly can improve the stability of the system.
2. A dynamic model of rotor-bearing system with rub-impact fault is established, taking the stator elasticity into account. The characteristics of the rub-impact system with elastic or inelastic stator are compared and discussed. The results indicate that the bigger stator mass and rubbing stiffness is, the greater coupling effects will happen on the rotor and stator. If the mass of the stator is much heavier than that of the rotor, rub-impact with elastic stator can be simplified as that with inelastic stator. Otherwise, rotor-stator coupling must be taken into account.
3. The dynamic characteristics of the cracked rotor are investigated, and the effects of all kinds of system parameters are also discussed. The results indicate that the crack can be more easily identified in a low speed, small eccentricity rotor system or when the crack exists in the middle of the rotor. And the existence of the crack has little influence on the system unstable speed and unstable pattern.
4. The crack and rub-impact fault signals are analyzed by the method of waveform, FFT spectrum and Hilbert-Huang spectrum. The vibration features of crack fault, rub-impact fault and their coupling fault are investigated systematically, and the conclutions are gotten:the displacement response of the rotor containing5X,3X and2X components reaches its maximum amplitude when its speed is at1/5,1/3and1/2of the critical speed. Hilbert-Huang spectrum identifies rub-impact more accurately and efficiently, even the slight ones that cannot be identified by FFT spectrum.
5. The experimental investigation of rotor with fault is performed. The results validate the conclusions of the numerical method and provide a basis for diagnosing rub-impact fault and crack in practice exactly.
6. By analyzing the rub-impact fault in the high-speed centrifugal compressor experiment, the renovation projects are submitted to avoid this failure in the next time. In the subsequent operation, the compressor can operate well at full working speed, which shows the rationality of fault analysis and the renovation projects.
引文
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