International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 383-391 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

IJMET
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THEORETICAL AND EXPERIMENTAL STUDY OF ROTOR BEARING SYSTEMS FOR FAULT DIAGNOSIS
Siwani Adhikari (Mechanical Engg , IIT Kharagpur, Kharagpur,India)

ABSTRACT Vibration monitoring plays an important role in order to avoid any catastrophic failure of rotating machines. This work involves theoretical analysis of a rotor bearing system using finite element method. Eigen Frequencies (natural frequencies) and Eigen Vectors (mode shapes) are obtained using state space concept. Subsequently, frequency response function, unbalance response and Campbell Diagram plotted for the same. Simulation for Model Based Fault Identification for Unbalance is carried out using modal analysis technique and least square method. Experiment results are also evaluated .At the end experimental modal analysis is also carried to find out modal damping. The coding for this work is done in Matlab. Keywords: Modal Analysis, Model Based Fault detection, Modal expansion, Least square method, Coherence, Intensity. I. INTRODUCTION

Many rotating machineries encounters a catastrophic failure on account of faults in the system such as unbalance, rigid coupling misalignment, flexible coupling misalignment, cracks ,rubs, rotor bends and other malfunctions. These faults which if ignored can incur heavy financial losses even to life thus obstructing normal life and development. These malfunctions have to be detected accurately and then the remedies would be devised accordingly.

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II.

1. MODEL BASED FAULT IDENTIFICATION

Vibration monitoring is one of the primary techniques of condition monitoring of rotating machines. Shaft misalignment and rotor unbalance are the main sources of vibration in rotating machines. The present day requirement for ever-increasing reliability in the field of rotor dynamics is now more important than ever before and continues to grow constantly. Advances are continually being made in this area, due largely to the consistent demand from the power-generation and transportation industries. Because of progress made in engineering and materials science, rotating machinery is becoming both faster and lighter, as well as being required to run for longer periods of time. All of these factors mean that the detection, location and analysis of faults play a vital role in the field of rotor dynamics. Model-based fault detection is, at this time, directly employed in most areas of fault diagnosis. The modelbased approach involves the establishment of a suitable process model, either mathematical or signal-based, which can estimate and predict process parameters and variables. Eshleman(1984) reviewed many aspects of significance, including the vibration analysis of faults in rotors, bearings, seals, dampers and foundations. Isermann (1994)[1] described the main principles involved in model-based procedures and outlined their importance for the realistic modeling of faults. Smith covered the general kinds of faults listed above and described qualitatively how they may be recognized from their vibration characteristics, and included effects caused by nonlinearity. Markert[2]outlined the procedure for model-based approach used in fault diagnosis of rotors. He mentioned basic steps to perform the diagnosis and optimized the fault parameters using least square fitting. Platz[3]further used this modelbased approach for on-line identification of fault in rotor systems. Model based Fault Identification in rotor systems by least square method has been accomplished by Richard Markert ,Roland Platzo and Siedler at Darmstadt University of Technology, Germany whose procedure is used extensively in this work. 1.1 Mathematical Description

The identification of any fault in rotor system incorporates the linear model of a healthy system as shown below [21] (1) for any N degrees of freedom rotor system. F0 includes the initial operating load acting on the system which may comprise elastic hysteresis, residual unbalances etc. In reality, a fault changes the dynamic behavior of a system while the system properties such as mass, stiffness and damping remaining unchanged thus assuming the system to be linear time invariant. However, change in speed of rotor changes matrices in eq 1 due to gyroscopic effects and journal bearings.A fault can be represented by virtual loads acting on the linear model of the undamaged system by modal analysis[4] [5]and hence eqn is modified to incorporating equivalent loads (2)

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Subtracting eqn 1from 2, the measured residual vibrations can be related to the equivalent forces due to fault as observed in eqn (3) Where, represents the fault parameters of a fault depending on its type, position, severity. For calculating the equivalent loads which represent the fault arising in the rotor system, the measured residual vibrations from the actual measurements and the corresponding normal vibrations has to be fed into eq.3. 1.2 Shape Expansion Method In practice, number of vibration transducers mounted on the system is less than the number of degrees of freedom of testing system and hence measurement of residual vibrations is available for less number of locations. Thus data from non-measurable locations has to be estimated from few measured locations. Shape Expansion is technique which accomplishes the above task of extending few measured data to extract full state residual vibrations. The relation between the full state residual vibrations and measured sensors output is given by r(t)=Cmrm(t) ( 4)

Numerous Shape Expansions method has been purposed and utilized such static expansion, dynamic expansion, modal expansion, hybrid expansion, minimum dynamic residual, and others. Modal Expansion comes with more accurate solution based on the assumption that the response at all DOF of FE model is a linear combination of mode shapes. Hybrid technique is a combination of more than one method of expansion. Least Squares Fitting in Time Domain In practice, measurement noise and errors, inadequate number of sensors signals and inaccurate modeling of the rotor system could lead to erroneous measurement of equivalent loads. Therefore, a least square algorithm is used to achieve the best fit between measured equivalent forces F(t) and theoretical equivalent forces Fi(i,t) produced by all kinds of faults taking into account all the fault parameters. 1.3

| F i ( i , t ) F ( t )| d t = m in i
1.4 Probability Measures

(5)

The quality of fit achieved can be used in estimating the probability of the different identified faults. Two probability measures coherence and intensity based cross correlation and autocorrelation respectively have been developed and successfully tested.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Coherence p1 is the normalized correlation of the identified equivalent forces F(,t) with the measured equivalent forces from measured data with a time lag=0 is

p1 =

Fi , F

(0)
(6)

Fi ,Fi (0)F ,F (0)

Coherence lies between values [-1,1] with p1=1 implies absolute matching of theoretical and measured equivalent loads. Intensity p2 is a measure of the contribution of a particular fault to the total measured equivalent load.

p2 =

F i , F i ( 0 ) Fto ta l , Fto ta l ( 0 )
(7)

The intensity measure p2 acquires value in interval 0p1,where p2=1 signifies identified fault is the only fault present in the system. For simulation purpose both above measures are evaluated. Suitable threshold value p110% and p220% indicates the specific fault is present in the system. 1.5 Scheme of Fault Diagnosis

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

1.6 Modal Expansion This technique uses the Fe model mode shapes to generate full state residual vibrations from measured residual vibrations. The full residual vector can be approximated by a set of mode shapes put together in the reduced modal matrix such as r(t) = q(t) (8) Where is the Fem modal matrix and q(t) is the vector of modal co-ordinates. The measured vibrations is then related with full state vibrations by measurement matrix Cm (9) No of mode shapes may not exceed the no. of independently measured vibrations. Practically it s not feasible to have enough sensors to be mounted on the system for all its DOFs and less number of sensors leads to selection of few no. of target modes thus giving erroneous results. 1.7 Determination of Equivalent Loads

The equivalent force F(t) characterising the unknown faults is calculated by putting the residual accelerations ,velocities , displacement of the full vibrational state. (10)[6] III. RESULTS

A matlab code is developed to estimate responses theoretically with the experimental set up data and with varying the number of sensors position in the direction of DOF ,theoretical residual vibrations are plotted for 60 DOF.The equivalent load for unbalance is calculated using eqn and is plotted for 60 DOF.The two probability measures coherence and intensity are calculated at each node and is found to be good enough values at node 8 where the unbalance is introduced at disc position. Table 1 Simulation results (Case 1) Measured signals Estimated signals by modal expansion Unbalance at disc node(node 8) Amount Phase Coherence(%) Intensity(%) 0.000999 kg m 60 degrees 100 100 All 60 DOFs All 60 DOFs

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

1000

500 A m p litu d e

0 -500 0.05 0.1 -1000 10 20 30 40 50 60 0.15 Time

Fig 1 Equivalent load for 60 DOFs with measured 60 DOFs

Measured signals

Table 2 Simulation results (Case 2) DOFs [1 3 29 31 56 58] All 60 DOFs

Estimated signals by modal expansion Unbalance at disc node(node 8) Amount Phase Coherence(%) Intensity(%)

.00074216 kg m 60 degrres 98.8593 97.8127

1000

500 A m p lit u d e

0 -500 0.05 0.1 -1000 10 20 30 40 50 60 0.15 Time

Fig 2 Equivalent load at all 60 DOFs with measured signals at [1 3 29 31 56 58] DOFs

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Table 3 Experimental results (Case 1)

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Measured signals

DOF[1 3 56]

Experimental

Estimated signals by modal expansion All 60 DOFs Unbalance at disc node(node 8) Amount Phase Coherence(%) Intensity(%) 1.7457e-008 kg m 46 degrees .26487(96.9811) 54.2622(94.2071)

Case 3
Measured signals DOF[1 3 56] Experimental

Estimated signals by modal expansion All 60 DOFs Unbalance at disc node(node 8) Amount Phase Coherence(%) Intensity(%) .34541 kg m 52 degrees 3.29690(58.8789) 41.72580(79.3568)

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IV.

CONCLUSION

The stimulated results for unbalance shows more the number of measured vibrations for a certain DOF system, probability measures tend to better results. However it can be inferred that it is not always feasible to apply forces at the active nodes. Estimation of vibrations of nonmeasured locations from few measured data by modal expansion is less accurate unless selection of target modes is good enough. Experimental results shows good intensity implying unbalance is the only fault present but coherence values are not prominent enough but coherence at disc relative to other nodes is much higher for particular selection of DOFs in experimental values. Work can be extended including modal damping and other effects (internal damping, shear deformation, bearing parameters, axial torque and force) taking into account. More effective techniques developed for model based fault identification which give accurate results over non-measured locations can be verified experimentally. REFERENCES 1. Isermann, R., 1994, On the Applicability of Model-Based Fault-Detection for Technical Processes ", Control Engineering Practice, Vol. 2, No. 3, PP. 439-450. 2. Platz, R., Markert, R., and Seidler, M., 2000, \Validation of On-line Diagnostics of Malfunctions in Rotor Systems", Transactions of the 7th IMechE-Conference on Vibrations in Rotating Machinery, University of Not- tingham,UK, S. 581-590. 3. Wattar, I, Hafez, W., and Gao, Z., Model-Based Diagnosis of Chaotic Vibration Signals", Department of Electrical and Computer Engineering, Cleveland State University. 4. H. D. Nelson and J. M. McVaugh, 1976. Journal of Engineering for Industry, vol. 98, pp. 500-600 , The Dynamics of Rotor-Bearing Systems Using Finite Elements. 5. H. D., Nelson, 1977, Engineering Research Center Report,ERC-R-77023, Arizona StateUniversity, p. 61., "A Finite Rotating Shaft Element Using Timoshenko Beam Theory. 6. Bachschmid, N., Pennacchi, P., and Vania A., 2001, \Identification of Multiple Fault in Rotor Systems", Journal of Sound and Vibration, Vol. 254, No. 2, PP. 327-366. 7. L.B. Bhuyar, S.V. Kshirsagar, G.K. Awari and A.S. Padalkar, Fault Detection and Condition Monitoring of Machine-Structure: Review, International Journal of Mechanical Engineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 166 - 181, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 8. B. R. Manju, B. R. Manju and V. Sugumaran, Wavelet Design for Fault Diagnosis of Roller Bearings using Continuous Wavelet Transforms, International Journal of Mechanical Engineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 38 - 48, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 9. Manju B R, A.R. Rajan and V. Sugumaran, A New Wavelet Feature for Fault Diagnosis of Roller Bearings using Decision Tree, International Journal of Mechanical Engineering & Technology (IJMET), Volume 2, Issue 2, 2011, pp. 70 - 84, ISSN Print: 0976 6340, ISSN Online: 0976 6359.

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