Fault simulation system for detecting unbalance and misalignment of gas turbine rotor

Abstract

The utility model discloses a simulation system for detecting unbalance and misalignment faults of a gas turbine rotor. The simulation system comprises a test support and a processing terminal. The test support comprises a first bearing, a second bearing and a driving motor, and the axis of the first bearing and the axis of the second bearing do not coincide when a misalignment fault is tested; the processing terminal comprises an audio acquisition module, a noise reduction module and a diagnosis module and is used for receiving the first noise reduction sound and the first test noise reduction sound and judging whether the rotor breaks down or not according to the first noise reduction sound and the first test noise reduction sound; according to the utility model, the unbalance fault of the rotor and the misalignment condition of the rotor can be simulated.

Description

Technical Field

[0001] The utility model belongs to the field of gas turbine rotor testing, in particular to a fault simulation system for detecting imbalance and misalignment of a gas turbine rotor. Background Art

[0002] As a key platform for studying gas turbine performance and fault diagnosis, the gas turbine rotor simulation test bench plays an irreplaceable role in improving equipment operating efficiency and ensuring equipment safety. This test bench can accurately simulate the actual operating conditions of gas turbine rotors, providing researchers with a stable and monitorable experimental environment. In this environment, researchers can monitor the rotor's vibration signals, vibration sounds, temperature, pressure and other key parameters in real time, so as to deeply analyze the rotor's operating conditions and potential failure risks.

[0003] However, during the operation of the gas turbine, the rotor may fail due to factors such as material fatigue, manufacturing defects, and harsh operating environment. These failures not only affect the normal operation of the gas turbine, but are also likely to cause serious damage to the equipment and even safety accidents. Therefore, conducting fault simulation experiments on the gas turbine model rotor isolated combat simulation test bench is extremely valuable for revealing the rotor failure mechanism, exploring fault diagnosis methods, and formulating preventive measures.

[0004] Through fault simulation experiments, researchers can simulate various rotor fault types such as misalignment, rotor cracks, imbalance, and friction, providing a solid guarantee for the safe and reliable operation of gas turbine equipment. Gas turbine rotor fault diagnosis does face a series of challenges.

[0005] First, gas turbines usually need to run continuously to meet the continuous needs of industries such as electricity and chemicals. Therefore, shutdown detection is often not feasible, which limits the timing and scope of fault diagnosis. To diagnose faults during the operation of the gas turbine, it is necessary to ensure that the detection methods will not interfere with the normal operation of the equipment, which increases the difficulty of rotor fault diagnosis. Secondly, there are also many difficulties in installing sensors inside the gas turbine, because the internal environment of the gas turbine is harsh, and factors such as high temperature, high pressure and strong vibration can damage the sensor or affect its accuracy. At the same time, the gas turbine has a compact structure and limited installation space, which also increases the difficulty of sensor installation. Utility Model Content

[0006] The utility model aims to provide a simulation system for detecting the imbalance and misalignment faults of a gas turbine rotor, so as to simulate the imbalance and misalignment faults of the gas turbine rotor and detect the faults thereof by using a processing terminal.

[0007] The utility model adopts the following technical scheme: a simulation system for detecting imbalance and misalignment faults of gas turbine rotors, comprising: a test bracket and a processing terminal;

[0008] The test stand includes:

[0009] The first bearing and the second bearing are separated by a predetermined distance, and the bottoms of the first bearing and the second bearing are fixed on the experimental table, and the inner cavities of the first bearing and the second bearing are used for the rotor shaft to pass through, and the rotor disk is arranged close to the first bearing and is located outside the gap between the first bearing and the second bearing;

[0010] A drive motor, whose output end is connected to the free end of the rotor main shaft through a coupling; the drive motor is used to drive the rotor main shaft to rotate through the coupling and the first bearing and the second bearing;

[0011] Wherein, when testing the misalignment fault, the axes of the first bearing and the second bearing do not coincide;

[0012] The processing terminals include:

[0013] an audio collection module, installed at a position close to the first bearing, for collecting a first sound emitted during the rotation process when the rotor main shaft and the rotor disk are balanced and aligned, and for collecting a first test sound emitted during the rotation process when the rotor main shaft and the rotor disk are unbalanced and misaligned;

[0014] A noise reduction module, used for receiving the first sound and the first test sound of the audio acquisition module, and performing noise reduction on the first sound and the first test sound to obtain a first noise-reduced sound and a first test noise-reduced sound respectively;

[0015] The diagnosis module is used to receive the first noise reduction sound and the first test noise reduction sound, and determine whether the rotor fails according to the first noise reduction sound and the first test noise reduction sound.

[0016] Furthermore, it also includes:

[0017] A vibration sensor is installed near the rotor disc and in contact with the rotor disc, and is used to collect the vibration amplitude during the rotation process when the rotor main shaft and the rotor disc are balanced and aligned, and is also used to collect the test vibration amplitude during the rotation process when the rotor main shaft and the rotor disc are unbalanced and misaligned;

[0018] The diagnosis module is also used to receive the vibration amplitude and the test vibration amplitude, and determine whether the rotor fails according to the vibration amplitude and the test vibration amplitude.

[0019] Furthermore, it also includes: a mass block installed at the edge of the rotor disc, the mass block is used to simulate an unbalanced fault of the rotor disc;

[0020] The audio acquisition module is also used to collect the second sound emitted by the rotor main shaft during normal rotation, and is also used to collect the unbalance test sound emitted when the rotor main shaft simulates an unbalance fault;

[0021] The noise reduction module is further used to receive the second sound and the unbalanced test sound from the audio acquisition module, and perform noise reduction on the second sound and the unbalanced test sound to obtain a second noise reduction sound and an unbalanced test noise reduction sound respectively;

[0022] The diagnostic module is further used to receive the second noise reduction sound and the unbalance test noise reduction sound, and determine whether the rotor fails based on the second noise reduction sound and the unbalance test noise reduction sound.

[0023] The beneficial effects of the utility model are:

[0024] The utility model can simulate both rotor imbalance fault and rotor misalignment;

[0025] When simulating an unbalanced fault, the utility model screws a mass block into a threaded hole at the edge of a rotor disc, and can accurately control the size and distribution of the mass block causing the unbalance, thereby simulating unbalanced faults of different degrees, and then analyzing the fault characteristics;

[0026] When simulating a misalignment fault, the utility model realizes accurate simulation of the misalignment fault by changing the relative positions of the first bearing and the second bearing on the coupling, and can reflect the influence of the misalignment fault on the dynamic characteristics of the rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the utility model.

[0028] Among them: 10, first bearing; 11, second bearing; 12, drive motor; 13, rotor main shaft; 14, rotor wheel; 15, mass block. DETAILED DESCRIPTION

[0029] The utility model is described in detail below with reference to the accompanying drawings and specific implementation modes.

[0030] In the description of the present utility model, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present utility model. In addition, the terms "first" and "second" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present utility model, unless otherwise specified, "multiple" means two or more. The "direction" in the present utility model is based on the position of the present utility model in the Figure 1 Description of the trend in the state.

[0031] The utility model discloses a simulation system for detecting imbalance and misalignment faults of gas turbine rotors. Figure 1 As shown, it includes: a test bracket and a processing terminal.

[0032] The test bracket includes: a first bearing 10 , a second bearing 11 , and a drive motor 12 .

[0033] The first bearing 10 and the second bearing 11 are separated by a predetermined distance, and the bottoms of the first bearing 10 and the second bearing 11 are fixed on the experimental table. The inner cavities of the first bearing 10 and the second bearing 11 are used for the rotor main shaft 13 to pass through. The rotor disk 14 is arranged close to the first bearing 10 and is located outside the gap between the first bearing 10 and the second bearing 11.

[0034] The output end of the driving motor 12 is connected to the free end of the rotor main shaft 13 through a coupling; the driving motor 12 is used to drive the rotor main shaft 13 to rotate through the coupling and the first bearing 10 and the second bearing 11.

[0035] When testing the misalignment fault, the axes of the first bearing 10 and the second bearing 11 do not coincide, so as to achieve accurate simulation of the misalignment fault, thereby reflecting the influence of the misalignment fault on the rotor dynamic characteristics.

[0036] The processing terminal includes: an audio acquisition module, a noise reduction module, and a diagnosis module.

[0037] The audio acquisition module is installed at a position close to the first bearing 10. The audio acquisition module is used to collect the first sound emitted during the rotation process when the rotor main shaft 13 and the rotor disk 14 are balanced and aligned. The audio acquisition module is also used to collect the first test sound emitted during the rotation process when the rotor main shaft 13 and the rotor disk 14 are unbalanced and misaligned.

[0038] The noise reduction module is used to receive the first sound and the first test sound of the audio acquisition module, and to perform noise reduction on the first sound and the first test sound to obtain the first noise reduction sound and the first test noise reduction sound respectively; the diagnosis module is used to receive the first noise reduction sound and the first test noise reduction sound, and to determine whether the rotor is faulty based on the first noise reduction sound and the first test noise reduction sound.

[0039] The utility model also includes: a vibration sensor, which is installed at a position close to the rotor disk 14 and in contact with the rotor disk 14. The vibration sensor is used to collect the vibration amplitude during the rotation process when the rotor main shaft 13 and the rotor disk 14 are balanced and centered. The vibration sensor is also used to collect the test vibration amplitude during the rotation process when the rotor main shaft 13 and the rotor disk 14 are unbalanced and misaligned; the diagnostic module is also used to receive the vibration amplitude and the test vibration amplitude, and determine whether the rotor is faulty based on the vibration amplitude and the test vibration amplitude.

[0040] The utility model also includes: a mass block 15 installed at the edge of the rotor disc 14, and the mass block 15 is used to simulate an unbalanced fault on the rotor disc 14; therefore, the audio acquisition module is also used to collect the second sound emitted by the rotor main shaft 13 during normal rotation, and the audio acquisition module is also used to collect the unbalanced test sound emitted when the rotor main shaft 13 simulates an unbalanced fault.

[0041] At this time, the noise reduction module is also used to receive the second sound and the unbalanced test sound of the audio acquisition module, and perform noise reduction on the second sound and the unbalanced test sound to obtain the second noise reduction sound and the unbalanced test noise reduction sound respectively. At this time, the diagnosis module is also used to receive the second noise reduction sound and the unbalanced test noise reduction sound, and determine whether the rotor is faulty according to the second noise reduction sound and the unbalanced test noise reduction sound.

[0042] Therefore, when collecting the first sound and the second sound, the axes of the first bearing 10 and the second bearing 11 coincide with each other, and when collecting the first test sound and the unbalanced test sound, the axes of the first bearing 10 and the second bearing 11 do not coincide with each other.

[0043] The denoising module uses wavelet basis functions and threshold processing methods. Wavelet transform can effectively remove the noise components in the signal, thereby extracting the effective information of the signal. Wavelet transform decomposes the original signal into wavelet components of different scales and frequencies. Then, by threshold processing of the wavelet coefficients, the noise in the high-frequency part can be removed, thereby realizing the denoising of the signal. Finally, the denoised signal can be obtained by inverse wavelet transform.

[0044] The diagnosis module uses a complex network modeling method to construct a rotor fault diagnosis model. On this model, the features of the complex network edge number, degree mean, clustering coefficient, etc. are extracted. These features can reflect the characteristic information of different types of rotor faults and provide key information for subsequent fault classification. The extracted features are input into the SVM classification algorithm for learning to obtain a gas turbine model rotor fault classification model. Subsequently, the model is verified and iterated using a test data set to ensure that the model meets the accuracy requirements. The fault diagnosis performance of the model is improved by continuously adjusting the model parameters and optimizing the algorithm. After the model training and verification are completed, the rotor data collected in real time is input into the rotor fault diagnosis model. The model will classify and diagnose the rotor fault in real time according to the characteristics of the input data and give the corresponding diagnosis results. The diagnosis method of the diagnosis module can refer to the patents with publication numbers CN116861231 A, CN 116861165 A, CN 116701999 A, and CN116861320A.

[0045] Experimental results show that the utility model has an accuracy rate greater than 95% and a false alarm rate less than 4% in the diagnosis of gas turbine rotor imbalance and misalignment faults.

[0046] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A simulation system for detecting imbalance and misalignment faults of gas turbine rotors, characterized in that: include: test stands and processing terminals; The test bracket comprises: The first bearing (10) and the second bearing (11) are separated by a predetermined distance and their bottoms are fixed on a test bench. The inner cavities of the first bearing (10) and the second bearing (11) are used for the rotor main shaft (13) to pass through. The rotor disk (14) is arranged close to the first bearing (10) and is located outside the gap between the first bearing (10) and the second bearing (11). A drive motor (12), the output end of which is connected to the free end of the rotor main shaft (13) through a coupling; the drive motor (12) is used to drive the rotor main shaft (13) to rotate through the coupling and the first bearing (10) and the second bearing (11); Wherein, when testing a misalignment fault, the axes of the first bearing (10) and the second bearing (11) do not coincide; The processing terminal comprises: an audio collection module, installed at a position close to the first bearing (10), for collecting a first sound emitted during rotation when the rotor main shaft (13) and the rotor disk (14) are balanced and aligned, and for collecting a first test sound emitted during rotation when the rotor main shaft (13) and the rotor disk (14) are unbalanced and misaligned; A noise reduction module, used for receiving the first sound and the first test sound of the audio acquisition module, and performing noise reduction on the first sound and the first test sound to obtain a first noise-reduced sound and a first test noise-reduced sound respectively; The diagnosis module is used to receive the first noise reduction sound and the first test noise reduction sound, and determine whether the rotor fails according to the first noise reduction sound and the first test noise reduction sound.

2. The simulation system for detecting imbalance and misalignment faults of gas turbine rotors according to claim 1, characterized in that: Also includes: A vibration sensor is installed at a position close to the rotor disk (14) and in contact with the rotor disk (14), and is used to collect the vibration amplitude during the rotation process when the rotor main shaft (13) and the rotor disk (14) are balanced and aligned, and is also used to collect the test vibration amplitude during the rotation process when the rotor main shaft (13) and the rotor disk (14) are unbalanced and misaligned; The diagnostic module is also used to receive the vibration amplitude and the test vibration amplitude, and determine whether the rotor fails according to the vibration amplitude and the test vibration amplitude.

3. The simulation system for detecting imbalance and misalignment faults of gas turbine rotors according to claim 1, characterized in that: Also includes: A mass block (15) mounted at the edge of the rotor disc (14), the mass block (15) being used to simulate an unbalanced fault on the rotor disc (14); The audio collection module is also used to collect a second sound emitted by the rotor main shaft (13) during normal rotation, and is also used to collect an unbalance test sound emitted by the rotor main shaft (13) when simulating an unbalance fault; The noise reduction module is further used to receive the second sound and the unbalanced test sound from the audio acquisition module, and perform noise reduction on the second sound and the unbalanced test sound to obtain a second noise reduction sound and an unbalanced test noise reduction sound respectively; The diagnosis module is also used to receive the second noise reduction sound and the unbalance test noise reduction sound, and determine whether the rotor fails according to the second noise reduction sound and the unbalance test noise reduction sound.

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