Reduced-Order Rotor Evaluation for Real-Time Thermal Stress Monitoring

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Solution Overview

Problem

Current methods for evaluating thermal stress in rotating machinery, such as one-dimensional heat transfer/structural rotor models and finite element methods, are either limited in accuracy or require high computational loads, making real-time monitoring during operation challenging.

Innovation Solution

A rotating machinery evaluation device and system that uses a reduced order model based on a prediction model including heat transfer and structural models, allowing for real-time calculation of evaluation values by reducing computational load through boundary condition calculation and storage of a reduced order model for quick evaluation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the finite element method is used to evaluate temperature or stress, then evaluation accuracy is improved, but computational load increases

Engineering Contradiction:

Improveevaluation accuracyVSAvoidcomputational load

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent segments the computational model into two distinct components: a prediction model constructed using the finite element method for high accuracy, and a reduced order model for efficient real-time calculation. This segmentation allows each model to serve its specific purpose without compromising overall system performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The prediction model is constructed in advance using the computationally intensive finite element method. This preliminary action creates a comprehensive model that captures the complex thermal and structural behavior, which is then used to generate the reduced order model for real-time applications.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 3:

The patent creates a reduced order model that is a simplified copy or approximation of the comprehensive prediction model. This copy retains the essential characteristics needed for real-time evaluation while significantly reducing computational requirements, allowing deployment in operational environments.

Inventive Principle:

Principle #26Copying

2Productivity

If the heat transfer/structural rotor model is used for real-time monitoring, then computational load is reduced, but evaluation accuracy deteriorates

Engineering Contradiction:

Improvereal-time monitoring capabilityVSAvoidevaluation accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent transforms the prediction model into a reduced order model by changing the parameters and complexity of the mathematical representation. This parameter change reduces the computational order while preserving the essential physical relationships, enabling real-time monitoring without significant accuracy loss.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the one-dimensional heat transfer/structural rotor model is used, then computational load is reduced, but evaluation accuracy and applicability range are limited

Engineering Contradiction:

Improvecalculation speedVSAvoidevaluation range

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent transitions from a one-dimensional radial model to a multi-dimensional model by incorporating axial and circumferential dimensions in the prediction model. This dimensional expansion allows the model to capture three-dimensional thermal and structural behavior while the reduced order technique maintains computational efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables accurate and real-time monitoring of evaluation values during the operation of rotating machinery, reducing computational load and improving monitoring capabilities.

Implementation Method 1

a prediction model constructed so as to include a heat transfer model and a structural model of the rotating machinery

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a prediction model constructed so as to include a heat transfer model and a structural model of the rotating machinery

Methodology Applied

Scientific EffectThermal convection: Convection

Implementation Method 3

Rotating machinery such as a turbine that handles a hot fluid such as steam or gas generates thermal stress in its interior

Methodology Applied

Scientific EffectThermal stress: Thermal Expansion

Data Source

PatentUS20230237218A1Rotating machinery evaluation device, rotating machinery evaluation system, tuning method for rotating machinery evaluation device, and rotating machinery evaluation method

Publication Date: 2023.07.27 MITSUBISHI HEAVY IND LTD

AI summary

Rotating machinery is evaluated by calculating a boundary condition based on a measured value of a parameter related to an operating state of the rotating machinery, and calculating an evaluation value corresponding to the calculated boundary condition based on the reduced order model, during operation of the rotating machinery. The reduced order model is created based on a prediction model including a heat transfer model and a structural model of the rotating machinery for predicting an evaluation value of the rotating machinery corresponding to the boundary condition.