vibration and clearance measurements using
TRANSCRIPT
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von Karman Institute - University of Perugia - CISAS, Padova
PhD Candidate: Roberto Tomassini
Supervisor: Gianluca Rossi
Vibration and clearance
measurements using
magnetoresistive sensors
CISAS, 24 October 2016
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BTT & BTC MEASUREMENT SYSTEMS
Contactless Measurement System of:
• The gap beetween the blade tip and the casing
• Blade vibrations
Sensors: Optical, Capacitive, Eddy current, Microwave, ...
Introduction Sensor
Test
Developments
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OBJECTIVE Introduction Sensor
Test
Developments
3
Starting from:
• Marie Curie of Prof.G.Rossi
• VKI – Research Master of R.Tomassini
• (no strain gauge telemetry system, no
commercial BTT & BTC system)
Objective of the PhD Project:
BTT & BTC measurement system based on
magnetoresistive sensors
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Δϑ Change resistance ΔV
ΔV= f(ϑ) ΔV : Signal Output M: Magnetic field I: Current ϑ: Angle between M and I vectors
Magnetoresistivity is the ability of a
material (e.g. Permalloy) to change
resistance under the influence of
magnetic fields
ϑ
INNOVATION: APPLICATION OF THE MAGNETORESISTIVE
SENSOR IN TURBOMACHINERY TESTING
Introduction
Sensor Test
Developments
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How to realize a sensor?
ϑ
System sensitive to the variation of the magnetic field:
Introduction
Sensor Test
Developments
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The magnetoresistive sensor Introduction
Sensor Test
Developments
Cylindrical
magnet
Cubic
magnet
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The magnetoresistive sensor Introduction
Sensor Test
Developments
7
Cylindrical
magnet
Cubic
magnet
ΔV at the blade
passage
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The FEM Model Introduction
Sensor Test
Developments
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The measurement chain Introduction
Sensor Test
Developments
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a2 a4
The signal at the blade passage
Range ± 20°
Step 2°
Introduction
Sensor
Test Developments
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a2 a4
The signal at the blade passage
+ gap
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Introduction
Sensor
Test Developments
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a2 a4
The signal at the blade passage
TOA
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Introduction
Sensor
Test Developments
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DAS
Amplificatore
Circuit
Amplifier
Sensor
The BTT & BTC calibration bench
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Blade
Motion
Decomposition
Introduction
Sensor
Test Developments
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The BTT & BTC calibration bench
Sh
ak
e
r
A shaker moves the BTT probe and a
displacement sensor records the imposed
vibration
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BTT
Probe
Introduction
Sensor
Test Developments
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The BTT & BTC calibration bench
Displacement
sensor
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A shaker moves the BTT probe and a
displacement sensor records the imposed
vibration
Introduction
Sensor
Test Developments
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Vibration test
Imposed sensor vibration: 100Hz, Amplitude A=0,1mm, always present up to 13000rpm
Vibration peaks @ 4000 rpm (asynchronous) and @ 6000 rpm (synchronous), A = 0,2mm
Introduction
Sensor
Test Developments
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The waterfall of the measured displacements
Simulated resonances @ 4000 and 6000 rpm
Introduction
Sensor
Test Developments
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The waterfall of the measured displacements Introduction
Sensor
Test Developments
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The individual blade spectrogram
Processing method: window of N samples, successive
FFTs
Measured displacement of blade 1:
Introduction
Sensor
Test Developments
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The individual blade spectrogram
Remarks:
One sensor: 1sample x blade x rev --> Fs. = Frev.
1) Speed change Fs change
Frev. < Fvib.
Aliasing:
2) FOLDED FREQUENCIES
Introduction
Sensor
Test Developments
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The individual blade spectrogram
FFT around 7000rpm:
116,66 100
The 100Hz
vibration:
FOLDED
around 17 Hz
7000rpm
Frev=Fs=116,66 Hz
Fs/2 = 58,33 Hz
Introduction
Sensor
Test Developments
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The individual blade spectrogram
successive FFTs:
Introduction
Sensor
Test Developments
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The individual blade spectrogram
NOTE: Vibration 100Hz
Aliasing + Change of Fs Zig-Zag patch
Fs = Frev >= 200Hz
NO ALIASING
Introduction
Sensor
Test Developments
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The individual blade spectrogram 100Hz vibration – folded up to 12000rpm zig-zag patch (Vib.peaks + Harmonics +
Noise 50Hz)
Remark: MEASURED DISPLACEMENTS NOT FILTERED
A[mm]
Introduction
Sensor
Test Developments
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Test case:
F.vibration: 60Hz Amp: 0,3mm
F.rotation: 60Hz (3600 rpm)
Rotor:
4 blades at [0,30,90,270]°
DAS: 12 bits, Fs 2MHz
Vibration measurement at fixed speed
F.vibration: 60 Hz = F.rotation
1 sensor and 4 samples per rev:
NO ALIASING
Working conditions:
The blade position simulates
the sensor position
Introduction
Sensor
Test Developments
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Experimental results
Numerical prediction with the
BTT simulation software
(EU Project BTTMON)
Measured vibration amplitude Introduction
Sensor
Test Developments
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The measured frequency is the same of the imposed one.
The measured amplitude is 0,25mm, the imposed is 0,3mm
Spectrum of the imposed
vibration
Spectrum of the measured
vibration
Measured frequency Introduction
Sensor
Test Developments
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Test at ITWL on a real engine
Dr. Radoslaw Przysowa
Air Force Institute
of Technology - ITWL - Warsaw
Introduction
Sensor
Test Developments
PZL_TS-11_Iskra
Polish_Air_Force
The SO-3
Jet Engine
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Test at ITWL on a real engine 4 sensors in the second compressor
stage
Typical engine test up to 15600rpm
Duration
≈18 min
Acquisition
along
acc. trans
The SO-3 turbojet engine:
Thrust 10 kN, 7 comp stages,
π = 4,69, m = 17,8 Kg/s
2° stage: 41 blades, Rtip = 207mm
Dr. Radoslaw Przysowa
Air Force Institute of Technology - ITWL - Warsaw
Δθ = 15°
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Introduction
Sensor
Test Developments
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The waterfalls of the measured displacements
Test1:
ITWL sensor
Test2:
Magnetoresisti
ve sensor
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Introduction
Sensor
Test Developments
Drift !
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Get data plot digitizer
Blade 1
Blade 6 Blade 11
ITWL MAG
Strong agreement,
both in amplitude and
respect to the speed.
The expected
resonances were
measured correctly.
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Introduction
Sensor
Test Developments
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Test in the R2 compressor rig High speed compressor
driven by a 185kW DC
motor. The rotational speed
can vary up to 6000 rpm. It
is a single
stage axial compressor with
a 400 mm tip diameter
test section. The rotor is
composed of 24 subsonic
blades of the NACA 65
family.
3 BTT sensors
at [0 90 180]°
Speed transient:
2000 to 5500 rpm
Fs: 1 MHz 32
Introduction
Sensor
Test Developments
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Test in the R2 compressor rig
• Inlet distortion grid
excite synchronous blade
resonances
• Air injection excite
asynchronous blade
resonances
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Introduction
Sensor
Test Developments
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What do we expect ? SPEED TRANSIENT: 3000 – 5000 RPM
Synchronous
Resonances:
4800 rpm
4200 rpm
3600 rpm
+
Asynchronous
Resonance
3500 rpm
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Introduction
Sensor
Test Developments
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Test in the R2 compressor rig
Asynchronous
Resonance
3500 rpm
Synchronous
Resonance
3650 rpm 35
Introduction
Sensor
Test Developments
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Test in the R2 compressor rig
Synchronous
Resonance
4200 rpm
Synchronous
Resonance
4900 rpm 36
Introduction
Sensor
Test Developments
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Effect of the gap variation
+ gap CALIBRATION CURVE
FOR GAP
MEASUREMENTS
Introduction
Sensor
Test
Developments
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Effect of different blades
+ gap
Different
Blades
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Introduction
Sensor
Test
Developments
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Effect of different blades and gap variation
+ gap
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Different peak to peak values:
It is possible to measure clearance but it requires a normalization
Introduction
Sensor
Test
Developments
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First sensor prototype
Sensing element
Magnet
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Introduction
Sensor
Test
Developments
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Sensing element
Magnet
Differential sensor
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Introduction
Sensor
Test
Developments
gap
The differential sensor
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Differential sensor
Blade passage two pulses:
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Introduction
Sensor
Test
Developments
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Differential sensor
Blade tip – S1: 1mm – 1,358V
Blade tip – S2: 2mm – 1,022V
Linear fitting
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Introduction
Sensor
Test
Developments
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Differential sensor
Typical calibration
(sensor S1):
Range: 0,5mm – 2,5mm
Step: 0,5mm
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Introduction
Sensor
Test
Developments
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No calibration !
Two points linear fitting
S1 S2 Calibration 2
Least squares
Linear fitting
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Introduction
Sensor
Test
Developments
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Conclusions and future developments
Magnetoresistive sensors can be used for
simultaneous BTT and BTC measurements
Features:
small size, fast rise time, cheap technology, high S/N,
possibility to measure withouth making holes
Limitations:
need of ferromagnetic materials (or special expedients)
Developments:
Rotary dies monitoring ?
Anti – Aliasing algorithm ?
Applications at higher temperature ?
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THANK YOU!