基于非接触测量的高速转子叶片裂纹故障监测

张松林; 乔百杰; 王亚南; 梁俊; 耿卫民; 刘美茹; 文璧; 陈雪峰

doi:10.13224/j.cnki.jasp.20240726

基于非接触测量的高速转子叶片裂纹故障监测

doi: 10.13224/j.cnki.jasp.20240726

张松林^1,,
乔百杰^1,*, ,,
王亚南¹,
梁俊²,
耿卫民²,
刘美茹^{1, 2},
文璧³,
陈雪峰¹

1.
西安交通大学机械工程学院，西安 710049
2.
中国航发四川燃气涡轮研究院，成都 610500
3.
太行实验室，成都 610299

基金项目: 国家自然科学基金（52475130，52305127）

详细信息

作者简介:
张松林（1998-），男，博士生，主要从事航空发动机叶片振动叶尖定时监测研究。E-mail：slz1106@stu.xjtu.edu.cn

通讯作者:
乔百杰（1985-），男，教授、博士生导师，博士，主要从事航空发动机叶片健康监测研究。E-mail：qiao1224@xjtu.edu.cn

中图分类号: V231.92
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出版历程
- 收稿日期: 2024-10-23
- 网络出版日期: 2024-12-31

Crack fault monitoring of high-speed rotor blades based on non-contact measurement

1.
School of Mechanical Engineering，Xi’an Jiaotong University，Xi’an 710049，China
2.
Sichuan Gas Turbine Establishment，Aero Engine Corporation of China，Chengdu 610500，China
3.
Taihang Laboratory，Chengdu 610299，China

摘要

摘要:
针对高速转子叶片裂纹监测需求，研究基于非接触式测量的高速转子叶片叶尖定时测量技术，提出了一种基于压缩感知的叶尖定时欠采样信号重构方法。基于叶片动频的时频稀疏特征，改进欠采样信号模型，并采用自适应分块正交匹配追踪方法对模型进行求解，以监测叶片在变转速工况下叶片动频随转速的变化规律。开展高速转子叶片高周疲劳试验，同时测量叶片动应变与叶尖振动信号，比较不同转速下正常叶片与裂纹叶片振动信号的时频特征，裂纹的存在会导致叶片振动频率的偏移，通过频移的变化能够实现对裂纹的早期诊断。当叶片出现裂纹时，动频降低了24.5 Hz，所提出的监测方法与应变片辨识结果对比动频误差均小于0.50%，该方法具有较高的信号重构精度和裂纹识别率，为旋转叶片的健康状态监测和早期故障诊断提供有效的解决方案。
- 叶尖定时 /
- 转子叶片 /
- 压缩感知 /
- 动频监测 /
- 故障诊断
Abstract:
In response to the need for crack monitoring in high-speed rotor blades, the blade tip timing technology for high-speed rotor blades was investigated using non-contact measurement. A method for reconstruction under sampled blade tip timing signals based on compressed sensing was proposed. Based on the time-frequency sparse characteristics of blade dynamic frequency, the under sampling signal model was improved, and adaptive block orthogonal matching tracking method was adopted to solve it, in order to monitor the change rule of blade dynamic frequency with rotational speed under the condition of variable rotational speed of the blade. High-cycle fatigue tests on high-speed rotor blades were conducted to measure both blade dynamic strain and blade tip vibration signals. The time-frequency characteristics of vibration signals from both intact and cracked blades were compared at different speeds. The presence of cracks led to a shift in blade vibration frequency, and the frequency shift allowed for early crack diagnosis. When a crack occurred, the natural frequency decreased by 24.5 Hz. The proposed monitoring method showed a dynamic frequency error of less than 0.50% when compared with strain gauge results, demonstrating high signal reconstruction accuracy and crack identification rate. This method can provide an effective solution for health monitoring and early fault diagnosis of rotating blades.
- blade tip timing /
- rotor blades /
- compression sensing /
- dynamic frequency monitoring /
- fault diagnosis

HTML

图 1 叶尖定时测量原理示意图

Figure 1. Schematic diagram of blade tip timing measurement principle

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图 2 自适应分块正交匹配追踪重构算法流程图

Figure 2. Flowchart of the adaptive block orthogonal matching pursuit reconstruction algorithm.

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图 3 试验叶盘模型与1阶模态位移振型

Figure 3. Blade disk model and first order mode shape displacement

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图 4 试验叶盘叶片坎贝尔图

Figure 4. Campbell diagram of the blade disk blades

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图 5 高速旋转试验传感器布置

Figure 5. Sensor arrangement for high-speed rotating tests

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图 6 叶片振动台疲劳试验与裂纹叶片

Figure 6. Blade vibration bench fatigue test and cracked blade

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图 7 2号叶片实验数据

Figure 7. Experimental data of blade No.2

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图 8 无裂纹试验叶尖定时数据和应变片数据处理结果

Figure 8. Processed results of blade tip timing data and strain gauge data for the crack-free test

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图 9 有裂纹叶盘各叶片分析结果

Figure 9. Analysis results of each blade in the cracked blade disk

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图 10 裂纹前后2号叶片时频图

Figure 10. Time-frequency maps of blade No.2 before and after cracking

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图 11 有裂纹叶盘2号叶片与其他叶片时频结果对比

Figure 11. Comparison of time-frequency results between cracked blade No.2 and other blades

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表 1 无裂纹叶片叶尖定时同步振动频率辨识结果

Table 1. Identification results of synchronized vibration frequencies for crack-free blade tip timing

方法	动频/Hz					平均误差/%
方法	1号叶片	2号叶片	3号叶片	4号叶片	5号叶片	平均误差/%
应变片	686.4	659.2	691.2	688.0	680.0
ABOMP	683.0	659.4	692.2	688.2	681.1
辨识误差/%	0.49	0.03	0.14	0.03	0.16	0.17

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表 2 无裂纹叶盘和有裂纹叶盘叶尖定时数据分析结果对比

Table 2. Comparison of blade tip timing data analysis results between crack-free and cracked blade disks

参数		1号叶片	2号叶片	3号叶片	4号叶片	5号叶片
叶盘各叶片动频/Hz	无裂纹	683.0	659.4	692.2	688.2	681.1
叶盘各叶片动频/Hz	有裂纹	682.9	624.9	691.9	685.5	682.2
变化量/Hz		−0.1	24.5	−0.3	−2.7	1.1
变化幅度/%		0.01	3.72	0.04	0.39	0.16

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