Experimental detection of an early developed crack in rotor-bearing systems using an AMB

Abstract

Purpose – The purpose of this paper is to present a method for early crack detection in rotating shafts. A rotor-bearing system, consisting of an elastic rotor mounted on fluid film bearings, is used to detect the presence of the crack at a depth of around 5 percent of shaft radius. The fluid film bearings, the shaft and the crack introduce coupled bending vibrations both in the horizontal and vertical plane. Experimental time series of the rotor composite response under normal steady-state operation are uncoupled, to develop a signal processing procedure able to reveal the presence of the crack. Design/methodology/approach – The variation of the coupling property that a crack (breathing or not) or a cut (always open) introduces into the system and the localization of the coupling in the time domain is a concept proposed as a means to detect transverse surface cracks in rotating shafts. This consideration is combined with the concept of external excitation for the development of an additional crack-sensitive response during system normal operation. Using an external excitation of an active magnetic bearing of specific duration, frequency and amplitude, the method uses this coupling variation during rotation. Findings – The method is simple, quick and effective for early crack detection, being able to detect cracks as shallow as 5 percent of the shaft radius while the system is under normal operation, and can even be applied real-time. Experimental verification uses a simple elastic rotor with a cut mounted on fluid film bearings, with the cut producing similar coupling phenomena as an opened crack. Experimental results are encouraging. Originality/value – The method used is simple, quick and effective for early crack detection, being able to detect cracks as shallow as 5 percent of the shaft radius while the system is under normal operation, and can even be applied real-time.