Development of Rotor Balancing Algorithm for a High‐Precision Rotor System considering Dynamic Reliability through Automatic‐Adaptive DBSCAN

Abstract

Recently, the demand for high‐precision balancing of rotors has increased in the automobile industry, as more rotors are designed to rotate at ever‐higher speeds to maximize energy efficiency. The accumulation of measurement uncertainty in the balancing process decreases the accuracy of the unbalanced mass estimation, which is the ultimate goal of balancing. Here, the problem of uncertainty is shown through a Monte Carlo simulation of signals acquired from an actual production line. To reduce the effect of measurement uncertainty in the balancing procedures, a signal‐processing technique that increases the dynamic reliability of the signal is proposed. The suggested method is based on density‐based spatial clustering of applications with noise (DBSCAN) with the use of the orthogonality‐based averaging method. Specifically, by adjusting radius values while clustering samples through the use of the DBSCAN method, the outliers that arise due to uncertainty are successfully removed. In this work, our proposed automatic‐adaptive DBSCAN (AA‐DBSCAN) method is validated by applying it to a balancing machine used for blower rotors in fuel cell electric vehicles. The results show that the deviation of the extracted influence coefficients is up to 0.0050, whereas the proposed method reduced it to less than 0.0037. In addition, the suggested procedure reduced the deviations of the unbalanced mass phase estimation by 35.2% as compared to the results found by the conventional method. Consequently, through the validation test, the suggested method was found to have the largest vibration decrease of any method considered in the study.