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Finite element study of a vertical rotor with tilting pads supported by an elastic structure
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development.ORCID iD: 0000-0002-5147-683X
Department of Civil and Architectural Engineering, KTH Royal Institute of Technology, Stockholm, Sweden.ORCID iD: 0009-0000-8078-5036
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development.ORCID iD: 0000-0001-6016-6342
Vattenfall AB Research and Development, Älvkarleby, Sweden.ORCID iD: 0000-0003-2812-2985
2025 (English)In: Applications in Engineering Science, E-ISSN 2666-4968, Vol. 23, article id 100242Article in journal (Refereed) Published
Abstract [en]

Although the dynamics of vertical rotor bearing systems have been studied, the interaction between vertical rotors, bearings, and supporting structures - such as casings, bearing brackets, and foundations, remains less explored. This study presents a combined experimental and numerical investigation of a coupled vertical rotor system, incorporating a nonlinear, speed- and eccentricity-dependent bearing. The novelty lies in the description of a complex, vertical, rotor-bearing-support system incorporating a nonlinear journal bearing model, to capture the effects of the rotor’s vertical orientation, as typical of hydropower applications. The system features an elastic mid-span rotor supported by a flexible tower structure. The four-shoe tilting pad bearings impose significant stiffness variations and nonlinearities, connecting the stationary and rotating components. Modal analysis identifies the critical speeds of the flexible supporting structure, and simulations in the time domain are conducted for various run-up conditions, focusing on the bearing response across the structure’s first two natural frequencies. The results show qualitative and quantitative agreement between the experimental and simulated responses, highlighting the distinct dynamic behaviors of the upper and lower bearings. The bearing response at the structure’s first critical speed is studied and demonstrates improved accuracy during critical conditions. This model builds on established methods to accurately represent vertical rotor dynamics with nonlinear, eccentricity- and speed-dependent bearing models, while extending its applicability to more complex systems by incorporating bearing support flexibility, effectively providing a framework for simulating systems such as complete hydropower units.

Place, publisher, year, edition, pages
Elsevier, 2025. Vol. 23, article id 100242
Keywords [en]
Rotor dynamics, Vertical rotors, FEM, Tilting pad journal bearings, Structural analysis
National Category
Applied Mechanics
Research subject
Machine Design
Identifiers
URN: urn:nbn:se:ltu:diva-111532DOI: 10.1016/j.apples.2025.100242ISI: 001525695800001Scopus ID: 2-s2.0-105009419396OAI: oai:DiVA.org:ltu-111532DiVA, id: diva2:1934724
Funder
Swedish Energy AgencyEnergy ResearchSwedish National GridLuleå University of TechnologyKTH Royal Institute of TechnologyChalmers University of TechnologyUppsala UniversityLund University
Note

Validerad;2025;Nivå 1;2025-07-08 (u8);

Funder: Swedish Hydropower Centre (SVC);

Full text license: CC BY;

This article has previously appeared as a manuscript in a thesis.

Available from: 2025-02-05 Created: 2025-02-05 Last updated: 2025-11-28Bibliographically approved
In thesis
1. Finite Element-Based Investigation of Rotor-Bearing-Stator Dynamics
Open this publication in new window or tab >>Finite Element-Based Investigation of Rotor-Bearing-Stator Dynamics
2025 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Rotating machinery forms the backbone of modern energy conversion, facilitating the transfer of energy between a fluid and a rotating component, the rotor. Mathematical modeling of rotating machinery has become increasingly sophisticated due to growing demands in modern machine design, primarily driven by the increase of angular momentum sustained by the rotor. Thus, the study of rotating machine dynamics has evolved to improve prediction accuracy and ensure operational stability.

A rotor typically consists of shafts, disks, and blades, supported by bearings that enable rotation relative to a stationary structure. Bearings are tasked to provide both support and energy dissipation. While rotor-bearing models often suffice for dynamic analysis of rotating machinery, stators—such as casings, housings, and foundations—can influence dynamics through rotor-stator interactions. For example, compliant bearing supports may impair bearing function, while generator stators exert significant electromagnetic forces that impact operational stability. The integrated model of these components is known as a rotor-bearing-stator (RBS) system.

While traditional rotor dynamic analysis typically utilizes shaft elements to model the rotor assembly and reduces the stator and bearing to discrete spring elements, a full three-dimensional representation overcomes the kinematic and geometric restrictions of beam theory, enabling the analysis of vastly more complex systems. Furthermore, the increased degrees of freedom lead to greater computational complexity, particularly noticeable for vertical machinery. Unlike horizontal rotors, vertical systems inherently experience large dynamic displacements and lack a stationary point of operation, necessitating the use of nonlinear bearing formulations. Hydropower machinery is generally supported by hydrodynamic journal bearings. This requires tracking the rotor position at each time step and solving equations for fluid-film interaction, further increasing computational demands.

This compilation thesis investigates the dynamics of integrated hydropower systems, with emphasis on how to accurately and efficiently model complex, vertical systems by finite element methods. The thesis constitutes three applied studies of vertical RBS-systems, mostly related to hydropower applications. The first paper focuses on a three-dimensional model of a floating-rim synchronous generator, with emphasis on deformation under electromagnetic and centrifugal loads. The second paper explores the interaction between tilting pad journal bearings and an elastic support frame, exploring the potential implementation of nonlinear journal bearing formulations within a three-dimensional finite element framework. Finally, the third paper investigates the impact of a compliant generator-bearing support on the stability of a hydropower rotor-bearing system.

Place, publisher, year, edition, pages
Luleå: Luleå University of Technology, 2025
Series
Licentiate thesis / Luleå University of Technology, ISSN 1402-1757
Keywords
Rotordynamics, Finite Element Analysis, Finite Element Method, Non-Linear Dynamics, Structural Dynamics, Rotor-Stator Interaction
National Category
Applied Mechanics
Research subject
Machine Design
Identifiers
urn:nbn:se:ltu:diva-111534 (URN)978-91-8048-750-4 (ISBN)978-91-8048-751-1 (ISBN)
Presentation
2025-03-28, A117, Luleå University of Technology, Luleå, 09:00 (Swedish)
Opponent
Supervisors
Available from: 2025-02-05 Created: 2025-02-05 Last updated: 2025-10-21Bibliographically approved

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Pääjärvi, SimonAidanpää, Jan-OlovGustavsson, Rolf

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