A Study on Dynamic Response and Diagnosis Method of the Wear on Connecting Rod Bush

Wear is a typical failure form for mechanical parts of a reciprocating compressor. The clearance of a connecting rod bearing will exceed the normal value due to the wear caused by poor lubrication or abnormal loads. Wear on the small-end bush of a connecting rod (SEBCR) in a reciprocating compressor is still a hard work to be monitored and diagnosed. In this paper, we focus on the study of the dynamic response and diagnosis method on wear fault of SEBCR based on the dynamic simulation and vibration signal analysis. A rigid-flexible coupling model of a connecting rod has been built, and the connecting rod is treated as a flexible body. The clearance between the crosshead pin and the small-end bush of a connecting rod is taken into account. The simulation results show that abnormal clearance will affect the dynamic characteristic significantly, and high acceleration impacts will occur at the reversal points of the crosshead pin. Based on the dynamic response and signal feature extraction, a new diagnosis method calculating the amplitude and change rate of average vibration energy per crank angle to detect the wear fault is proposed. The experiment results on a reciprocating compressor show that the vibration of the compressor crosshead is consistent with numerical simulation results, and the method is capable of detecting the wear fault in real time. Research presented in this paper is significant in providing tools for diagnosing wear fault of reciprocating compressors.

[1]  G. Price,et al.  Numerical and Experimental Analysis of the Flow Characteristics Through a Channel Valve , 1992 .

[2]  Hamid M. Lankarani,et al.  Continuous contact force models for impact analysis in multibody systems , 1994, Nonlinear Dynamics.

[3]  Olivier A. Bauchau,et al.  Modeling of joints with clearance in flexible multibody systems , 2001 .

[4]  D. Marghitu,et al.  Dynamic analysis of a planar rigid-link mechanism with rotating slider joint and clearance , 2003 .

[5]  Gabriel Rilling,et al.  Empirical mode decomposition as a filter bank , 2004, IEEE Signal Processing Letters.

[6]  Jorge Ambrósio,et al.  A study on dynamics of mechanical systems including joints with clearance and lubrication , 2006 .

[7]  Steinar Fossen,et al.  Radar-Based Sensors - A New Technology For Real-Time, Direct Temperature Monitoring Of Crank And Crosshead Bearings Of Diesels And Hazardous Media Reciprocating Compressors. , 2006 .

[8]  Ke Zhang,et al.  The FEM analysis and approximate model for cylindrical joints with clearances , 2007 .

[9]  Andrew Ball,et al.  Numerical simulation and experimental study of a two-stage reciprocating compressor for condition monitoring , 2008 .

[10]  Wenxian Yang,et al.  Interpretation of mechanical signals using an improved Hilbert-Huang transform , 2008 .

[11]  C. A. Papadopoulos,et al.  Identification of clearances and stability analysis for a rotor-journal bearing system , 2008 .

[12]  Matteo Giacopini,et al.  Influence of the initial clearance on the peak stress in connecting-rod small ends , 2009 .

[13]  Yaoyu Li,et al.  A review of recent advances in wind turbine condition monitoring and fault diagnosis , 2009, 2009 IEEE Power Electronics and Machines in Wind Applications.

[14]  Selçuk Erkaya,et al.  Experimental investigation of joint clearance effects on the dynamics of a slider-crank mechanism , 2010 .

[15]  Paulo Flores,et al.  A parametric study on the dynamic response of planar multibody systems with multiple clearance joints , 2010 .

[16]  Raghuvir B Pai,et al.  Stability of Tri-taper journal bearings under Dynamic load using a Non-linear Transient method , 2010 .

[17]  Margarida F. Machado,et al.  A new model for dry and lubricated cylindrical joints with clearance in spatial flexible multibody systems , 2011 .

[18]  Yang Zhao,et al.  Dynamic behaviour analysis of planar mechanical systems with clearance in revolute joints using a new hybrid contact force model , 2012 .

[19]  Bernd Sauer,et al.  Modeling planar slider-crank mechanisms with clearance joints in RecurDyn , 2014 .