Dynamic unbalance identification in steady-state rotating machinery: A hybrid methodology integrating physical and data-driven techniques

Abstract

Rotating machinery plays a strategic role in key industrial sectors, making its analysis a subject of great interest for both academia and industry. Effective maintenance planning for this equipment is essential for asset management and for meeting current industrial requirements. To address this demand, this work presents a novel unbalance identification approach based on a digital representation of a rotating machine's dynamic behavior in relation to the development of specific faults. A hybrid methodology is proposed, integrating Finite Element Modeling, a Kalman Filter for parameter estimation, and Referenced Moving Window Principal Component Analysis. This Principal Component Analysis extension enhances vibration pattern recognition, enabling accurate fault quantification directly from slight changes in the system's steady-state behavior. The methodology uniquely eliminates the need for phase angle measurements, facilitating continuous monitoring of unbalance progression in steady-state conditions. Two case studies demonstrate the methodology's potential: one utilizing synthetic data from a Floating Production Storage and Offloading centrifugal compressor unit, and the other based on real data from a hydroelectric turbine-generator. These studies illustrate the integration of computational modeling, data-driven analysis, and monitored vibration data, achieving robust and accurate unbalance identification. This approach provides valuable insights into current capabilities and opens promising pathways for future applications, particularly in the digital twin domain for rotating machinery.