ARotor laboratory research projects
Research projects in preparation
Several research projects are currently under preparation. If you are an industrial partner looking to join a consortium, please contact [email protected]
Ongoing research projects
Artificial intelligence optimization of rotating machinery governed production lines
The AI-ROT project, funded by Academy of Finland, investigates the runnability and quality of production lines governed by rotating machinery, especially products formed by rolls, such as paper, cardboards or steel.
Methods for modelling the end product quality as well as methods for separating the effects of geometry errors of different rolls from measured end product quality variation will be developed in the project. Additionally, the project focuses on how to utilize the information in operation and maintenance of the production line.
EMPIR Met4Wind, 2020-2023
Metrology for enhanced reliability and efficiency of wind energy systems
The Met4Wind project is focused on improving dimensional metrology for drivetrain components and rotor blades for wind energy systems. Accurate metrology is a prerequisite to enable reliable production processes for fail-safe parts. Additionally, improved metrology and better rotational accuracy contribute to improving the availability and efficiency of wind energy systems.
The project 19ENG07 Met4Wind has received funding from the EMPIR programme co-financed by the Participating States and from the European Union’s Horizon 2020 research and innovation programme.
REBOOT, Business Finland, 2019-2021
Visit the Reboot IoT Factory webpages
Digital Twin of Rotor system
Funded by the Academy of Finland, the TwinRotor project conducted between 2017 and 2019 focused on the digital twin of a rotor system. A proof of concept digital twin system was conceived during the project and a data driven machine learning model for the dynamic behaviour of rotors was created. Further applications of similar data driven methods are virtual sensors utilizing collected data from a fleet of installed products, which can improve condition monitoring and predictive maintenance services.
EMPIR 2018-2021 and SmartCom-Tutli 2019-2021
Communication and validation of smart data in IoT-networks
The central mission of the SmartCom project is to establish a secure, unambiguous and unified exchange of data in all communication networks where metrological data is used. SmartCom will develop, provide and distribute a formal framework for the transmission of metrology data on the basis of the SI (International System of Units). The framework will be applicable to all metrology domains. Furthermore, a worldwide-applicable concept for the use of digital calibration certificates (DCC) will be made available for the first time. The development of demonstrators in two industrial domains will also prove the benefit and innovation potential of the project’s outputs for industry.
EMRP DriveTrain, 2014 - 2017
Traceable measurement of drivetrain components for renewable energy
Wind energy systems are regarded as one of the most promising technologies for the generation of renewable energy. However, the reliability of the drivetrain components needs to be improved. The high costs associated with the repair of drivetrain components of large scale wind mills and also lost power generation due to unplanned maintenance is a common problem for renewable energy suppliers. The DriveTrain project developed new approaches to deliver measurement standards and procedures to enable the reliable estimation of a quantitative measurement uncertainty for highly accurate drivetrain components (for bearings, shafts and gears) as demanded in international guidelines and will be optimized for industrial use.
The drivetrain of large scale wind-energy systems consists of large rotating parts. In this project ARotor developed a novel large scale bearing element measurement method and device. Its characteristics and measurement uncertainty were determined in cooperation with VTT/Mikes. In addition, ARotor was responsible for determining measurement strategies for large scale drivetrain components with precise round features together with Moventas. In addition VTT/Mikes and ARotor developed an Interferometric step gauge for CMM verification to tackle the uncertainty issues regarding the measurement of large round features.
Link to research paper on Interferometric step gauge for CMM verification
EMRP TIM, 2013 - 2016
Traceable in-process dimensional measurements
Traceable in-process dimensional measurements by machine tools offer high product quality, lower manufacturing costs, high productivity and prompt and real-life assessment of product quality. Measurement errors of machine tools are from different sources and are influenced by complex environmental factors on the shop floor.
ARotor was responsible for developing a compensative manufacturing methods for large round workpieces. The work resulted in the verification of compensative 3D grinding method, which uses the four-point hybrid roundness measurement data to compensate the systematic errors occurring during the grinding process. A micrometer level accuracy in roundness was reached. In addition, the first Monte Carlo simulation based uncertainty analyses considering the four-point hybrid roundness measurement method were made. A large scale roundness artefact (diameter 500 mm) with a specific distribution of waviness components of the roundness profile was manufactured.
Vidrom, Academy of Finland, 2014-2018
Virtual Design of Rotating Machines - ViDROM
Novel simulation approaches for transient dynamic analysis of non-ideal rotor-bearing system
ARotor investigated the effect of the bearing inner ring roundness profile on the subcritical vibrations of a flexible rotor. A test bench was developed to verify the investigations with industrial large scale rotor system. The roundness profile for the inner ring of the installed bearing was measured. It was modified to achieve five different geometries to investigate five excitation cases. Rotor subcritical vibration was measured for each bearing inner ring geometry in the horizontal and vertical directions. The analysis focused on the 2nd, 3rd, and 4th harmonic vibration components, which occur at 1/2, 1/3, and 1/4 of the critical rotational speed. The results clearly suggest that the roundness profile of the roller race of the bearing inner ring significantly affects rotor subcritical vibration. The increased waviness components of the bearing inner ring roundness profile increased corresponding subcritical vibration amplitude. Minimizing the roundness error decreased subcritical vibration substantially.
The effects of different bearing and rotor non-idealities on the dynamic behavior of the system were studied with a physical modelling based simulations. Modelling approaches varied from simplified but computationally efficient analytical models to detailed multibody or finite element approaches. The non-idealities studied were rotor asymmetry, bearing misalignment, bearing surface waviness, off-sized balls, and bearing friction. The influence of non-idealities on the dynamic responses of the rotor bearing system, bearing temperatures, and contact stresses were studied. Simulated waviness responses were also verified with experiments. The developed models can be used to predict responses, bearing temperature rise, and contact stresses in the bearing more accurately than was before possible.
During the project, ARotor also developed a test bench to investigate the backup bearings of AMB’s (active magnetic bearings)
Link to conference paper on Backup Bearing Testing Device for Active Magnetic Bearing