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Energy Conversion and Management 185 (2019) 183–201

Contents lists available at ScienceDirect

Energy Conversion and Management


journal homepage: www.elsevier.com/locate/enconman

Dynamic evolution of a bulb hydroelectric generating unit considering T


effects of the blades
Donglin Yan, Qijuan Chen , Yang Zheng, Weiyu Wang, Yuchen An

Key Laboratory of Transients in Hydraulic Machinery (Wuhan University), Ministry of Education, Wuhan 430072, PR China

ARTICLE INFO ABSTRACT

Keywords: The stability problems of the hydroelectric generating unit caused by the vibration of the runner blades have
Blade modeling been gradually exposed in the long-term operation, especially in the hydropower stations equipped with the bulb
Bulb turbine turbine. However, in the previous studies, the effects of the blades were not considered. Aiming at these pro-
Conversion efficiency blems, this research will be focused on studying the dynamic characteristics of the bulb hydroelectric generating
Continuum model
unit in consideration with the effects of blades. Firstly, a novel continuum shaft system model of the bulb
Dynamic evolutions
hydroelectric generating unit is originally established considering the effects of the blades. Meanwhile, the
rationality of the novel model is verified by comparing with the field test data. Then, the dynamic evolutions of
the shaft system with and without blades are contrastively analyzed and discussed with the changing of the
runner mass eccentricity, the seal gap, the rotational speed and the exciting current. Fortunately, some critical
values and stability evolution characteristics of the shaft system are obtained. In addition, the effects of the
blades are also found. More importantly, these results could provide a reference for the safe operation of the
hydropower stations.

1. Introduction numerical modeling and some typical artificial intelligence techniques


to the condition monitoring and fault diagnosis of Francis turbine. Al-
With the rapid economy development of China in the last two berto et al. [14] analyzed the typical failure reasons of the runner
decades, the electricity demand sharply increases [1–3]. In this process, blades based on some engineering cases. Using an integration of grey
to make up for the lack of the electricity supply, the water resource, as a correlation analysis and entropy weights method, Li et al. [15] analyzed
clean energy, has been paid more and more attention to. The most ty- the safety performance of the unit under four heads and presented an
pical one is the construction of a lot of hydropower stations for sa- optimal operational schedule for managing the electricity uncertainties.
tisfying the electricity demand [4–6]. And, by 2017, The total installed Trivedi et al. [16] investigated the changing laws of the pressure am-
capacity of the hydropower stations in China has reached to 340 GW plitudes in the Francis turbine with the increasing rotational speed and
[7,8]. In the long-term operation of hydropower stations, some stability gotten the relationship between the pressure and the rotational speed.
problems of the hydroelectric generating unit have been gradually ex- Lu et al. [17] presented an improved Hilbert-Huang transform method
posed, which can not only influence the energy conversion efficiency, with an energy-correlation fluctuation criterion and then used it to
but also threat the safe operation of the whole hydropower stations analyze the vibration characteristics of the shaft for a Francis turbine.
[9–11]. These analysis methods are advantageous to estimate the current state
For the hydroelectric generating unit, a mass of studies were put of the unit in the operation. However, if there are some serious faults in
forward to research their stability. And these researches mainly include the unit, a large number of field experimentations could aggravate the
two aspects. The one hand is the stability analyses for the current state faults and even cause unpredictable dangers. At the same time, limited
of the hydroelectric generating unit using some monitoring and test by the operation time and monitoring data, the dynamic characteristics
data. Based on a multidimensional frequency band energy ratio analysis of the unit in the long time-scale or some extreme conditions cannot be
method, Wang et al. [12] analyzed the pressure fluctuations char- gotten. Therefore, on the other hand, scholars attempt to establish some
acteristics in the Francis turbine at different operation conditions and reliable and flexible mathematical models to study the system char-
discussed the relationships between the pressure fluctuation and the acteristics of the hydroelectric generating unit in the long time-scale or
shaft vibration. Saeed et al. [13] applied a combined method of the some extreme conditions instead of establishing field experimentations.


Corresponding author.
E-mail address: qjchen@whu.edu.cn (Q. Chen).

https://doi.org/10.1016/j.enconman.2019.02.002
Received 22 November 2018; Accepted 1 February 2019
0196-8904/ © 2019 Elsevier Ltd. All rights reserved.
D. Yan, et al. Energy Conversion and Management 185 (2019) 183–201

Fig. 1. The schematic diagram of the shaft system for a BHGU.

Gustavsson et al. [18] analyzed the dynamic evolution of the shaft vi- stability studies for the tubular hydroelectric generating unit using the
bration considering the impact and contact between the runner and the monitoring and test data in current conditions, the studies aiming at
discharge ring. Xu et al. [19] established a fractional-order model of the dynamic evolution characteristics of the tubular hydroelectric gen-
hydroelectric generating unit considering the effects of the unbalanced erating unit in the long time-scale and extreme conditions are neces-
magnetic pull, and then presented the stability ranges of the unit with sary.
the changing of the exciting current. Combining a finite difference In light of the above analyses, comparing with previous works, there
guide bearing model and a finite element rotor model, Bettig et al. [20] are three main advantages making our research attractive. First, in
established an integrated hydro-generator rotordynamic model to cal- previous works, the mass concentration method is mainly applied in the
culate natural frequencies, and to analyze the stability of the unit. Due modeling of the shaft system, in which the effects of the shaft are ig-
to that these studies only investigated the dynamic characteristics and nored. Here, a continuum method is employed to build the model of the
evolutions of the hydroelectric generating unit under the single fault, shaft, in which the bending and torsional vibration of the shaft are both
many researchers have turned their eyes to the effects of the interaction considered. Secondly, the blade model of the bulb hydroelectric gen-
of the multiple faults or instability factors. Huang et al. [21] analyzed erating unit (BHGU) is originally established by simplifying the blade as
the vibration characteristics of the hydroelectric generating unit con- a cantilever beam. Finally, the dynamic evolutions of the shaft system
sidering the rotor rub-impact fault and the parallel misalignment fault. for the BHGU in the long time-scale and some extreme conditions are
Considering the coupling effects of hydro-electric unbalance force, Kim analyzed and the effects of the blades on them are also discussed.
et al. [22] studied the vibration characteristics of a Francis turbine The rest of the paper is organized as follows: The model of the whole
using rotodynamic methods. In view of the bending and torsion coupled shaft system is established in Section 2. Based on this model, the dy-
vibration of the generator rotor shaft system, Yan et al. [23] built a namic evolution characteristics of the shaft system with some system
fractional model to analyze the dynamic characteristics of the system parameters are discussed in Sections 3 and 4 closes the paper.
under multiple faults. For a large Francis hydroelectric generating unit,
Xu et al. [24] modeled the oscillation modal interaction under the 2. Mathematical modeling
hydraulic-electrical-mechanical unbalance forces.
The previous studies about the stability of the hydroelectric gen- For a BHGU, the schematic diagram of the shaft system is shown in
erating unit mainly aim at the Francis hydroelectric generating unit. Fig. 1. And it is mainly composed of the generator rotor, the shaft, the
However, in the recent years, with the low-head water resources bearings and the runner. For the convenience of the modeling, the total
exploited largely, the installed capacity of the tubular hydroelectric shaft system of the BHGU can be resolved into two parts. The first one is
generating unit is also rapidly increasing [25–27]. Thus, the stability the blade part which includes all blades. And the second is the disk-
analyses and studies of the tubular hydroelectric generating unit will be shaft part including the disk-1, the shaft and the disk-2, which would be
more essential for development of the hydroelectric engineering. On the regarded as a shaft with variable cross-sections.
one hand, for the stability estimations of the tubular hydroelectric The coordinate systems of the two parts are respectively presented
generating unit in the current condition, the previous methods applied in Fig. 2, in which O-XYZ is the global coordinate system, o-xryrzr re-
in the Francis hydroelectric generating unit are applicative, which has presents the rotational coordinate system for the disk-shaft part, o-xsyszs
been also widely employed in the actual engineering [28–29]. On the denotes the fixed coordinate system for the disk body, and ob-xbybzb is
other hand, for the modeling of the tubular hydroelectric generating the local coordinate system of the blade. Besides, u, v, and w represent
unit in the long time-scale or some extreme conditions, the mathema- the deformations of the blade in longitudinal, flexural and swing di-
tical models of the Francis hydroelectric generating unit in some re- rections, respectively. β is the rotation angle of the blade with respect to
spects are similar with that of the Francis hydroelectric generating unit the initial blade coordinate system (ob-xb0yb0zb0). θx, θy and θz are swing
and can be applied to the tubular hydroelectric generating unit, such as angle of the disk in X, Y and Z directions, respectively. And θ(t) is the
the mass eccentricity of the generator rotor model, the rub-impact fault rotational angle of the runner.
model and generator electromagnetic imbalance model. However, be- For simplifying the modeling and solving processes, the mathema-
cause of the differences of the runner structure, the runner model of the tical model of the whole shaft system will be built based on following
Francis hydroelectric generating unit (assumed as a mass eccentricity assumptions.
disk) cannot be applied to the tubular hydroelectric generating unit.
Specifically, the runner blades of the tubular turbine are anchored at (1) The boundary conditions of the blade are uniform with that of the
only one end, which means that it is flexible under some unbalanced cantilever beam. So, the blade is simplified as a cantilever beam.
exciting forces. So, the flexural vibration of the blades needs to be (2) The blade is strictly nested on the disk-1, which means that the
considered. Namely, it is pivotal for the tubular hydroelectric gen- relative movement of them is completely restricted in a constant
erating unit to establish a reasonable mathematical model of the runner condition. Therefore, the connection relationship of them is ig-
including the blades. At the same time, for covering the shortage of the nored.

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D. Yan, et al. Energy Conversion and Management 185 (2019) 183–201

Fig. 2. The coordinate systems. (a) The coordinate system of the blade part; (b) The coordinate system of the disk-shaft part with swing angles; (c) The location of the
rotation blade.

(3) The stiffness of the blade is far less than that of the disk. Thus, for 12
Tdk = 2 mdk xdk 2
+ 2 mdk ydk
1
+ 2 Jdzk
1 2
xdk
1
+ 2 Jdzk
2
ydk
analyzing the effects the blade, the disk-1 and disk-2 are treated as 1 1
+ 2 Jpzk ( 2
two concentrated mass points. xdk ydk ydk xdk ) + 2 Jpzk (3)
(4) The materials of the shaft system is isotropy and the Hooke’s law is
and
applicable.
(5) The torsion stiffness of the disk is much larger than that of the shaft. 1 2
Udk = 2 kdk (xdk 2
+ ydk ), (4)
So, the torsion angle at the hub of the disk is ignored in the mod-
eling. where mdk and Tdk are the mass and the kinetic energy of the disk-k;
(xdk, ydk) are the coordinates of the disk’s barycenter, xdk = xsk + ekcos
Besides, define any variables using the symbol (*), and then using (θ0) and ydk = ysk + eksin(θ0); ek is the eccentric distance of the disk-k;
( ) ( )
= (displacement) and = (time) to express the partial differentiation of Jdzk and Jpzk respectively denote the cross-sectional moment of inertia
any variables with respect to the displacement and the time, respec- and polar moment of inertia of the disk-k; θxdk and θydk is the swing
tively. angle of the disk-k in X and Y directions, respectively; Udk represents the
potential energy of the disk-k; kdk is the bending stiffness of the disk-k.

2.1. Modeling of the disk-shaft part 2.1.2. Discretization


Here, the assumed modal method will be used to discretize the
2.1.1. Energy characteristics of the disk-shaft part energy equation of the disk-shaft part. The mode shape function in
For the disk-shaft part, the bending, torsional and swing vibration bending and torsional directions can be respectively defined as X(z), Y
will be considered in the modeling. So, the whole kinetic energy of the (z) and Φ(z). At the same time, introducing a group of corresponding
shaft can be written as canonical coordinate η(t), ξ(t) and τ(t), x, y and θT will be expressed as

x (z , t ) = Xi (z ) i (t ) = X (z ) (t )
( )
Ls 1 1 2 i=1
Ts = A
2 s s
(x 2 + y 2 ) + 2 Is T
+ dz
0 t y (z , t ) = i=1
Yi (z ) i (t ) = Y (z ) (t ) .
Ls 1 1 1 2 2
T (z , t ) = i (z ) i (t ) = (z ) (t )
2
+
0
J
2 p
+ 2 Jp ( x y y x ) + 2 Jd ( x + y) dz , (1) i=1 (5)

Based on the Ref. [30], Xi(z) and Yi(z) can be calculated by


where Ts denotes the total kinetic energy of the shaft; Ls is the length of
the shaft; ρs is the density of the shaft; As is the cross-sectional area of Xi (z ) = Yi (z ) = cosh ri z + cos ri z
cosh ri cos ri
(sinh ri z + sin ri z ),
sinh ri sin ri
the shaft; θT is the torsional angle of the shaft; ω is the rotational speed;
Jp, Jd, and Is are defined as the polar moment of inertia, the cross-sec- (6)
tional moment of inertia and the second moment of shaft area, re- where the eigenvalues of bending vibration can be calculated using a
spectively. transcendental equation [31]: cos(λri)cosh(λri) = 1. Then, using these
The potential energy of the shaft can be expressed as eigenvalues λri, βri can also be gotten by ri2 = ri2 Ls2 .
For the torsional vibration, the mode shape function [30] can be
represented as
( ) +( )
2 2
( )
Ls 1 2 2x 2y
T
Us = GI
2 s p
+ Es Is
0 z z2 z2
(2i 1) z
i (z ) = sin .
(7)
( ) +( )
x 2 y 2 2Ls
+ s Gs As x y dz,
z z
(2) Besides, according to the relationships among the swing angle, the
shear angle and the displacement, the swing angle will be represented
where Us is the potential energy of the shaft; Gs represents the shearing as
modulus of elasticity of the shaft; Ip is the polar second moment of area;
And Es is the Young modulus; κs is shear coefficient. x (z , t ) = X (z ) (t ) +
Es Is
X (z ) (t )
As Gs
The kinetic energy and potential energy of the disk-k (k = 1, 2) can Es Is
.
be calculated using y (z , t ) = Y (z ) (t ) + Y (z ) (t )
As Gs (8)

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D. Yan, et al. Energy Conversion and Management 185 (2019) 183–201

Take the Eqs. (5) and (8) into Eqs.(1)–(4), the kinetic and potential Tb (j ) =
Lb 1
Ab
0 2 b
energy will be discretized. And it can be expressed as 2 + y 2 + u 2 + v 2 + w 2 + 2 cos
xsd1 sd1 (j) (j ) (j) (j ) [x sd1 u(j) + ysd1 (v (j ) cos + w(j ) sin )]
+ 2 (j ) [(Rd1 + xb (j ) + u(j) )(v (j ) cos + w(j ) sin ) u(j ) (v(j) cos + w(j) sin )]
Ms1 + Md11 + Md21 0 0 (t )
2
Tds = [ (t ) 0 Ms2 + Md12 + Md22 0 + (j ) [(Rd1 + xb (j ) + u (j ) )2 + (v (j ) cos + w(j ) sin )2]
(t ) (t ) ] (t ) dxb (j ) ,
0 0 M (t ) + 2 cos (j) ·( (j ) )[xsd1 (v (j ) cos + w(j ) sin ) ysd1 (Rd1 + x b (j) + u (j ))]
+ 2 sin (j ) [ xsd1 (v(j ) cos + w(j ) sin ) + ysd1 u (j )]
0 Gs1 + Gd11 + Gd21 0 (t )
2 (j ) sin (j) [xsd1 (Rd1 + xb (j ) + u (j )) + ysd1 (v (j ) cos + w(j ) sin )]
+ [ (t ) (t ) (t ) ] Gs2 + Gd12 + Gd22 0 0 (t )
0 0 0 (t ) (9) (17)
where Lb is the length of the blade; xsd1 and ysd1 are the centroid co-
and
ordinates of the disk-1 relative to global coordinate system.
(t )
The whole potential energy of the j-th blade can be written as:
K s1 + K d11 + K d21 0 0
Uds = [ (t ) (t ) (t )] 0 K s 2 + K d12 + K d22 0 (t ) , 2 2
Lb u(j ) 2u
0 0 K s + K d1 + K d2 1 1 (j )
(t ) Ub (j) = EA
2 b b x b (j)
+ 2 Eb Ib x b2(j)
0
(10)
u(j ) 2
1 2
where the detailed deducing process and matrix expressions have been + A
4 b b (j )
[Lb2 xb2(j) + 2Rd1 (Lb xb (j ) )] xb (j )
dxb (j) ,
listed in Appendix A. (18)

where Ub(j) is the potential energy of the j-th blade; Eb denotes the
Young modulus of the blade; Ib is the cross-sectional moment of inertia
2.2. Modeling of the blade part of the blade.

2.2.1. Energy characteristics of the blade part 2.2.2. Discretization


With respect to the coordinate system of o-xryrzr, the position vector For the cantilever beam, the mode shape function [30] can be ex-
of any point Q on the j-th blade can be expressed as pressed as
r(j) = [Rd1 + xb(j) + u(j) v(j) w(j)]T, in which xb(j) is the longitudinal po-
sition of the point Q on blade, Rd1 is the radius of the disk-1. Through
the coordinate transformations, the coordinate of Q in the global co-
Ui (x ) = Vi (x ) = Wi (x ) = cosh bi
Lb
x + cos bi
Lb
x
cosh bi + cos bi
sinh bi + sin bi (sinh bi
Lb
x sin bi
Lb
x ),
ordinate system could be described as (19)
where λbi is the i-th order eigenvalue, which can be calculated using
rQ (j) = rsd1 + A 4 A3 A2 A1r(j), (11) following characteristic equation [31]

where rsd1 is the centroid coordinate of the disk-1 in global coordinate cos( i ) cosh( i ) + 1 = 0. (20)
system, rsd1 = [xsd1, ysd1, 0]T; A1, A2, A3 and A4 are four transfer ma- Using the similar discretization method with the disk-shaft part, a
trixes, which can be respectively expressed as group of canonical coordinates, χ(t), ς(t), and σ(t), are also introduced
for the blade. Based on these, u(j), v(j) and w(j) can be represented using
1 0 0
A1 = 0 cos sin , u (j ) ( x b , t ) = i=1
Ui (xb ) i (t ) = U (xb ) (j) (t )
0 sin cos (12) v (j ) ( x b , t ) = V (xb ) i (t ) = V (xb )
i=1 i (j ) (t ) .
w(j) (xb , t ) = i=1
Wi (xb ) i (t ) = W (xb ) (j ) ( t ) (21)
1 0 0
A2 = 0 cos x sin x , Connecting Eqs. (17), (18) and (21), and through a series of de-
0 sin x cos x (13) ductions (see in Appendix B(1, 3), the kinetic and potential energy of
the blade can be written as
T
cos y 0 sin y Tb (j) = (t ) (t ) (j ) (t ) (j) (t ) (j ) (t ) [Mtb ] (t ) (t ) (j ) (t ) (j ) (t ) ( j ) (t )
A3 = 0 1 0 , T
+ (t ) (t ) ( j ) (t ) (j ) (t ) (j ) (t ) [Gtb ][ (t ) (t ) (j ) (t ) (j ) (t ) ( j ) (t ) ]
sin y 0 cos y (14)
T
+ [ (t ) (t ) (j ) (t ) (j) (t ) (j ) (t ) ][Ktb ][ (t ) (t ) (j ) (t ) (j ) (t ) (j ) (t ) ]

and (22)

cos sin 0 and


(j ) (j )
A4 = sin cos 0 , (j) (t )
(j ) (j ) Kb11 0 0
0 0 1 (15) Ub (j) = [ (j ) (t ) (j) (t ) (j ) ( t ) ] 0 Kb22 0 (j ) ( t ) ,
0 0 Kb33 (j ) ( t )
where ψ(j) = θ(t) + (j-1) × 2π/Nb, Nb is the number of the blade. (23)
Based on Eqs. (11)–(15), the kinetic energy of the j-th blade can be where [Mtb], [Gtb], and [Ktb] are three 5 × 5 composite matrixes with
calculated by 25 submatrixes, respectively. And the specific expressions of these
Lb 1 Lb 1
matrixes are shown in Appendix B(2, 4).
Tb (j) = A r 2 dxb (j)
2 b b Q (j )
= A r T · r dxb (j) ,
2 b b Q (j) Q (j ) (16)
0 0
2.3. Coupled motion equations
where Tb(j) indicates the kinetic energy of the j-th blade; ρb denotes the
density of the blade; Ab expresses the cross-sectional area of the blade. In previous sections, the energy characteristics of the blade part and
Introducing the Eq. (11) into Eq. (16), and ignoring the high-order disk-shaft part have been presented. Based on these, the kinetic energy
terms, the kinetic energy of the j-th blade could be expressed as and potential energy of the whole shaft system can be written as

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D. Yan, et al. Energy Conversion and Management 185 (2019) 183–201

Nb Ls
Tdb = Tds + Tb (j ), WQ = y (z, t ) s As (z ) dz + y (z d1, t )(md (1) + mb Nb ) g (z )
0
j=1 (24) Ls
+ y (z d2 , t ) md (2) g (z Ls ) = Y (z ) (t ) s As (z ) dz
0
Nb
+ Y (z d1 ) (t )(md (1) + mb Nb ) md (1) g (z )
Udb = Uds + Ub (j ).
j=1 (25) + Y (z d2 ) (t ) md (2) g (z Ls ), (32)

Here, the Lagrange equation [31] will be employed to establish the where zd1 and zd2 are the coordinate of the runner and the generator
coupled motion equations of the total shaft system. First, defining a rotor in Z direction. Then, it can be rewritten as
generalized variable q, which is Ls T
0 0
Y (z ) s As (z ) dz + Y (z d1 )(md (1) + Nb md ) g (z ) 0
T
WQ = [ (t ) (t ) (t )]
q = [ (t ) (t ) (t ) 1 (t ) 1 (t ) 1 (t ) Nb (t ) Nb (t ) Nb (t ) ] . + Y (z d2 ) md (2) g (z Ls )

(26) . (33)

And the Lagrange function of the system could be expressed as Therefore, according to property of the Dirac function, the vector
expression of the gravity could be described as
Nb
T
Ldb = Tdb Udb = Tds Uds + [Tb (j) Ub (j )]. 0
Ls
Y (z ) s As (z ) dz + Y (z d1 )(md (1) + Nb md ) g (z ) 0
j=1 (27) FQ = 0
.
+ Y (z d2 ) md (2) g (z Ls )
Next, substituting Eqs. (26) and (27) into Lagrange equation, it will
(34)
be gotten
Similarly, the other unbalance forces acting on the disk-shaft part
d Ldb Ldb can be expressed as
= F.
dt q q (28)
Fd unbalance = [ X ( z ) f x Y (z ) f y (z ) f ]T , (35)
where ΣF is the vector of the unbalance forces, which will be presented
where fx, fy and fθ are the unbalance forces in transverse, longitudinal,
in next subsection.
and torsional direction, respectively. And the forces acting on the blade
Then, combining Eqs, (26)–(28), it could be gotten that
can be expressed as
Mdb q̈ + Gdb q + K dbq = F, (29) = [ U (xb ) fu V (xb ) fv W (xb ) fw ]T .
Fb unbalance (36)
where Mdb, Gdb, and Kdb are coupled mass matrix, gyroscopic matrix where fu, fv and fw is the unbalance forces in u, v and w direction, re-
and stiffness matrix. spectively.
Finally, considering the damping effects, the damping matrix (see in
Appendix C) of the whole system is substituted into Eq. (29), it will be 2.4.2. Rub-impact of the blade
transferred into For a tubular turbine, when the blade hits against the volute, the
blade will appear obvious bending deformation, which will further in-
Mdb q̈ + (Cdb + Gdb) q + K dbq = F, (30) fluence the dynamic characteristics of the shaft system. Here, an impact
force model [33] of the blade presented by Jiang et al. will be em-
where the coupled results of these matrixes (Mdb, Cdb, Gdb, and Kdb) are ployed, it can be written as
shown in Fig. 3, and the concrete expressions of the submatrix are listed
in Appendix C. fn b = 2.5
Eb Ib 1.549 / Lb
Lb µb + 1.549 / Lb
+
11
A L
56 b b b
2
( 5
L
22 b
+
35
R
22 d1 ) 1.549
µ + 1.549
/ Lb
/ Lb

(37)
2.4. Unbalanced forces
where Eb is the Young modulus of the blade; Ib is the second moment of
area of the blade; μb is the friction coefficient, ε is the insert depth of the
With regard to a BHGU, the unbalanced factors mainly conclude
blade in the impact.
mechanical, electrical and hydraulic instability factors. In this mod-
Besides, the tangential friction force [33] can be calculated by
eling, some typical instability factors are considered. First, the un-
balanced magnetic pull is considered as the electrical instability factor. f b = µb fn b. (38)
Second, for the mechanical instability factors, the centrifugal forces and
Based on Eqs.(36)–(38), the vector expression of the rub-impact
rub-impact forces are considered. Third, for the bulb turbine, the blade
force on the j-th blade could be described as
can rotate with the guide vane opening to realize the optimal inflow of
the water on the blade. Thus, assuming that the flow state of the water
on the runner is optimal, only the hydraulic unbalance at the seal is
U (Lb ) 2.5 ( Eb Ib 1.549 / Lb
Lb µb + 1.549 / Lb
+
11
A L
56 b b b
2
( 5
L
22 b

considered.
In previous studies, some dependable models about the unbalanced
+
35
R
22 d1 ) 1.549
µ + 1.549
/ Lb
/ Lb )
magnetic pull (fump), the seal force (fseal), and the centrifugal effect (fcen)
have been presented. The specific expressions of them can be obtained
F (bj) ri =
V (Lb ) µb 2.5 ( Eb Ib 1.549
/ Lb
Lb µb + 1.549 / Lb
+
11
A L
56 b b b
2
( 5
L
22 b
.
from Refs. [19,32,30], respectively. Here, the gravity of the whole shaft
system and the rub-impact forces of the blade are only explained. +
35
R
22 d1 ) 1.549
µ + 1.549
/ Lb
/ Lb ) cos

2.4.1. Gravity
W (Lb ) µb ( E I
2.5 Lb b
1.549 / Lb
b µb + 1.549 / Lb
+
11
A L
56 b b b
2
( 5
L
22 b

Employing the Dirac function: +


35
R
22 d1 ) 1.549
µ + 1.549
/ Lb
/ Lb ) sin (39)
a (z ) = (z a) = 0, (z a), (31)
In the end, the vector of the unbalance forces of the whole shaft
the acting of the gravity on the whole shaft system can be expressed as system can be written as

187
D. Yan, et al. Energy Conversion and Management 185 (2019) 183–201

(a) (b)

(c) (d)
Fig. 3. The coupled relationship of the matrixes. (a) Mass matrix; (b) Gyroscopic matrix; (c) Damping matrix. (d) Stiffness matrix;

FQ + Fump + Fseal + Fcen changed as time goes on. Therefore, the studies for the dynamic evo-
F (1) lution of the unit with the mass eccentricity of the runner and the seal
b ri
F= gap are necessary. Besides, it is also very important to study the system
characteristics in some extreme conditions, such as the load shedding,
F (bNbri) (40) the runaway operating condition, and the severe excitation system
fault. Therefore, the dynamic evolutions of the unit with the mass ec-
where Fump, Fseal, and Fcen are the unbalance forces caused by the
centricity of the runner (e1), the seal gap (Cs), the rotational speed (ω)
electromagnetic imbalance, the hydraulic imbalance at the seal, and the
and the exciting current (ij) at the water guide bearing will be discussed
mass eccentricity, respectively.
here.
For illustrating the effects of the blades on the system stability, the
3. Analyses and discussions dynamic characteristics of the system will be contrastively analyzed
under two models: with blades and without blades. Meanwhile, the
The BHGU is a complicated nonlinear system. Therefore, the non- vibrations of the shaft at the water guide bearing are respectively de-
linear dynamic analysis methods, such as the bifurcation diagram, the noted by x1 and y1 in X and Y directions and the vibration of the balde-1
largest Lyapunov index, and the phase diagram, will be used to analyze in flexural direction is expressed as v1. And x2 and y2 denote the vi-
the dynamic characteristics of them. The numerical simulation will be bration of the shaft at the combination bearing. These symbols will be
carried out using Gear's method (ode15s solver in MATLAB R2016b). employed in the following analyses. Here, a model comparison and
For the simulation variables, the initial values of them are all selected as validation is firstly presented.
1 × 10-6 [23]. The step size is 0.001 [23] and the simulation para-
meters comes from wangcun hydropower station of China, which are 3.1. Model comparison and validation
listed in Appendix. D.
In the actual hydropower stations, the runner, as a flow passage In the previous studies about the modeling of the hydroelectric
component, always contacts with the water and silt. Thus, the blades generating unit, the concentrated mass method [19,21,23] was mainly
can be corroded, abraded and even broken in the long-term operation. applied, and the blades were regarded as a concentrated mass point
These faults will cause the gradual changes of the mass eccentricity in a fixed on the disk part of the runner. Here, for verifying the rationality of
long time-scale. Similarly, the seal gap of the hydro-turbine also the model established in Section 2, a comparison among the previous

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concentrated mass method without blades (CMMWB), the new con- new model is consistent with the test. But, for the previous model, the
tinuity method with blades and the field test data will be put forward change at the water guide bearing is inconspicuous. On the other hand,
under different conditions. Besides, considering that the peak-to-peak from case-2 to case-3, the load and the exciting current increase to rated
value is applied in the industry standard of hydroelectric engineering in values and the blade rotation angle also changes with the load. For the
China, the model comparison will be also based on the peak-to-peak test, the vibration at the water guide bearing increases obviously. The
value. And the comparison results are presented in Table. 1. change trend of the new model is also concordant with that of the test.
First, three typical cases are employed for the model comparison However, for the previous model, the change of the vibration state
and validation. Case-1 represents that unit rotates with a 50% rated cannot be found. The trend differences between them are also com-
rotational speed under no load condition. Case-2 represents that unit pletely relevant to the differences of modeling methods and the as-
rotates with a 100% rated rotational speed under no load condition. sumptions mentioned above.
And Case-3 represents that unit rotates with a 100% rated rotational Based on above comparison analyses, the new model has more ad-
speed under the rated load condition. The process from case-1 to case-2 vantages to study the vibration response of the unit here compared with
represents the speed increase process and the process from case-2 to the previous model. Meanwhile, the new model can match with the test
case-3 represents the load increase process in the start-up. These three data well whether the vibration value or the change trend. Therefore, it
cases not only include rated conditions of the unit, but also reflect the is reasonable to use the new model to study the dynamic evolution of
changes of the unit state with the rotational speed and the load. the unit in this research. In addition, the inflow state of the water on the
Therefore, these cases are representative to verify the accuracy of the blade is assumed to be optimal, so the current model is effective for all
model. optimized hydraulic conditions of the blade. In other words, if the head
From case-1, case-2 and case-3 in Table. 1, the maximum error and discharge can meet that the inflow state of the water on the blade is
between the new model and the test is always < 25% whether at the optimal, the established model will be reasonable and reliable.
water guide bearing or the combination bearing. The error between the
new model and the test is mainly caused by some complex and un-
certain hydraulic factors, which are not considered here. Considering 3.2. Mass eccentricity of the runner
that the focus of this study is the effects of the blade on the dynamic
evolution of the unit under some observable mechanical, electrical in- The mass eccentricity of the runner (e1) is an important factor in-
stability and the hydraulic instability at the seal. The effects of these fluencing the operation stability. The nonlinear dynamic evolutions of
uncertain hydraulic factors can be covered when the mechanical, the shaft system at the water guide bearing with the mass eccentricity of
electrical instability and the hydraulic instability at the seal are pro- the runner are shown in Fig. 4.
minent. So, the new model is applicable to describe the dynamic Firstly, when the blades are not considered, the nonlinear vibration
characteristic of the unit in this study. characteristics of the shaft system are illustrated in Fig. 4(a), (c) and (f).
For the previous model, all the errors at the water guide bearing are Specifically, x1 and y1 maintain a stable period-1 oscillation when
larger than 50%. Except for the influences of the uncertain hydraulic e1 < 43.8 mm. Then, through a quasi-periodicity oscillation in the
instability, the effects of the torsion and shear of the shaft is not also range from 43.8 mm to 47.8 mm, the largest Lyapunov index of the
considered and the mass of the shaft is assumed as two lumped mass shaft system suddenly increases from 0 to 0.0367, which means that the
rather than distributed to the whole range of the shaft. Moreover, the shaft system enters into a chaos state at e1 = 47.8 mm. Meanwhile, the
rotation motion of the blade was not described in the previous model. bifurcation diagrams of them show an obviously irregular oscillation
Based on these, more instability factors are ignored in the previous when e1 ≥ 47.8 mm.
model. Thus, the error of the previous model is more obvious than that Secondly, when the runner blades are considered in the model, the
of the new model, and the vibrations of the unit in the previous model is nonlinear dynamic evolutions of the x1, y1 and v1 are shown in
less than those of the new model and the test. Fig. 4(b), (d) and (e). In this condition, x1, y1 and v1 keep a period-1
Besides, for the models and test data, the comparisons of the change oscillation when e1 < 40.7 mm. Then, in the range of 40.7 mm <
trend are also carried out to enhance the model validation. On the one e1 < 43.8 mm, the states of the x1, y1 and v1 change repeatedly be-
hand, from case-1 to case-2, the rotational speed of the unit increases tween the periodic oscillation and the irregular oscillation. At the same
from 53.5 r/min to 107.1 r/min. According to the test, the vibration of time, the largest Lyapunov index of the shaft system converts again and
the unit at the water guide bearing obviously increases. The trend of the again between zero and the positive number. These phenomena in-
dicate that the shaft system is in an intermittent chaos state when

Table 1
The comparisons of peak-to-peak value under different conditions.
Parameters Case-1 Case-2 Case-3

value percentage value percentage value percentage

Conditions Rotational speed (r/min) 53.5 107.1 107.1


Load (MW) 0.0 0.0 20.0

Test x1 (um) 61 – 81 – 95 –
y1 (um) 51 – 65 – 76 –
x2 (um) 50 – 53 – 54 –
y2 (um) 38 – 39 – 51 –

New model x1 (um) 54 11.5% 68 16.0% 75 21.1%


y1 (um) 39 23.5% 57 12.3% 63 17.1%
x2 (um) 40 20.0% 40 24.5% 44 18.5%
y2 (um) 34 10.5% 34 12.8% 39 23.5%

CMMWB (previous model) x1 (um) 26 57.3% 31 61.7% 31 67.3%


y1 (um) 25 50.9% 29 61.7% 29 61.8%
x2 (um) 38 24.0% 38 28.3% 42 22.2%
y2 (um) 35 7.9% 35 10.3% 39 23.5%

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Fig. 4. The nonlinear dynamic evolutions of the shaft system with the mass eccentricity of the runner from 0 mm to 70 mm: (a) x1 without blades; (b) x1 with blades;
(c) y1 without blades; (d) y1 with blades; (e) v1 with blades; (f) Largest Lyapunov index.

40.7 mm < e1 < 43.8 mm. In the end, the system turns into the chaos Therefore, in the actual engineering, it is more reasonable to forecast
state at e1 = 43.8 mm. the chaos according the intermittent chaos rather than the quasi-peri-
Comparing vibration characteristics of the shaft system under two odicity. Finally, for the largest Lyapunov index in the chaos state, the
different conditions: with blades and without blades, three main effects value in the condition with blades is always larger than that in the
of the blades on the dynamic evolutions of the shaft system will be model without blades. In other words, the blades could enhance the
found. The first to mention is the period-1 oscillations of the shaft sensibility of the initial shaft system conditions to the mass eccentricity
system under these two conditions both could evolve into chaos state, of the runner (e1).
but the values of entering chaos are different, namely, the blades could In the actual engineering, excepting the influences of the value of
bring forward the starting point of the chaos and shorten the period-1 the mass eccentricity on the dynamic characteristics of the shaft system,
range of the mass eccentricity of the runner. From the angle of the the angle difference of the mass eccentricity between the runner and the
engineering, the blade can decrease the stable range of the BHGU about generator rotor can also influence the dynamic characteristics of the
the mass eccentricity of the runner, which means the drastic vibration shaft system. Here, the angle difference is expressed by Δφ. The orbit
of the unit can appear more easily because of the influence of the blade. diagram of shaft center at the water guide bearing with the increasing
Second, the routes leading to the chaos are also different from these two of Δφ is shown in Fig. 5. From Fig. 5, it can be acquired that the vi-
conditions. To be specific, in the condition without blades, the system bration amplitude of the shaft at the water guide is largest when
enters into the chaos state through quasi-periodicity route. But in the Δφ = 0°. With the increasing of the Δφ, the vibration amplitude of the
condition with blades, it is replaced by the intermittent chaos routes. shaft gradually decreases. At the same time, when Δφ < 90°, the

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decreasing speed of it is slow. Interestingly, when 90° < Δφ < 180°, range of 139 r/min < ω < 145 r/min. Third, the system enters into a
the vibration amplitude of the shaft at the water guide bearing could chaotic state at the point of ω = 145 r/min, which can be distinctly
quickly decrease with the increasing of Δφ. identified by the change of the largest Lyapunov index in Fig. 7(f).
Interestingly, this chaos state changes at the point ω = 153 r/min. Fi-
3.3. Seal gap nally, the largest Lyapunov index of the shaft system decreases to a
negative number at ω = 160 r/min, which means the system gets rid of
For a BHGU, the dynamic evolutions of the shaft system with the the chaos at this point. Meanwhile, from the bifurcation diagrams of x1
seal gap under two conditions: with blades and without blades, are and y1, it can also be found that the system keep a period-2 oscillation
presented in Fig. 6. in the range of 160 r/min < ω < 170 r/min.
As is shown in Fig. 6, whether the blades of the runner are con- Besides, when the runner blades are coupled to the model of the
sidered or not, the dynamic evolutions of the shaft system both show shaft system, the evolution process can also be classified as five steps
three stages: the period-1 stage, the quasi periodicity stage, and the according to the changing of the nonlinear dynamic phenomena. First,
chaos stage. Concretely, in the range of Cs < 0.73 mm, x1 and y1 the system maintains a period-1 oscillation when ω < 137 r/min.
maintain a stable period-1 oscillation. Meanwhile, there is an obvious Second, in the range from 137 r/min to 145 r/min, the system is in a
increasing tendency for y1 in this range, which means the vibration of chaos state. And then, through a transitory quasi-periodicity process,
the shaft at the water guide bearing is gradually intensified. Then, the the system enters into a chaos state again at ω = 150 r/min and con-
shaft system enters into a quasi-periodic oscillation at the point of verts to a new chaos state at ω = 160 r/min.
Cs = 0.73 mm, and finally turns into chaos at Cs = 0.80 mm. Interest- Comparing the nonlinear dynamic evolutions of the shaft system
ingly, in the chaos stage, the overall trend of the dynamic evolution is with the rotational speed under two different conditions: with blades
firstly increasing and then maintaining constant, in which the turning and without blades, it can be found that the effects of the blades mainly
point is Cs = 1.45 mm. includes two aspects. On the one hand, the blades can obviously in-
In addition, for the flexural vibration of the blades (v1), there are fluence the start point and the development route of chaos. Specifically,
two types of nonlinear dynamic behaviors in the development process, the transient process of the quasi-periodicity oscillation is hidden under
which are period-1 and chaos. In the ranges of the condition with blades, and the starting point of chaos is also
0.45 mm < Cs < 0.88 mm and 1.66 mm < Cs < 1.75 mm, it keeps a brought forward in this condition. On the other hand, when the blades
period-1 oscillation. And the chaos state appears in the range of are not considered in the model, the system can get rid of the chaos in
0.88 mm < Cs < 1.66 mm and 1.75 < Cs < 2.00 mm. Based on the range of 160 r/min < ω < 170 r/min. But in the model with
these, the dynamic evolutions of the shaft system with the seal gap are blades, the system cannot break away from chaos in this range.
similar under the condition with blades and without blades. In other Therefore, it can be obtained that the blades could amplify the chaos
words, the effects of the blades on the changes of the dynamic behaviors range of the rotational speed. In other words, the blade can enlarge the
of the shaft system caused by seal gap are insignificant. This phenom- range of the strenuous vibration for the BHGU.
enon indicates that the dynamic characteristics of the shaft system is For further expounding the dynamic responses of the shaft system in
more sensitive to the changing of seal gap than that of the blade vi- extreme conditions, the time domain responses of the shaft system are
bration. So, the influences of the blades on the dynamic evolutions of presented in Fig. 8. Here, three typical conditions will be discussed,
the shaft system have been covered by the effects of the seal gap. Based which are ω = 107 r/min, ω = 141 r/min, and ω = 156 r/min. Mean-
on above analyses, it can be gotten that the seal gap is more pivotal while, because the dynamic evolutions of the x1 and y1 are similar, the
than the blade vibration. In the operation and maintenance processes of time domain analyses will be only carried out for x1 and v1. As is shown
the unit, the seal gap should be paid more attention. in Fig. 8, when ω = 107 r/min, the vibration amplitude of the blade is
small, and the vibration of the shaft is not obviously impacted by the
3.4. Rotational speed blades. When ω = 141 r/min, the intermittent rub-impact of the blades
appears. And the x1 enters into an irregular wave with a larger ampli-
For the BHGU, the flywheel moment is obviously less than that of tude. Finally, when ω = 156 r/min, the drastic rub-impact of the blades
other types of units so that the growth rate of the rotational speed of is found in Fig. 8(b). And influenced by the blade vibration, the vi-
BHGU can reach to 70% in the load shedding process. Therefore, it is bration amplitude of the x1 increases to a higher value and its vibration
necessary to investigate the dynamic evolutions of the shaft system with frequency is also changed. In this condition, it is possible to result in the
the changing of the rotational speed. And Fig. 7 has been presented to metal fatigue and even the crack of the blades. So, the rub-impact of the
express the dynamic evolutions of the shaft system with the rotational blades should be avoided using some effective control and precaution
speed. means in the actual engineering. Therefore, for the operation of the
When the runner blades are not considered in the model, the non- BHGU, the shaft vibration cannot be influenced by the blade in the
linear dynamic evolutions of x1 and y1 can be divided into four stages. steady state, but the effects of the blade in some extreme conditions
First, x1 and y1 maintain period-1 oscillations when ω < 139 r/min. should be attached great attention.
Then, they gradually convert to a quasi-periodicity oscillation in the
3.5. Exciting current

In this subsection, the nonlinear dynamic evolutions of x1, y1 and v1


with the exciting current will be discussed, which are presented in
Fig. 9.
On the one hand, when the blades of the runner are not considered
in the model, the dynamic evolutions of x1 and y1 with the exciting
current are presented in Fig. 9(a) and (c). From Fig. 9(a) and (c), three
different nonlinear behaviors could be found, which are period-1,
period-2 and the chaos. For x1 and y1, the ranges maintaining the
period-1 oscillation state are 0 A < ij < 1038 A and 0 A < ij < 936
A. Meanwhile, the regions of the period-2 oscillation are 1038 A <
Fig. 5. The orbit diagram of shaft center at the water guide bearing with the ij < 1265 A and 936 A < ij < 1265 A. There is a turning point
angle difference. ij = 1159 A needed to be concerned about in the process of the period-2

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Fig. 6. The nonlinear dynamic evolutions of the shaft system with the seal gap from 0.45 mm to 2.00 mm: (a) x1 without blades; (b) x1 with blades; (c) y1 without
blades; (d) y1 with blades; (e) v with blade; (f) Largest Lyapunov index.

oscillation. At this point, x1 enters into a Hopf bifurcation and the on the comparisons of the bifurcation diagrams, it can be obtained that
period-1 oscillation of y1 is hidden. Finally, whether x1 or y1, they both the blades can change the evolution routes of chaos. To be specific,
turn to the chaos state at the point of ij = 1265 A. when the blades are considered, the shaft system will evolve to chaos by
On the other hand, when the blades are coupled in the model of the a period-doubling mode rather than a period-2 oscillation mode. Be-
shaft system, the bifurcation diagrams of x1, y1 and v1 are illustrated in sides, affected by the blades, the stable period-1 oscillation range of the
Fig. 9(b), (d), and (e). For the vibration response of x1, the period-2 shaft system is cut short.
state firstly appears at ij = 893 A and disappears at ij = 1081 A. Then, For illustrating the rub-impact characteristics of the blades in dif-
two typical period-doubling bifurcations are found at the points of ferent exciting currents, the time domain responses of the blades in
ij = 1241 A and ij = 1270 A. In the end, the period-doubling bifurcation different exciting currents are presented in Fig. 10. As is shown in
evolves into chaos at ij = 1353 A. For the vibration response of y1, the Fig. 10, When ij = 1000 A, ij = 1300 A, and ij = 1400 A, there are
evolution process is similar with the process of x1 on the whole with the obvious rub-impact phenomena for the blades. At the same time, it can
period-1 oscillation replaced by a period-3 oscillation at the point of also be found that the holding time of the rub-impact could increase
ij = 893 A. with the increasing of the exciting current. Besides, the rub-impact
Based on above analyses, the effects of the blades on the dynamic frequency of the blade in a large exciting current is faster than that in a
evolution of the shaft system will be discussed. From Fig. 9(f), because small exciting current.
of the effects of the blades, the chaos of the shaft system can be ob-
viously delayed with the changing of the exciting current. Then, based

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Fig. 7. The nonlinear dynamic evolutions of the shaft system with the rotational speed from 10 r/min to 170 r/min: (a) x1 without blades; (b) x1 with blades; (c) y1
without blades; (d) y1 with blades; (e) v1 with blade; (f) Largest Lyapunov index.

(a) (b)
Fig. 8. The time domain responses of the shaft system under three typical rotational speed. (a) x1; (b) v1.

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Fig. 9. The nonlinear dynamic evolutions of the shaft system with the exciting current from 0 A to 1450 A: (a) x1 without blades; (b) x1 with blades; (c) y1 without
blades; (d) y1 with blades; (e) v1 with blades; (f) Largest Lyapunov index.

4. Conclusions the exciting current. Besides, for the runner mass eccentricity, the
quasi-periodical route of entering chaos is replaced by the intermittent
In this research, considering the effects of the blades, a novel con- route; for the rotational speed, the quasi-periodical route is hidden, and
tinuum shaft system model of the BHGU has been built, which is ver- the system directly enters chaos; for the exciting current, the period-2
ified by comparing with the test data. At the same time, the superiority route is substituted by the period-doubling route. Third, the shaft
of the new model over the previous model without blades is presented. system is more sensitive to the changing of the seal gap than the blade
Then, the dynamic evolution processes of the BHGU with some system vibration, so the effects of the blades on the dynamic evolution with the
parameters are presented and the effects of the blade on these processes seal gap can be negligible. Finally, it can also be found that the in-
are also obtained. Here, there are four main conclusions need to be creasing different angle (Δφ) could gradually decrease the vibration
concerned about. First, with the changing of the system parameters, amplitude of the shaft. Furthermore, the new model with blades pro-
some turning points about the system stability characteristics have been vides a reliable basics for the further study about the BHGU.
gotten, which are e1 = 40.7 mm for the runner mass eccentricity, Meanwhile, the above analyses results can also guide the operation of
Cs = 0.80 mm for the seal gap, ω = 137 r/min for the rotational speed the bulb tubular hydropower station.
and ij = 1353 A for the exciting current. Second, the starting points and The above studies are all based on the rated condition of the unit.
development routes of the chaos state for the shaft system with some So, the hydraulic instability caused by the inflow instability on the
system parameters (e1, ω, and ij) could be obviously changed by the blade are not mentioned. However, in the actual engineering, it could
blades. Specifically, the starting point of chaos could be put forward for exist in some nonideal conditions. Therefore, in the further research,
the runner mass eccentricity and the rotational speed, and delayed for the model of the inflow instability on the blade needs be established for

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v1 (mm)
3
0
ij=1400 A

ij=1300 A

ij=1000 A

ij=500 A
0 100 200 300 400 500 600 700 800 900 1000
Sequence
Fig. 10. The time domain response of the blades in different exciting current.

analyzing more complex conditions. Acknowledgment

Conflict of interest This work was supported by the Natural Science Foundation of
China (grant number 51679171).
None declared.

Appendix A. The formula derivations and matrix expressions about the disk-shaft part.

(1) The discrete version of the shaft’s kinetic energy is shown as following:
1 T (t ) X T (z ) X (z ) T
A
2 s s
[ (t ) + (t ) Y T (z ) Y (z ) (t )]
1 Es Is T Es Is
+ 2 Jd X (z ) (t ) + As Gs
X (z ) (t ) X (z ) ( t ) + As Gs
X (z ) (t )
1 Es Is T Es Is
Ls + 2 Jd Y (z ) (t ) + As Gs
Y (z ) (t ) Y ( z ) (t ) + As Gs
Y (z ) (t )
Ts = dz.
0 1 Es Is T Es Is
+ J
2 p
X (z ) (t ) + As Gs
X (z ) (t ) Y (z ) (t ) + As Gs
Y (z ) (t )
1 Es Is T Es Is
J
2 p
X (z ) (t ) + As Gs
X (z ) (t ) Y (z ) ( t ) + As Gs
Y (z ) (t )
1 2 1 2 1 1
+ 2 Jp + 2 Is + 2 Is (z ) (t ) + 2 Is [ T (t ) T (z ) (z ) (t )] (A-1)
Sorting the Eq. (A-1), it can be written as

Ms1 0 0 (t ) 0 Gs1 0 (t )
Ts = [ (t ) (t ) (t ) ] 0 Ms2 0 (t ) + [ (t ) (t ) (t ) ] Gs2 0 0 (t ) ,
0 0 M 0 0 0 (t )
(t ) (A-2)
where
T (z ) X (z ) Es Is Es Is
Ls s As X + Jd X T (z ) X (z ) + Jd As Gs
X T (z ) X (z ) + Jd As Gs
X T (z ) X (z )
1
Ms1 = dz,
2 0
+ Jd ( As Gs )
Es Is 2
X T (z ) X (z )
(A-3)

T (z ) Y (z ) Es Is Es Is
Ls s As Y + Jd Y T (z ) Y (z ) + Jd As Gs
Y T (z ) Y (z ) + Jd As Gs
Y T (z ) Y (z )
1
Ms2 = dz,
2 0
+ Jd ( As Gs)
Es Is 2
Y T (z ) Y (z )
(A-4)
Es Is Es Is
Ls
Jp X T (z ) Y (z ) + Jp As Gs
X T (z ) Y (z ) + Jp As Gs
X T (z ) Y (z )
1
Gs1 = dz ,
2 0
+ Jp ( As Gs )
Es Is 2
X T (z ) Y (z )
(A-5)
Es Is Es Is
Ls
Jp Y T (z ) X (z ) Jp As Gs
Y T (z ) X (z ) Jp As Gs
Y T (z ) X (z )
1
Gs2 = dz,
2 0
Jp ( As Gs )
Es Is 2
Y T (z ) X (z )
(A-6)

1 Ls
M = {Is T (z ) (z )} dz.
2 0 (A-7)

(2) The discrete version of the shaft’s potential energy is expressed as

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Gs Ip [ (z ) (t )]T [ (z ) (t )] + Es Is [X (z ) (t )]T [X (z ) (t )]
Es Is T Es Is
Ls
Us =
1
As Gs
X (z ) (t ) As Gs
X (z ) (t ) dz.
2 + Es Is [Y (z ) (t )]T [Y (z ) (t )] +
0 s Gs As T
Es Is Es Is
+ Y (z ) (t ) Y (z ) (t )
As Gs As Gs (A-8)
Simplifying the Eq. (A-8), it can be expressed as

Ks1 0 0 (t )
Us = [ (t ) (t ) (t )] 0 Ks2 0 (t )
0 0 Ks (t ) (A-9)
where
1 Ls (Es Is )2
Ks1 = Es Is X T (z ) X (z ) + X T (z ) X (z ) dz ,
2 0 As Gs (A-10)

1 Ls (Es Is )2
K s2 = Es Is Y T (z ) Y (z ) + Y T (z ) Y (z ) dz,
2 0 As Gs (A-11)

1 Ls
Ks = [Gs Js T (z ) (z )] dz.
2 0 (A-12)

(3) The discrete version of the disk-1’s kinetic energy is shown as following:
1 1 1 Ed1 Id1 T Ed1 Id1
Td1 = 2 md1 [X (z d1 ) (t )]T [X (z d1 ) (t )] + 2 md1 [Y (z d1 ) (t )]T [Y (z d1 ) (t )] + 2 Jd1 X (z d1 ) (t ) + Ad1 Gd1
X (z d1 ) (t ) X (z d1 ) (t ) + Ad1 Gd1
X (z d1 ) (t )
1 Ed1 Id1 T Ed1 Id1
+ 2 Jd1 Y (z d1 ) (t ) + Ad1 Gd1
Y (z d1 ) (t ) Y (z d1 ) (t ) + Ad1 Gd1
Y (z d1 ) (t )
1 Ed1 Id1 T Ed1 Id1
+ 2 Jp1 Y (z d1 ) (t ) + Ad1 Gd1
Y (z d1 ) (t ) X (z d1 ) (t ) + Ad1 Gd1
X (z d1 ) (t )
1 Ed1 Id1 T Ed1 Id1 1
J X (z d1 ) (t ) + X (z d1 ) (t ) Y (z d1 ) (t ) + Y (z d1 ) (t ) + 2 Jp1 2
2 p1 Ad1 Gd1 Ad1 Gd1 (A-13)
After the reduction for Eq. (A-13), it can be rewritten as

Md11 0 0 (t ) 0 Gd11 0 (t )
Td1 = [ (t ) (t ) (t ) ] 0 Md12 0 (t ) + [ (t ) (t ) (t ) ] Gd12 0 0 (t ) .
0 0 0 (t ) 0 0 0 (t ) (A-14)
where
E I
md1 X T (z d1 ) X (z d1) + Jd1 X T (z d1 ) X (z d1) + Jd1 Ad1 Gd1 X T (z d1 ) X (z d1)
1 d1 d1
Md11 = ,
( )
2
2 + Jd1 Ed1 Id1 X T (z d1 ) X (z d1) + Jd1 Ed1 Id1 X T (z d1 ) X (z d1)
A G d1 d1 A G d1 d1 (A-15)
Ed1 Id1
md1 Y T (z d1 ) Y (z d1) + Jd1 Y T (z d1 ) Y (z d1) + Jd1 Y T (z d1 ) Y (z d1)
1 Ad1 Gd1
Md12 = ,
( )
2
2 + Jd1 Ed1 Id1 Y T (z d1 ) Y (z d1) + Jd1 Ed1 Id1 Y T (z
d1 ) Y (z d1)
A G d1 d1 A G d1 d1 (A-16)
E I E I
J Y T (z d1 ) X (z d1) + Jp1 Ad1 Gd1 Y T (z d1 ) X (z d1) + Jp1 Ad1 Gd1 Y T (z d1 ) X (z d1)
1 p1 d1 d1 d1 d1
Gd11 = ,
( )
2
2 + Jp1 Ed1 Id1 Y T (z d1 ) X (z d1)
A G d1 d1 (A-17)
Ed1 Id1 Ed1 Id1
Jp1 X T (z d1 ) Y (z d1) Jp1 X T (z d1 ) Y (z d1) Jp1 X T (z d1 ) Y (z d1)
1 Ad1 Gd1 Ad1 Gd1
Gd12 = ,
2 Jp1 ( Ed1 Id1 2
Ad1 Gd1 )
X T (z d1 ) Y (z d1)
(A-18)

(4) The discrete version of the disk-1’s potential energy is shown as following:

K d11 0 0 (t )
1 1 1
Ud1 = 2 kd1 [X (z d1 ) (t )]T [X (z d1 ) (t )] + 2 kd1 [Y (z d1 ) (t )]T [Y (z d1 ) (t )] + 2 kt1 [ (z d1 ) (t )]T [ (z d1 ) (t )] = [ (t ) (t ) (t )] 0 K d12 0 (t )
0 0 K d1 (t )
(A-19)
where
1
K d11 = 2 kd1 X T (z d1 ) X (z d1), (A-20)
1
K d12 = k Y T (z d1 ) Y (z d1),
2 d1 (A-21)

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1 T (z
K d1 = 2 kt1 d1 ) (z d1). (A-22)

(5) The discrete version of the disk-2’s kinetic energy is shown as following:
1 1 1 Ed2 Id2 T Ed 2 Id2
Td2 = 2 md2 [X (z d2 ) (t )]T [X (z d2 ) (t )] + 2 md2 [Y (z d2 ) (t )]T [Y (z d2 ) (t )] + 2 Jd2 X (z d2 ) (t ) + Ad 2 Gd2
X (z d 2 ) (t ) X (z d2 ) (t ) + Ad2 Gd2
X (z d2 ) (t )
1 Ed2 Id2 T Ed2 Id2
+ 2 Jd2 Y (z d2 ) (t ) + Ad2 Gd2
Y (z d 2 ) (t ) Y ( z d 2 ) (t ) + Ad2 Gd 2
Y (z d2 ) (t )
1 Ed2 Id2 T Ed2 Id2
+ 2 Jp2 Y (z d2 ) (t ) + Ad2 Gd2
Y (z d 2 ) (t ) X ( z d 2 ) (t ) + Ad2 Gd2
X (z d 2 ) (t )
1 Ed2 Id 2 T Ed2 Id2 1
J X (z d 2 ) (t ) + X (z d 2 ) (t ) Y (z d 2 ) ( t ) + Y (z d2 ) (t ) + 2 Jp2 2
2 p2 Ad2 Gd2 Ad 2 Gd2 (A-23)
It can be written as a normative form shown as

Md21 0 0 (t ) 0 Gd21 0 (t )
Td2 = [ (t ) (t ) (t ) ] 0 Md22 0 (t ) + [ (t ) (t ) (t ) ] Gd22 0 0 (t ) ,
0 0 0 (t ) 0 0 0 (t ) (A-24)
where
Ed2 Id 2
md2 X T (z d2 ) X (z d2) + Jd2 X T (z d2 ) X (z d2 ) + Jd2 X T (z d2 ) X (z d 2 )
1 Ad 2 Gd2
Md21 = ,
2 +
E I
Jd2 Ad2 Gd2 X T (z d2 ) X
d2 d2
(z d2) + Jd2 ( Ed2 Id 2 2
Ad 2 Gd2 )
X T (z d2 ) X (z d 2 )
(A-25)
Ed2 Id2
md2 Y T (z d2 ) Y (z d2) + Jd2 Y T (z d2 ) Y (z d2) + Jd2 Y T (z d 2 ) Y (z d 2 )
1 Ad2 Gd2
Md22 = ,
( )Y
2
2 + Jd2
Ed2 Id 2
Y T (z d 2 ) Y (z d2) + Jd2
Ed 2 Id2 T (z
d2 ) Y (z d 2 )
Ad 2 Gd2 Ad2 Gd2 (A-26)
Ed 2 Id2 Ed 2 Id2
Jp2 Y T (z d2 ) X (z d2) + Jp2 Y T (z d 2 ) X (z d2 ) + Jp2 Y T (z d 2 ) X (z d 2 )
1 Ad2 Gd2 Ad2 Gd2
Gd11 = ,
( )Y
2
2 + Jp2
Ed2 Id2 T (z
d2 ) X (z d2)
Ad2 Gd 2 (A-27)
Ed2 Id 2 Ed2 Id2
Jp2 X T (z d2 ) Y (z d2 ) Jp2 X T (z d 2 ) Y (z d 2 ) Jp2 X T (z d 2 ) Y (z d 2 )
1 Ad 2 Gd2 Ad2 Gd2
Gd12 = .
( )X
2
2 Jp2
Ed2 Id 2 T (z
d2 ) Y (z d 2 )
Ad2 Gd2 (A-28)

(6) The discrete version of the disk-2’s potential energy is shown as following:
1 1 1
Ud2 = 2 kd2 [X (z d2 ) (t )]T [X (z d2 ) (t )] + 2 kd2 [Y (z d2 ) (t )]T [Y (z d2 ) (t )] + 2 kt 2 [ (z d2 ) (t )]T [ (z d2 ) (t )] = Ud2

K d21 0 0 (t )
= [ (t ) (t ) (t )] 0 K d 22 0 (t ) ,
0 0 K d2 (t ) (A-29)
where
1
K d21 = 2 kd2 X T (z d2 ) X (z d2), (A-30)
1
K d22 = k Y T (z d2 ) Y (z d2),
2 d2 (A-31)
1 T (z
K d2 = k
2 t2 d2 ) (z d2). (A-32)

Appendix. B. The detailed formula derivations and matrix expressions about the blade part.

(1) The kinetic energy of the j-th blade can be expressed as

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[X (z d ) (t )]T [X (z d ) (t )] + [Y (z d ) (t )]T [Y (z d ) (t )] + [U (xb ) T


(j) (t )] [U (xb ) (j) (t )]

+ [V (xb ) (j ) (t )]T [V (x b ) (j) (t )] + [W (xb ) (j ) (t )]T [W (x b ) (j ) (t )]

[U (xb ) (j ) (t )]T [cos V (x b ) (j ) (t ) + sin W (xb ) (j ) (t )]


+2 T
[U (xb ) (j ) (t )] [cos V (xb ) (j) (t ) + sin W (xb ) (j) (t )]

[U (xb ) (j ) (t )]T [U (x b ) (j) (t )] + (cos ) 2 [V (x T


b ) (j ) (t )] [V (xb ) (j) (t )]
2 2 sin cos [V (xb ) T
+ (j) (t )] [W (xb ) (j ) (t )]

+(sin ) 2 [W (x T
b ) (j) (t )] [W (xb ) (j ) (t )]

Lb 1 [X (z d ) (t )]T [U (xb ) (j ) (t )] + cos [Y (z d ) (t )]T [V (xb ) (j ) (t )]


Tb (j) = b Ab + 2 cos dxb (j)
0 2
+ sin [Y (z d ) (t )]T [W (x b ) (j) (t )]

cos [X (z d ) (t )]T [V (xb ) (j) (t )] + sin [X (z d ) (t )]T [W (xb ) (j ) (t )]


2 cos
[Y (z d ) (t )]T [U (xb ) (j) (t )]

cos [X (z d ) (t )]T [V (xb ) (j) (t )] sin [X (z d ) (t )]T [W (xb ) (j) (t )]


+ 2 sin
+ [Y (z d ) (t )]T [U (xb ) (j) (t )]

[X (z d ) (t )]T [U (xb ) (j ) (t )] + cos [Y (z d ) (t )]T [V (xb ) (j ) (t )]


2 sin
+ sin [Y (z d ) (t )]T [W (x b ) (j) (t )]
(B-1)
And the Eq. (22) can be gotten by normalizing the Eq. (B-1).

(2) The original structure of the [Mtb], [Gtb] and [Ktb].


M11 0 M13 M14 M15
0 M22 M23 M24 M25
[Mtb ]= M31 M32 M33 0 0 ,
M41 M42 0 M 44 0
M51 M52 0 0 M55 (B-2)

0 0 G13 G14 G15


0 0 G23 G24 G25
[Gtb] = G31 G32 0 G34 G35 ,
G41 G42 G43 0 0
G51 G52 G53 0 0 (B-3)

0 0 0 0 0
0 0 0 0 0
[Ktb] = 0 0 K33 0 0 ,
0 0 0 K 44 0
0 0 0 0 K55 (B-4)
in which
Lb 1 Lb 1
M11 = A X T (z d ) X (z d ) dxb ;
2 b b
M22 = A Y T (z d ) Y (z d ) dxb ;
2 b b
0 0

Lb 1 Lb 1
M33 = A U T (xb ) U (xb ) dxb ;
2 b b
M44 = A V T (xb ) V (xb ) dxb ;
2 b b
0 0

Lb 1 Lb 1
M55 = A W T (xb ) W (xb ) dxb ;
2 b b
M13 = A
2 b b
cos X T (z d ) U (xb ) dxb ;
0 0

Lb 1 Lb 1 Lb 1
M14 = A
2 b b
sin cos X T (z d ) V (xb ) dxb ; M15 = A
2 b b
sin sin X T (z d ) W (xb ) dxb ; M23 = A
2 b b
sin Y T (z d ) U (xb ) dxb ;
0 0 0
Lb 1
M24 = A
2 b b
cos cos Y T (z d ) V (xb ) dxb
0

Lb 1
M25 = A
2 b b
cos sin Y T (z d ) W (xb ) dxb ;
0

T T T T T T
M31 = M13 ; M32 = M23 ; M41 = M14 ; M42 = M24 ; M51 = M15 ; M52 = M25
Lb 1 Lb 1
G13 = 2
sin X T (z d ) U (xb ) dxb G14 = 2
cos cos X T (z d ) V (xb ) dxb ;
0 0

Lb 1 Lb 1
G15 = 2
cos sin X T (z d ) W (xb ) dxb ; G23 = 2
cos X T (z d ) U (xb ) dxb ;
0 0

Lb 1 Lb 1
G24 = 2
sin cos Y T (z d ) V (xb ) dxb ; G25 = 2
sin sin Y T (z d ) W (xb ) dxb ;
0 0

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Lb Lb
G34 = b Ab cos U T (xb ) V (xb ) dxb ; G35 = b Ab sin U T (xb ) W (xb ) dxb ;
0 0

Lb Lb
G43 = b Ab cos V T (xb ) U (xb ) dxb ; G53 = b Ab sin W T (xb ) U (xb ) dxb ;
0 0

Lb 1 Lb 1
K33 = A 2 U T (x 2 (cos ) 2V T (xb ) V (xb ) dxb ;
2 b b b ) U (xb ) dxb ; K 44 = A
2 b b
0 0

Lb 1
K 45 = A
2 b b
2 sin cos V T (xb ) W (xb ) dxb ; K54 = K T45;
0

Lb 1
K55 = A 2 (sin ) 2W T (xb ) W (xb ) dxb
0 2 b b

(3) The potential energy of the j-th blade.


1 Lb T 1 Lb T T
Ub (j) = 2 Eb 0
{Ab [U (xb ) (j) (t )] [U (x b ) (j) (t )]} dxb + 2 Eb Ib 0
{[V (xb ) (j ) (t )] [V (xb ) (j ) (t )] + [W (xb ) (j) (t )] [W (x b ) (j) (t )]} dxb

[V (xb ) T
1 Lb (j ) (t )] [V (xb ) (j) (t )]
+ 4 b
2
0
Ab [Lb2 xb2 + 2Rd1 (Lb xb )] dxb .
+ [W (xb ) T
(j) (t )] [W (x b ) (j) (t )] (B-5)
And the Eq. (23) can be gotten by normalizing the Eq. (B-5).

(4) The specific matrixes in Eq. (23).


Lb 1
Kb11 = E A U T (xb ) U
2 b b
(xb ) dxb , (B-6)
0

Lb 1 Lb 1
Kb22 = E I V T (x b ) V (xb ) dxb + A 2 [L 2 xb2 + 2Rd1 (Lb xb )] V T (xb ) V (xb ) dxb ,
0 2 b b 0 4 b b b (B-7)
Lb 1 Lb 1
Kb33 = E I W T (xb ) W (xb ) dxb + A 2 [L 2 xb2 + 2Rd1 (Lb xb )] W T (xb ) W (xb ) dxb .
0 2 b b 0 4 b b b (B-8)

Appendix. C. The matrix expressions for the whole shaft system.

(1) The mass matrix


Ms1 + Md11 + Md21 + M11 0
Ms = 2
0 Ms2 + Md12 + Md22 + M22 (C-1)

M33 0 0
Mbj = 2 0 M44 0
0 0 M55 (C-2)

M13 M14 M15


Msbj = 2
M23 M24 M25 (C-3)

(2) The damping matrix


Cd1 0
Cd = ,
0 Cd2 (C-4)
where Cd1 = Cd2 = diag(cd, cd, … , cd,)n×n, cd is the damping of the shaft bend.
C = diag (ct , ct , …, ct , )n × n . (C-5)
where ct is the damping of the shaft torsion.
Cbj = diag (cb, c b, …, cb, )3n × 3n . (C-6)
where cb is the damping of the blade bend.

(3) The gyroscopic matrix


0 Gs1 + Gd11 + Gd21
Gs = 2
Gs2 + Gd12 + Gd22 0 (C-7)

0 G34 + G35 0
Gbj = 2 G43 + G53 0 0
0 0 0 (C-8)

G13 G14 G15


Gsbj = 2
G23 G24 G25 (C-9)

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(4) The stiffness matrix


Ks1 + K d11 + K d21 0
Ks = 2
0 Ks2 + K d12 + K d22 (C-10)

K = 2[Ks + K d1 + K d2 ] (C-11)

K33
K bj = 2 K 44
K55 (C-12)

Appendix D:. The simulation parameters.

Parameter Symbol Value Unit

3
Density of the shaft ρs 7.8 × 10 kg/m3
Radius of the shaft Rs 0.25 m
Length of the shaft Ls 6.0 m
Young modulus of the shaft Es 2.06 × 1011 Pa
Shear coefficient of the shaft κs 0.886
Shearing modulus of elasticity of shaft Gs 7.94 × 1010 Pa
polar moment of inertia Jp 287.2 kg·m2
the cross-sectional moment of inertia Jd 143.6 kg·m2
the second moment of shaft area Is 0.0031 m4
the polar second moment of area Ip 0.0061 m4
Cross-sectional area of the blade As 0.1963 m2
Damping of the shaft bend cd 4 × 106 N/(m/s)
Damping of the shaft torsion ct 3 × 106 N/(m/s)
Radius of the disk-1 Rd1 0.5 m
Young modulus of the disk-1 Ed1 2.06 × 1011 Pa
Shear coefficient of the disk-1 κ1 0.886
Shearing modulus of elasticity of disk-1 Gd1 7.94 × 1010 Pa
Bending stiffness of the disk-1 kd1 1 × 109 N/m
Torsional stiffness of the disk-1 kt1 2 × 109 N/m
Cross-sectional moment of inertia of disk-1 Jdz1 382.8 kg·m2
Polar moment of inertia of the disk-1 Jpz1 765.7 kg·m2
Radius of the rotor Rd2 2.707 m
Young modulus of the rotor Ed2 2.06 × 1011 Pa
Shear coefficient of the rotor κ2 0.886
Shearing modulus of elasticity of disk-2 Gd2 7.94 × 1010 Pa
Bending stiffness of the disk-2 kd2 1.5 × 109 N/m
Torsional stiffness of the disk-2 kt2 4 × 109 N/m
Cross-sectional moment of inertia of disk-2 Jdz2 1.3 × 105 kg·m2
Polar moment of inertia of the disk-2 Jpz2 2.6 × 105 kg·m2
Density of the blade ρb 7.8 × 103 kg/m3
Length of the blade Lb 2.2 m
Number of the blade Nb 4
Young modulus of the blade Eb 2.06 × 1011 Pa
Damping of the blade cb 3 × 106 N/(m/s)
The rotation angle of the blade β 31.2 °
Cross-sectional moment of inertia of the blade Ib 2.3163 m4
Cross-sectional area of the blade Ab 0.607 m2
Rated rotational speed ωr 107.1 r/min
Air gap of the generator δump0 0.002 m
Air permeance μump0 1.256 × 10-6
Exciting current ij 701.2 A
Number of pole pairs Np 28
Seal gap Cs 0.001 m
Dynamic-viscosity coefficient of the fluid vseal 1.5 × 10-3
Pressure drop of the seal ΔPseal 1.5 × 105 Pa
Length of the seal Lseal 0.15 m
Seal radius Rseal 0.25 m
Mass eccentricity of the rotor e2 0.001 m
Mass eccentricity of the runner e1 0.01 m
Friction coefficient μb 0.1
Flow velocity coefficient κseal 21

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