Josu Beloki

An Optical Fiber Bundle Sensor for Tip Clearance and Tip Timing Measurements in a Turbine Rig

When it comes to measuring blade-tip clearance or blade-tip timing in turbines, reflective intensity-modulated optical fiber sensors overcome several traditional limitations of capacitive, inductive or discharging probe sensors. This paper presents the signals and results corresponding to the third stage of a multistage turbine rig, obtained from a transonic wind-tunnel test. The probe is based on a trifurcated bundle of optical fibers that is mounted on the turbine casing. To eliminate the influence of light source intensity variations and blade surface reflectivity, the sensing principle is based on the quotient of the voltages obtained from the two receiving bundle legs. A discrepancy lower than 3% with respect to a commercial sensor was observed in tip clearance measurements. Regarding tip timing measurements, the travel wave spectrum was obtained, which provides the average vibration amplitude for all blades at a particular nodal diameter. With this approach, both blade-tip timing and tip clearance measurements can be carried out simultaneously. The results obtained on the test turbine rig demonstrate the suitability and reliability of the type of sensor used, and suggest the possibility of performing these measurements in real turbines under real working conditions.

Different Configurations of a Reflective Intensity-Modulated Optical Sensor to Avoid Modal Noise in Tip-Clearance Measurements

Tip clearance is critical to the performance of rotating turbomachinery. The objective of this paper is to develop a noncontact sensor with a precision of 30 μm to measure tip clearance in a turbine rig assembled in a wind tunnel. To carry out the measurements, an optical sensor whose main component is a bundle of optical fibers is employed. We use four different configurations of this sensor, which are tested in two distinct turbines with the aim of minimizing the effect of the noise on the repeatability of the measurements. Each configuration serves to increase the precision until the required performance is achieved for the measurement of the tip clearance. Our results may be helpful to develop applications related to structural health monitoring or active clearance-control systems.

Improvements in the Design of an Optical Sensor for Tip-Clearance Measurements in Turbines

For the last few years, we have been carrying out tip-clearance (TC) measurements in turbine rigs using optical sensors in collaboration with the Aeronautical Technologies Center. Several turbines with completely different blade profiles have been tested with satisfying results. The reflective intensity-modulated sensor used in these tests is based on a trifurcated bundle of optical fibers. This sensor is the ideal candidate for TC measurements because of its low cost, simplicity, robustness and the capability of performing tip-timing measurements (TT) employing the same probe. In the case of TC measurements, the main requirement is a precision of at least 30 μm. In order to get this precision, the latest improvements of the sensor have been focused on reducing the modal noise at the endface of the transmitting fiber of the bundle. For this purpose, different approaches were developed using mode-scramblers, plastic optical fibers and a single-mode illuminating fiber. The results obtained in the tests demonstrate that it is possible to achieve the demanded precision. Hence, in next test campaign, three sensors will be used to determine clearance at three different points of a rotating disk that belongs to a real aircraft engine.

Comparison of three different configurations of an optical sensor for tip-clearance measurements in turbines

The influence of the tip clearance on the performance of rotating turbo machinery is well known. The objective of this work was to measure this parameter using a non-contact sensor with a precision of 30 μm in a real turbine. An optical sensor whose main component is a bundle of optical fibers was selected to carry out the measurements. Three different configurations of the sensor have been tested by taking measurements on two distinct turbines. Tip-clearance measurements are achieved with the desired precision, providing the opportunity to develop applications related to structural health monitoring or active clearance-control systems.

Turbine-blade tip clearance and tip timing measurements using an optical fiber bundle sensor

Traditional limitations of capacitive, inductive or discharging probe sensor for tip timing and tip clearance measurements are overcome by reflective intensity modulated optical fiber sensors. This paper presents the signals and results corresponding to a one stage turbine rig which rotor has 146 blades, obtained from a transonic wind-tunnel test. The probe is based on a trifurcated bundle of optical fibers that is mounted on turbine casing. It is composed of a central illuminating fiber that guides the light from a laser to the turbine blade, and two concentric rings of receiving fibers that collect the reflected light. Two photodetectors turn this reflected light signal from the receiving rings into voltage. The electrical signals are acquired and saved by a high-sample-rate oscilloscope. In tip clearance calculations the ratio of the signals provided by each ring of receiving fibers is evaluated and translated into distance. In the case of tip timing measurements, only one of the signals is considered to get the arrival time of the blade. The differences between the real and theoretical arrival times of the blades are used to obtain the deflections amplitude. The system provides the travelling wave spectrum, which presents the average vibration amplitude of the blades at a certain nodal diameter. The reliability of the results in the turbine rig testing facilities suggests the possibility of performing these measurements in real turbines under real working conditions.

Optical tip clearance measurements for rotating disk characterization

An experimental study about the vibrational behaviour of two prototypes of a rotating disk by means of three optical sensors is presented. Both prototypes were assembled in a wind tunnel in order to reproduce real operation conditions. The optical sensors identified the vibration frequency and the nodal diameter of the first prototype by measuring the clearance of the disk to the casing of the wind tunnel. This method was also employed to check the improvements obtained with an upgraded design of the rotating disk, showing that the measuring system presents a great potential to perform non-contact evaluation of rotating components.

Design, Fabrication and Testing of a High-Sensitive Fibre Sensor for Tip Clearance Measurements

A highly sensitive fibre bundle-based reflective optical sensor has been designed and fabricated for Tip Clearance measurements in a turbine rig. The sensor offers high spatial and temporal resolution. The sensor probe consists of a single-mode transmitting fibre and two concentric rings of receiving multimode fibres that collect reflected light in a differential detection gain configuration, yielding a highly linear calibration curve for distance measurements. The clearance measurement range is approximately 2 mm around the central point fixed at 3.2 mm from the probe tip, and the sensitivity of the probe is 61.73 mm−1. The fibre bundle has been designed to ensure that the distance security specifications required for the experimental program of the turbine are met. The optical sensor has operated under demanding conditions set by the blade and casing design. The experimental results obtained so far are promising and lead us to think that the optical sensor has great potential for online clearance measurements with high precision.

Optical Tip Clearance Measurements as a Tool for Rotating Disk Characterization

An experimental investigation on the vibrational behavior of a rotating disk by means of three optical fiber sensors is presented. The disk, which is a scale model of the real disk of an aircraft engine, was assembled in a wind tunnel in order to simulate real operation conditions. The pressure difference between the upstream and downstream sides of the disk causes an airflow that might force the disk to vibrate. To characterize this vibration, a set of parameters was determined by measuring the tip clearance of the disk: the amplitude, the frequency and the number of nodal diameters in the disk. All this information allowed the design of an upgraded prototype of the disk, whose performance was also characterized by the same method. An optical system was employed for the measurements, in combination with a strain gauge mounted on the disk surface, which served to confirm the results obtained. The data of the strain gauge coincided closely with those provided by the optical fiber sensors, thus demonstrating the suitability of this innovative technique to evaluate the vibrational behavior of rotating disks.

Evaluation of the vibrational behaviour of a rotating disk by optical tip-clearance measurements

The results of an experimental investigation on the vibrational behaviour of a rotating disk are reported. This disk is a prototype that simulates a component of an aircraft engine. The air flow through the gap between the edge of the disk and the casing, produced because of the pressure difference between the upstream and downstream parts of the disk, might force the disk to flutter under certain circumstances. This situation is simulated in a wind tunnel. The main goal of the tests is to evaluate the vibrational behaviour of a rotating disk, obtaining the correspondence between the vibration frequencies of the disk and the pressure differences when the disk is rotating at diverse speeds. An innovative noncontact technique is utilised, which employs three optical sensors that are angularly equidistributed on the casing of the wind tunnel. In order to verify the results given by the optical sensors, a strain gauge was mounted on the surface of the rotating disk. The results show a perfect agreement between the vibration frequencies detected by both kinds of sensors, proving that the combination of both allows the calculation of the nodal diameter corresponding to the vibration of the disk.