During its operation, a rotor system can be exposed to multiple faults, such as rub-impact, misalignment, cracks and unbalancing. When a crack fault occurs on the rotor shaft, the vibration response signals contain some nonlinear components that are considerably tougher to be extracted through some linear diagnosis methods. By combining the Nonlinear Output Frequency Response Functions weighted contribution rate (WNOFRFs) and Kullback-Leibler (KL) divergence, a novel fault diagnosis method of improved WNOFRFs is proposed. In this method, an index, improved optimal WNOFRFs (IOW), is defined to represent the nonlinearity of the faulty rotor system. This method has been tested through the finite element model of a cracked rotor system and then verified experimentally at the shaft crack detection test bench. The results from the simulation and experiment verified that the proposed method is applicable and effective for cracked rotor systems. The IOW indicator shows high sensitivity to crack faults and can comprehensively represent the nonlinear properties of the system. It can also quantitatively detect the crack fault, and the relationship between the values of IOW and the relative depth of the crack is approximately positively proportional. The proposed method can precisely and quantitatively diagnose crack faults in a rotor system.
Keywords: WNOFRFs; cracked rotor; fault diagnosis; nonlinear systems.