A Hybrid Diagnostic Framework with Compensation Algorithms for Inherent Rotor Faults Using Rotor Experiments

In practical engineering applications, rotor–bearing systems inevitably exhibit inherent or residual faults such as imbalance and shaft-bow, originating from manufacturing tolerances, thermal deformation, or operational loading. Accurate monitoring of these faults and their evolution is fundamental to the effectiveness of modern prognostics and health management (PHM) frameworks. However, if such inherent faults are not identified at an early stage, substantial deviations in fault diagnosis may occur, thereby compromising the accuracy of subsequent prognostic assessments and maintenance strategies. This study presents a hybrid diagnostic methodology that integrates a physics-based model with neural network techniques to enhance rotor fault diagnosis. A Jeffcott rotor subjected to simultaneous disk imbalance and shaft-bow is used to demonstrate the methodology, and the results proves its superior capability for simultaneous fault identification. Nonetheless, discrepancies between model predictions and experimental results are observed, attributed to the presence of inherent faults within the rotor system. To address this issue, algorithms for inherent fault identification and compensation, supported by experimental verification, are developed. Following compensation, the accuracy in simultaneously diagnosing and estimating the parameters of imbalance and shaft-bow is significantly improved. The proposed methodology is designed for seamless integration into real-time monitoring systems of industrial rotating machinery.