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<p>Rotating machinery is critical in industrial production, where operational reliability strongly depends on rotor dynamic behaviour and vibration response. This study presents a comprehensive dynamic characterization of the Atomizer02 rotor, a key component in ceramic manufacturing systems prone to unplanned shutdowns. A two-dimensional axisymmetric finite element (FEM) model is coupled with the classical Jeffcott rotor formulation to analyze lateral vibrations, natural frequencies, mode shapes, and critical rotational speeds. Material-sensitive parametric analyses show that lightweight alloys can increase the first natural frequency by up to 29%, significantly improving the separation margin and reducing vibration amplitudes. The nominal operating speed (74.2&#xa0;Hz) remains below the first critical speed (87.3&#xa0;Hz), ensuring a safety margin of approximately 15%. FEM predictions are experimentally validated with deviations below 2%, confirming model accuracy. The validated hybrid FEM–analytical model is integrated into a monitoring-oriented framework, enabling early fault detection and condition-based maintenance. Although real-time bidirectional Digital Twin updating is not implemented, the proposed framework provides a physics-informed foundation for predictive maintenance strategies. </p>

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Dynamics of an industrial centrifugal atomizer with application to digital twin–based predictive maintenance

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Rabah Magraoui,
  • Mohammed Ouali,
  • Nesrine Melzi

摘要

Rotating machinery is critical in industrial production, where operational reliability strongly depends on rotor dynamic behaviour and vibration response. This study presents a comprehensive dynamic characterization of the Atomizer02 rotor, a key component in ceramic manufacturing systems prone to unplanned shutdowns. A two-dimensional axisymmetric finite element (FEM) model is coupled with the classical Jeffcott rotor formulation to analyze lateral vibrations, natural frequencies, mode shapes, and critical rotational speeds. Material-sensitive parametric analyses show that lightweight alloys can increase the first natural frequency by up to 29%, significantly improving the separation margin and reducing vibration amplitudes. The nominal operating speed (74.2 Hz) remains below the first critical speed (87.3 Hz), ensuring a safety margin of approximately 15%. FEM predictions are experimentally validated with deviations below 2%, confirming model accuracy. The validated hybrid FEM–analytical model is integrated into a monitoring-oriented framework, enabling early fault detection and condition-based maintenance. Although real-time bidirectional Digital Twin updating is not implemented, the proposed framework provides a physics-informed foundation for predictive maintenance strategies.