柴油机进气系统集成设计若干基础问题研究
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摘要
随着汽车工业的爆炸性发展和环境恶化,“节能减排”已经成为国家“十二五规划”中一项基本国策。对于传统发动机来说,提升燃烧性能是减少各项损耗、回收废弃能量的关键技术,相对于汽油机,柴油机是节能产品。而进气系统是影响柴油机经济性、动力性与排放性能的主要因素。近年来进气系统仍然是研究的热点,但是基于历史和供求关系等原因始终存在一个普遍的问题,即针对进气系统的研究往往是单独和零散的,没有从系统级角度进行整体开发、匹配研究和集成设计,可以认为,目前进气系统的开发设计流程仍不完善。
作为一种探索性的研究,本文以某型号柴油机作为研究对象,遵循系统级分析的原则,对其进气系统的流动性能、匹配特性以及对整机性能的影响,进行了试验测试与仿真分析。本文主要的研究内容有以下几个方面：
柴油机进气管理试验平台开发搭建了进气系统综合流动性能检测试验平台,可以实现相关零部件单独性能检测和系统流动性能校核,以此作为进气系统匹配试验和基础数据库建立的基础。
柴油机进气系统评价方法研究对目前进气系统的性能评价方法进行了对比和分析,研究了目前主流的三种定压差评价方法彼此之间的区别、联系和局限性,在此基础上通过相似原理和能量守恒定律,推导出了通用的评价方法,为后续的进气系统分析提供了评价标准。
柴油机进气系统试验研究通过对试验系统的标定试验,确定了合理的试验方法,在此基础上对研究对象进行了流动性能试验与结果分析,以期探索进气系统的匹配流动特性以及各零部件对系统流动性能的影响。
柴油机进气系统仿真分析建立进气系统性能仿真分析平台,力图从系统级角度解释试验现象产生的原因,通过将仿真结果与系统流动性能试验结果及缸内流场可视化试验结果的对比分析,验证了采用仿真分析方法预测进气系统性能的可行性。
柴油机进气系统对整机效能影响的分析通过与整机性能试验结果的标定,验证了建立的一维整机数值仿真模型的准确性,在此基础上利用数值仿真的方法,探索分析了进气系统性能与整机性能之间联系,有助于建立完整的进气系统设计流程,并基于系统系统设计思想,确定了关键零部件的设计参数的取值方法。
通过上述研究工作,本文取得了以下主要结论：
(1)由于压强系数对涡压数的减弱效果,涡压数无法全面衡量进气系统流动性能,采用涡压数和涡流比可以作为通用的进气系统评价参数,为消除独立变量气门升程影响,应采用加权平均的方法；
(2)涡压数明显受进气零部件的流阻特性影响,涡流比和涡压数的变化步调一致,进气系统的流通特性主要受到进气歧管编号的影响；
(3)采用S型传递激励函数与RPROP反向误差传递算法的MLP神经网络方法可以预测进气系统的性能,提高进气系统分析效率,平均绝对误差小于3%；
(4)选用合适的多孔介质参数,仿真计算结果与试验误差小于5%,进气系统仿真分析在小气门升程下偏差较大,随气门升程增加偏差较小,采用加权平均方法计算结果与试验结果偏差小于5%,是否加装气缸盖对进气均匀性结果影响不大,进气均匀性为2.74%；
(5)采用合适的参数建立一维数值仿真模型分析整机性能,与试验结果相比,在各工况下计算得到的功率、扭矩等性能参数误差均小于5%；
(6)采用基于零维燃烧模型的一维整机数值模拟方法时,无法校核涡流比变化对整机性能影响,而可以用进气涡压数反映流动损失对整机性能影响很大,对优化设计和系统集成设计十分重要。
(7)采用系统集成设计的方法分析结果表明,星形空气滤清器的滤纸夹角应处于3-4。；
本文采用试验测试结合数值仿真分析的方法,研究了一款柴油机的进气系统的流通性能,探讨了进气系统性能评价方法,搭建了进气系统、整机模型的仿真模型及试验平台,为进气系统集成设计和匹配优化奠定了坚实的基础,并提供了一定方向性的指导。
With the explosive development of Automobile and the deterioration of the environment, energy saving and emission reduction has become a basic policy of1025planning. As for the traditional internal combustion engine (ICE), the key technology to explore its energy saving potential is to improve its combustibility. Especially, diesel engine faces great challenge due to its feature of compression ignition. The realization of combustion optimization requires the cooperation of fuel injection, valve mechanism and other systems, and none of them could work without the inlet system. The inlet system is the main factor to the economic and dynamic properties of diesel engine, as well as its emission characteristic. Recently the inlet system is a hot spot in research, however, there is a common problem that the research on inlet system happened to be independent and scattered, and there are no ensemble development, matching research and collaborative design based on the whole system. Therefore, it could regard that the design cycle of inlet system is still far from perfection.
As an exploratory research, one diesel engine was taken as the research object in the dissertation. According to the principle of systematic analysis, numerical research together with experimental examination were completed on the flow characteristic, matching properties and the effects on engine performance. The main contents are as follows:
The development of diesel engine inlet system test platform. The test platform of comprehensive flow characteristic of inlet system was established. Though the application of the platform,the independent performance test of inlet components, as well as matching examination could be realized with the platform. The test was regarded as the foundation of systematic research and data-accumulation.
The research on inlet system evaluation methodology. The evaluation methods on inlet system performance is compared and analyzed, and the main three constant pressure differential methods were researched to reveal their difference, communication and limitation. Then the common evaluation method was raised upon it according to the principle of similitude and the energy conservation law, providing the standard for the following research.
The experiment research on diesel engine inlet system. The reasonable experiment method was settled through the calibration. The test and result analyze of flow characteristic was completed on the research object, so that the systematic matching and the effects on components performance could be revealed.
The simulation on diesel engine inlet system. The simulation platform of inlet system was set up to explain the phenomena in the experiment on a systematic level. By the flow test and cylinder visiable result comparison, the feasibility of simulation to predict the inlet system performance is examined.
The analysis of the effect of inlet system on engine performance. On the base of1-D simulation model, the relation between the performance of inlet system and that of engine was explored. Then the complete inlet system design cycle was set up and the range of design parameters was settled following the principle of the collaborative design.
By researches mentioned above, the following conclusions were achieved:
Ⅰ. Since the swirl pressure number could be weakened by the pressure coefficient, the swirl pressure number and swirl rate could be used as the ordinary evaluation parameters of inlet system to achieve the overall measurement. In order to eliminate the effect of independent variable, the weighted average should be taken.
Ⅱ. The flow resistance of inlet components has main effect on swirl pressure number. The change of swirl rate agreed with that of swirl pressure number. The flow characteristic of inlet system was mainly affected by the exit position of inlet manifold.
Ⅲ. The performance of inlet system could be predicted by S transfer excitation function and MLP neural network of RPROP reverse error transfer, so that the analyze efficiency of inlet system could be improved and the mean absolute error was below3%.
Ⅳ. The error between simulation and experiment was less than5%when choosing the right of porous media parameters. The deviation between simulation and the test result decreased along with the increase of the valve lift and could be limited below5%using the weighted average method. The uniformity of inlet system was2.74%, and it has no influence on the uniformity with or without the cylinder head.
V. The engine performance could be examined through1-D simulation and error of the parameters such as power and torque could be below5%comparing with test results.
VI. Within1-D simulation, the swirl rate could only reflect the flow pattern and the character of the engine, while the swirl pressure number could reflect the pressure loss and the change of the engine.
VII. The adjacent angle presented the structure of the filter element should be between three degree to four degree following the principle of the collaborative design.
The method combined with experiment and simulation was adopted within the dissertation to analyze the flow characteristic of the inlet system. The evaluation methodology was studied, and the simulation model and test platform of inlet system and engine were built up to provide a firm base and an oriental guide for the collaborative design and matching optimization of inlet system.
作为一种探索性的研究,本文以某型号柴油机作为研究对象,遵循系统级分析的原则,对其进气系统的流动性能、匹配特性以及对整机性能的影响,进行了试验测试与仿真分析。本文主要的研究内容有以下几个方面：
柴油机进气管理试验平台开发搭建了进气系统综合流动性能检测试验平台,可以实现相关零部件单独性能检测和系统流动性能校核,以此作为进气系统匹配试验和基础数据库建立的基础。
柴油机进气系统评价方法研究对目前进气系统的性能评价方法进行了对比和分析,研究了目前主流的三种定压差评价方法彼此之间的区别、联系和局限性,在此基础上通过相似原理和能量守恒定律,推导出了通用的评价方法,为后续的进气系统分析提供了评价标准。
柴油机进气系统试验研究通过对试验系统的标定试验,确定了合理的试验方法,在此基础上对研究对象进行了流动性能试验与结果分析,以期探索进气系统的匹配流动特性以及各零部件对系统流动性能的影响。
柴油机进气系统仿真分析建立进气系统性能仿真分析平台,力图从系统级角度解释试验现象产生的原因,通过将仿真结果与系统流动性能试验结果及缸内流场可视化试验结果的对比分析,验证了采用仿真分析方法预测进气系统性能的可行性。
柴油机进气系统对整机效能影响的分析通过与整机性能试验结果的标定,验证了建立的一维整机数值仿真模型的准确性,在此基础上利用数值仿真的方法,探索分析了进气系统性能与整机性能之间联系,有助于建立完整的进气系统设计流程,并基于系统系统设计思想,确定了关键零部件的设计参数的取值方法。
通过上述研究工作,本文取得了以下主要结论：
(1)由于压强系数对涡压数的减弱效果,涡压数无法全面衡量进气系统流动性能,采用涡压数和涡流比可以作为通用的进气系统评价参数,为消除独立变量气门升程影响,应采用加权平均的方法；
(2)涡压数明显受进气零部件的流阻特性影响,涡流比和涡压数的变化步调一致,进气系统的流通特性主要受到进气歧管编号的影响；
(3)采用S型传递激励函数与RPROP反向误差传递算法的MLP神经网络方法可以预测进气系统的性能,提高进气系统分析效率,平均绝对误差小于3%；
(4)选用合适的多孔介质参数,仿真计算结果与试验误差小于5%,进气系统仿真分析在小气门升程下偏差较大,随气门升程增加偏差较小,采用加权平均方法计算结果与试验结果偏差小于5%,是否加装气缸盖对进气均匀性结果影响不大,进气均匀性为2.74%；
(5)采用合适的参数建立一维数值仿真模型分析整机性能,与试验结果相比,在各工况下计算得到的功率、扭矩等性能参数误差均小于5%；
(6)采用基于零维燃烧模型的一维整机数值模拟方法时,无法校核涡流比变化对整机性能影响,而可以用进气涡压数反映流动损失对整机性能影响很大,对优化设计和系统集成设计十分重要。
(7)采用系统集成设计的方法分析结果表明,星形空气滤清器的滤纸夹角应处于3-4。；
本文采用试验测试结合数值仿真分析的方法,研究了一款柴油机的进气系统的流通性能,探讨了进气系统性能评价方法,搭建了进气系统、整机模型的仿真模型及试验平台,为进气系统集成设计和匹配优化奠定了坚实的基础,并提供了一定方向性的指导。
With the explosive development of Automobile and the deterioration of the environment, energy saving and emission reduction has become a basic policy of1025planning. As for the traditional internal combustion engine (ICE), the key technology to explore its energy saving potential is to improve its combustibility. Especially, diesel engine faces great challenge due to its feature of compression ignition. The realization of combustion optimization requires the cooperation of fuel injection, valve mechanism and other systems, and none of them could work without the inlet system. The inlet system is the main factor to the economic and dynamic properties of diesel engine, as well as its emission characteristic. Recently the inlet system is a hot spot in research, however, there is a common problem that the research on inlet system happened to be independent and scattered, and there are no ensemble development, matching research and collaborative design based on the whole system. Therefore, it could regard that the design cycle of inlet system is still far from perfection.
As an exploratory research, one diesel engine was taken as the research object in the dissertation. According to the principle of systematic analysis, numerical research together with experimental examination were completed on the flow characteristic, matching properties and the effects on engine performance. The main contents are as follows:
The development of diesel engine inlet system test platform. The test platform of comprehensive flow characteristic of inlet system was established. Though the application of the platform,the independent performance test of inlet components, as well as matching examination could be realized with the platform. The test was regarded as the foundation of systematic research and data-accumulation.
The research on inlet system evaluation methodology. The evaluation methods on inlet system performance is compared and analyzed, and the main three constant pressure differential methods were researched to reveal their difference, communication and limitation. Then the common evaluation method was raised upon it according to the principle of similitude and the energy conservation law, providing the standard for the following research.
The experiment research on diesel engine inlet system. The reasonable experiment method was settled through the calibration. The test and result analyze of flow characteristic was completed on the research object, so that the systematic matching and the effects on components performance could be revealed.
The simulation on diesel engine inlet system. The simulation platform of inlet system was set up to explain the phenomena in the experiment on a systematic level. By the flow test and cylinder visiable result comparison, the feasibility of simulation to predict the inlet system performance is examined.
The analysis of the effect of inlet system on engine performance. On the base of1-D simulation model, the relation between the performance of inlet system and that of engine was explored. Then the complete inlet system design cycle was set up and the range of design parameters was settled following the principle of the collaborative design.
By researches mentioned above, the following conclusions were achieved:
Ⅰ. Since the swirl pressure number could be weakened by the pressure coefficient, the swirl pressure number and swirl rate could be used as the ordinary evaluation parameters of inlet system to achieve the overall measurement. In order to eliminate the effect of independent variable, the weighted average should be taken.
Ⅱ. The flow resistance of inlet components has main effect on swirl pressure number. The change of swirl rate agreed with that of swirl pressure number. The flow characteristic of inlet system was mainly affected by the exit position of inlet manifold.
Ⅲ. The performance of inlet system could be predicted by S transfer excitation function and MLP neural network of RPROP reverse error transfer, so that the analyze efficiency of inlet system could be improved and the mean absolute error was below3%.
Ⅳ. The error between simulation and experiment was less than5%when choosing the right of porous media parameters. The deviation between simulation and the test result decreased along with the increase of the valve lift and could be limited below5%using the weighted average method. The uniformity of inlet system was2.74%, and it has no influence on the uniformity with or without the cylinder head.
V. The engine performance could be examined through1-D simulation and error of the parameters such as power and torque could be below5%comparing with test results.
VI. Within1-D simulation, the swirl rate could only reflect the flow pattern and the character of the engine, while the swirl pressure number could reflect the pressure loss and the change of the engine.
VII. The adjacent angle presented the structure of the filter element should be between three degree to four degree following the principle of the collaborative design.
The method combined with experiment and simulation was adopted within the dissertation to analyze the flow characteristic of the inlet system. The evaluation methodology was studied, and the simulation model and test platform of inlet system and engine were built up to provide a firm base and an oriental guide for the collaborative design and matching optimization of inlet system.
引文
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