LC250摩托车发动机配气机构的开发设计研究
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摘要
为解决LC250摩托车发动机在市场上出现的气门飞脱的问题,保证发动机低速动力性和配气机构的高速可靠性,本文从运动学和动力学分析的角度出发,针对LC250发动机的配气机构设计进行研究,详细论述了该款小型高速摩托车发动机配气机构的设计、CAE分析与优化以及综合试验分析与验证的情况。
本文利用AVL公司的TYCON软件建立了LC250摩托车发动机的配气机构仿真模型,详细介绍了模型的建立和评价准则,阐述了凸轮升程曲线的设计及其影响因素,分析了气门等零部件的运动特性和凸轮及其从动件的运动规律极其影响因素,以及原机气门存在飞脱故障的问题所在;针对此问题优化设计了凸轮型线,并重新进行了计算分析。结果显示,改进后的发动机配气机构设计达到了设计目标,能够在满足原机性能不变的情况下解决气门飞脱的问题;同时,发动机样机试验验证了经优化设计后的凸轮轴应用的可靠性,改进凸轮型线后的发动机的最大功率和扭矩分别增加5.41%和1.42%,燃油消耗率显著下降超过5.5%。通过考核发动机疲劳寿命,评价发动机的耐久性指标、可靠性指标、噪音指标等均满足行业标准。自2009年10月投放市场后反应良好,满足市场要求,达到了优化的目的,同时也验证了模拟计算的有效性和设计的可行性。
本文根据企业的实际出发,针对小型高速发动机的特点,在国内行业中首次提出了发动机超速试验和变速试验两种配气机构专项综合试验方法,解决了摩托车行业发动机配气机构实验手段单一、实验设备缺乏、评价方式简单的问题,是目前配气机构综合评价行之有效的试验方式。
本文工作为LC250发动机配气机构的进一步优化和企业内其他新品发动机的配气机构的正向开发设计奠定了基础,所实施的LC250发动机项目占领了部分市场,为企业创造了一定的效益。
To solve the loss of contact between cam and follower of the LC250 motorcycle engine valve train in the market,and in order to ensure the engine performance and the high speed reliability of Engine Valve train,based on the theory of kinematics and dynamics analysis, this paper studies and designs the Valve train of LC250 engine . It describes design, CAE analysis, optimization and comprehensive test of valve train in this small high speed motorcycle engine.
In this paper, at first, it used AVL TYCON software to set up simulation model of the engine valve train, introduced the establishment and evaluation standards in detail, described the design of cam profile and factors that influence the profile, and analyzed the motion characteristics of valve, cam follower and the reason of loss of contact between cam and follower. Then,the new cam profile was designed and analyzed according to above research. Results show that the new cam profile could reach the design target and solve the problem of loss of contact between cam and follower, and the performance of the engine is the same as before. After that, a new sample cam according to the new design was developed, and the performance comparing test was conducted between the new sample cam and the old one in the same engine conditions. Testing results show that the power of the tested engine was increased by 5.41%, torque was increased by 1.42% and fuel consumption was reduced by 5.5%. Finally, engine performance and endurance test on the bench and noise test results could reach the requirements of motorcycle industry standards. Loncin started the mass production of this engine in October, 2009. Up to now, products quality is stable to satisfying customers. All these proved that the new design of cam was feasible.
Based on the reality of our company, according to the characteristics of the small high speed engine, over speed and change speed test method have been issued firstly for the engine valve train performance testing in motorcycle industry in China. It solved the problems including that simple testing method, not enough equipment and simple evaluation, etc. It is the simplest, the most reliable and the most effective method to evaluate valve train comprehensively now.
Additionally, a platform for further valve train optimization and design of LC250 engine and new engines in our company has been set up effectively. Modified LC250 engines have occupied one part of the motorcycle engine markets with good benefits and honors for Loncin Company.
本文利用AVL公司的TYCON软件建立了LC250摩托车发动机的配气机构仿真模型,详细介绍了模型的建立和评价准则,阐述了凸轮升程曲线的设计及其影响因素,分析了气门等零部件的运动特性和凸轮及其从动件的运动规律极其影响因素,以及原机气门存在飞脱故障的问题所在;针对此问题优化设计了凸轮型线,并重新进行了计算分析。结果显示,改进后的发动机配气机构设计达到了设计目标,能够在满足原机性能不变的情况下解决气门飞脱的问题;同时,发动机样机试验验证了经优化设计后的凸轮轴应用的可靠性,改进凸轮型线后的发动机的最大功率和扭矩分别增加5.41%和1.42%,燃油消耗率显著下降超过5.5%。通过考核发动机疲劳寿命,评价发动机的耐久性指标、可靠性指标、噪音指标等均满足行业标准。自2009年10月投放市场后反应良好,满足市场要求,达到了优化的目的,同时也验证了模拟计算的有效性和设计的可行性。
本文根据企业的实际出发,针对小型高速发动机的特点,在国内行业中首次提出了发动机超速试验和变速试验两种配气机构专项综合试验方法,解决了摩托车行业发动机配气机构实验手段单一、实验设备缺乏、评价方式简单的问题,是目前配气机构综合评价行之有效的试验方式。
本文工作为LC250发动机配气机构的进一步优化和企业内其他新品发动机的配气机构的正向开发设计奠定了基础,所实施的LC250发动机项目占领了部分市场,为企业创造了一定的效益。
To solve the loss of contact between cam and follower of the LC250 motorcycle engine valve train in the market,and in order to ensure the engine performance and the high speed reliability of Engine Valve train,based on the theory of kinematics and dynamics analysis, this paper studies and designs the Valve train of LC250 engine . It describes design, CAE analysis, optimization and comprehensive test of valve train in this small high speed motorcycle engine.
In this paper, at first, it used AVL TYCON software to set up simulation model of the engine valve train, introduced the establishment and evaluation standards in detail, described the design of cam profile and factors that influence the profile, and analyzed the motion characteristics of valve, cam follower and the reason of loss of contact between cam and follower. Then,the new cam profile was designed and analyzed according to above research. Results show that the new cam profile could reach the design target and solve the problem of loss of contact between cam and follower, and the performance of the engine is the same as before. After that, a new sample cam according to the new design was developed, and the performance comparing test was conducted between the new sample cam and the old one in the same engine conditions. Testing results show that the power of the tested engine was increased by 5.41%, torque was increased by 1.42% and fuel consumption was reduced by 5.5%. Finally, engine performance and endurance test on the bench and noise test results could reach the requirements of motorcycle industry standards. Loncin started the mass production of this engine in October, 2009. Up to now, products quality is stable to satisfying customers. All these proved that the new design of cam was feasible.
Based on the reality of our company, according to the characteristics of the small high speed engine, over speed and change speed test method have been issued firstly for the engine valve train performance testing in motorcycle industry in China. It solved the problems including that simple testing method, not enough equipment and simple evaluation, etc. It is the simplest, the most reliable and the most effective method to evaluate valve train comprehensively now.
Additionally, a platform for further valve train optimization and design of LC250 engine and new engines in our company has been set up effectively. Modified LC250 engines have occupied one part of the motorcycle engine markets with good benefits and honors for Loncin Company.
引文
[1]吴广全,内燃机配气机构的动态模拟及系统优化:[博士学位论文],长春:吉林工业大学,1991
[2]杨连生,内燃机设计,北京:中国农业出版社,1989,P417
[3]唐彬,摩托车CG系列发动机配气凸轮机构的分析与研究:[硕士学位论文],重庆大学,2006
[4]李惠珍,袁兆成,乐俊秉等,配气凸轮设计的进展,内燃机工程,1989,01,P36-41
[5] Winston.M.Dudley, New Methods in Valve Cam Design, SAE Transactions,1948,P19~33
[6] D.A.Stoddart,Polydyne Cam Design,Machine Design,Jan-Mar,1953
[7] [苏] B.K.巴留克,.A.E.波什科著,朱仙鼎等译,高速柴油机配气机构的工作可靠性,北京:中国农业出版社,1985
[8]秋叶机四郎,高速ディ一ゼルエンヅンの并机构の振动,东京:日本船舶机关学会志,第22卷,第8号
[9]隋允康,滕弘飞,韦日钰,柴油机配气机构有限元动力分析,内燃机学报,1988,03,P51-58
[10]袁兆成,李惠珍,用有限元法研究配气机构动力学,内燃机学报,1986,03,P74-84
[11]王明武,华建文,七项式动力凸轮及最佳设计,内燃机工程,1985,03,P30-37
[12]洪家娣,施振邦,高速凸轮机构动态优化设计研究,华东交通大学学报,第1 6卷第1期,1999,03,P31-35
[13]张可村,关小智,配气凸轮型线设计新方法,西安交通大学学报,1983,06,P106-111
[14]张可村,凸轮设计的多目标规划,西安交通大学学报,1988,02,P121-129
[15]吴兆汉,陈深龙,内燃机气门弹簧的优化设计,内燃机工程,1981,04,P19-26
[16]邓国林,彭健,内燃机气门弹簧优化设计及计算机绘图,配气机构研究与开发论文集,上海内燃机研究所、吉林工业大学、复旦大学,1990,P346-351
[17]韦日钰,柴油机配气机构有限元分析及动力优化设计:[硕士学位论文],大连:大连工学院,1986
[18]陆际清,孟宗嗣,汽车发动机设计(第二册),清华大学出版社,1993,P277
[19] [苏] A.И.高尔钦,B.П.杰米道夫著,朱仙鼎等译,汽车拖拉机发动机计算,机械工业出版社1985,P337~338
[20]杨光兴,摩托车发动机原理与设计,武汉测绘科技大学出版社,1993,P300-304
[21]许道延,丁贤华,高速柴油机概念设计与实践,机械工业出版社,2004,P186
[22] AVL user guild,2004
[23]蒋立军,钟相强,许文松等,内燃机配气凸轮参数驱动优化设计,机械设计与制造,2006,04,P15-16
[24]吴广全,李惠珍,陆孝宽,汽车发动机配气凸轮型线优化设计,吉林工业大学学报1990,02,P53-59
[25]李惠珍,高峰,配气凸轮型线动态优化设计,内燃机学报,第8卷第4期,1990,04,P329-336
[26] Mechael M.Schechter and Michael B.Levin, Camless engine, SAE Paper 960581
[27]唐琦,吴华杰,孙晓燕,DOHC 4气门配气机构对发动机性能的影响,小型内燃机,2001,01,P41~42
[28] [德]H.梅梯格著,高宗英等译,高速内燃机设计,机械工业出版社,1981,P234-241
[29]邹慧君,胡恩,S195内燃机配气凸轮机构动力性能研究及改进措施,机械设计与研究,1991,01,P18-21
[30]施玉春,DA1发动机配气机构可靠性研究:[硕士学位论文],哈尔滨:哈尔滨工程大学,2006
[31]朱兰,LJ750摩托车发动机配气机构研究:[硕士学位论文],武汉:华中科技大学,2008
[32]武占华,王迎新,段树林等,转速变化对配气机构相关参数的影响,大连海事大学学报,2004,03,P70-73
[33]罗虹,夏铁权,胡加强,125型发动机配气机构的噪声分析,重庆大学学报(自然科学版),2007,09,P9-12
[34]夏铁权,内燃机配气机构噪声发生机理与控制措施研究:[硕士学位论文],重庆:重庆大学,2007
[2]杨连生,内燃机设计,北京:中国农业出版社,1989,P417
[3]唐彬,摩托车CG系列发动机配气凸轮机构的分析与研究:[硕士学位论文],重庆大学,2006
[4]李惠珍,袁兆成,乐俊秉等,配气凸轮设计的进展,内燃机工程,1989,01,P36-41
[5] Winston.M.Dudley, New Methods in Valve Cam Design, SAE Transactions,1948,P19~33
[6] D.A.Stoddart,Polydyne Cam Design,Machine Design,Jan-Mar,1953
[7] [苏] B.K.巴留克,.A.E.波什科著,朱仙鼎等译,高速柴油机配气机构的工作可靠性,北京:中国农业出版社,1985
[8]秋叶机四郎,高速ディ一ゼルエンヅンの并机构の振动,东京:日本船舶机关学会志,第22卷,第8号
[9]隋允康,滕弘飞,韦日钰,柴油机配气机构有限元动力分析,内燃机学报,1988,03,P51-58
[10]袁兆成,李惠珍,用有限元法研究配气机构动力学,内燃机学报,1986,03,P74-84
[11]王明武,华建文,七项式动力凸轮及最佳设计,内燃机工程,1985,03,P30-37
[12]洪家娣,施振邦,高速凸轮机构动态优化设计研究,华东交通大学学报,第1 6卷第1期,1999,03,P31-35
[13]张可村,关小智,配气凸轮型线设计新方法,西安交通大学学报,1983,06,P106-111
[14]张可村,凸轮设计的多目标规划,西安交通大学学报,1988,02,P121-129
[15]吴兆汉,陈深龙,内燃机气门弹簧的优化设计,内燃机工程,1981,04,P19-26
[16]邓国林,彭健,内燃机气门弹簧优化设计及计算机绘图,配气机构研究与开发论文集,上海内燃机研究所、吉林工业大学、复旦大学,1990,P346-351
[17]韦日钰,柴油机配气机构有限元分析及动力优化设计:[硕士学位论文],大连:大连工学院,1986
[18]陆际清,孟宗嗣,汽车发动机设计(第二册),清华大学出版社,1993,P277
[19] [苏] A.И.高尔钦,B.П.杰米道夫著,朱仙鼎等译,汽车拖拉机发动机计算,机械工业出版社1985,P337~338
[20]杨光兴,摩托车发动机原理与设计,武汉测绘科技大学出版社,1993,P300-304
[21]许道延,丁贤华,高速柴油机概念设计与实践,机械工业出版社,2004,P186
[22] AVL user guild,2004
[23]蒋立军,钟相强,许文松等,内燃机配气凸轮参数驱动优化设计,机械设计与制造,2006,04,P15-16
[24]吴广全,李惠珍,陆孝宽,汽车发动机配气凸轮型线优化设计,吉林工业大学学报1990,02,P53-59
[25]李惠珍,高峰,配气凸轮型线动态优化设计,内燃机学报,第8卷第4期,1990,04,P329-336
[26] Mechael M.Schechter and Michael B.Levin, Camless engine, SAE Paper 960581
[27]唐琦,吴华杰,孙晓燕,DOHC 4气门配气机构对发动机性能的影响,小型内燃机,2001,01,P41~42
[28] [德]H.梅梯格著,高宗英等译,高速内燃机设计,机械工业出版社,1981,P234-241
[29]邹慧君,胡恩,S195内燃机配气凸轮机构动力性能研究及改进措施,机械设计与研究,1991,01,P18-21
[30]施玉春,DA1发动机配气机构可靠性研究:[硕士学位论文],哈尔滨:哈尔滨工程大学,2006
[31]朱兰,LJ750摩托车发动机配气机构研究:[硕士学位论文],武汉:华中科技大学,2008
[32]武占华,王迎新,段树林等,转速变化对配气机构相关参数的影响,大连海事大学学报,2004,03,P70-73
[33]罗虹,夏铁权,胡加强,125型发动机配气机构的噪声分析,重庆大学学报(自然科学版),2007,09,P9-12
[34]夏铁权,内燃机配气机构噪声发生机理与控制措施研究:[硕士学位论文],重庆:重庆大学,2007