直喷柴油机喷雾撞壁双反射燃烧系统的研究
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摘要
根据传统柴油机喷雾的特点,在直喷式柴油机上开发了一种基于喷束壁面引导和分层扩散的空间分散式“喷雾撞壁双反射”燃烧系统,通过低温燃烧来降低NOx、通过预混合燃烧和“喷雾撞壁双反射”技术来降低微粒排放,实现了降低NOx和PM的“柴油机两难”解决方案。此燃烧系统所具有的特征是：低爆压、快速混合、滞燃期长和低温燃烧。所谓的“喷雾撞壁双反射”技术,在燃烧室壁面上设有导向凸弧和小台阶,多孔喷油器喷出的液态油束,撞击在燃烧室壁面上,经壁面上导向凸弧和小台阶的双反射,形成分层扩散射流结构,简称“双反射”技术,将这种燃烧系统称为“双反射”燃烧系统。反射后的油束分布在燃烧室的挤流区和凹坑区,形成大的油束涡流,并向较大范围扩展。这样,壁面射流的油束能卷吸更多的空气,在有限的滞燃期内形成更多的可燃混合气,产生多个着火点,缩短燃烧持续期。燃烧后,上下两层的射流油束能相互辐射吸收热量,上层油束中雾化不好的质量大的油滴受离心力的作用能在下层油束中继续燃烧,下层未完全燃烧产物受活塞逆挤流的作用上升,能在上层油束中进一步燃烧。另外,反射可比通常的喷雾分裂微粒化程度更高,同时由于撞击扩散,有望快速形成更均匀的混合气。
针对“双反射”燃烧系统的特点,在一台4100ZL柴油机上进行了该燃烧系统的试验研究。对燃烧系统的结构参数优化,包括燃烧室、缸盖涡流比、喷孔夹角、喷孔直径/数目、喷射压力和喷油定时的优化,并研究了其对发动机性能和燃烧的影响,使发动机有最佳的性能指标,并与原机进行了性能对比。试验结果表明：在2100r·min-1/307N·m(扭矩点)工况NOx从712×10-6降低到487×10-6,在3000r·min-1/267N·m(功率点)工况NOx从593×10-6降低到369×10-6,分别降低了31.6%和37.7%。改善了低速全负荷的油耗率和烟度,油耗率从240.5g·(kw·h)-1降低到225.4g·(kw-h)-1,降低了6.3%；烟度从3.67BSU降低到2.1BSU。'‘双反射”柴油机的缸压较原机有很大程度的降低,扭矩点的缸压从原机的128bar降低到108bar,降低了15.6%。
对优化后的“双反射”燃烧系统进行以下几个方面深入研究并得出结论。
(1)基于高速放热率控制的直喷式柴油机性能研究,保证柴油机有最佳的排放性能和经济性能。改善燃烧性能的主要难点是高速与大负荷工况下对着火始点和燃烧速率的控制,即瞬时放热率的控制。本文通过降低几何压缩比推迟车用柴油机高速工况下的着火始点,并采用几何方法(双反射技术)提高缸内混合气的燃烧速率,达到同时降低NOx排放并保持高的热效率的效果,也就是说有效地控制燃烧相位和瞬时放热率的重心。“双反射”燃烧系统能在较低压缩比下,保持柴油机高速工况下的燃烧速率,在动力性不降低的情况下,保证了柴油机有最佳的排放性能和经济性能。基于上述思想,在柴油机3000r·min-1转速下进行了试验研究。
(2)基于单峰放热率特性的“双反射”燃烧系统的直喷柴油机低爆压低油耗的研究。试验结果表明：“双反射”燃烧系统具有单峰放热率特性。采用低压缩比后的“双反射”燃烧系统,在全工况范围内降低了气缸爆发压力。与此同时,从燃烧过程中的累计放热率、累计放热量百分比、单峰放热率和指示热效率等参数分析了油耗率特性,控制油耗率在一个很低的水平。
(3)低压缩比概念的直喷柴油机“双反射”燃烧系统快速燃烧的试验研究。试验表明：降低压缩比后,燃烧始点向后推迟2-3℃A,在保证动力性能的前提下,气缸压力大大降低,降低了缸内最高燃烧温度和NOx排放。通过外特性工况瞬时放热率在中高速呈单峰趋势以及累积放热率5%～70%对应的曲轴转角θ5～θ70范围内与原机有相同的燃烧速率,证实了低几何压缩比的“双反射”燃烧系统仍然具有快速燃烧的特性。
(4)提前喷油低碳烟排放的研究。将“双反射”燃烧系统静态供油提前角提前到18℃A BTDC,能实现扭矩点与功率点同为0.21BSU的低碳烟排放。
进行“双反射”燃烧系统试验研究的同时,分别在大平板和燃烧室中对其喷雾场进行了相关的数值模拟研究。燃油撞击到带到导向凸弧和小台阶的大平板上,以燃油蒸汽的形式反射,形成分层壁面射流。射流油束以反射物为中心,形成高浓度的燃油区域,不断向外扩散,形成稀混合气。在燃烧室中,上止点前受挤流的影响,在燃烧室中形成了大尺寸的旋涡,燃烧室壁面上设置了导向凸弧与小台阶后,旋涡的尺度会更大,而且底面凸台的低速区域与虚拟原机相比减小。活塞到达上止点后,随着活塞的下行,在“双反射”燃烧室底部形成了一个中等尺度的旋涡,有利于油气的充分混合。“双反射”燃烧室燃油分布在燃烧室的侧壁上,燃油没有到达凹坑,在壁面上的空燃比分布比例较少,说明燃油已经汽化蒸发,形成稀薄混合气。在粒子分布上也能得出相同的结论,在19°CA ATDC燃油喷射结束后,原机与虚拟原机在整个侧壁和凹坑壁面都存在大量的未来得及蒸发的液滴,而“双反射”燃烧室只有着壁点处存在还没来得及蒸发的粒子,可以得出,“双反射”燃烧室燃油蒸发的速率较快,同时也证明了快速混合理论。
According to the characteristic of spray of traditional diesel engine, a Double Reflex combustion system with spary impingement was designed based on wall-guiding, stratified-diffusion and space-dispersed on a DI Diesel Engine. NOx was reduced by low combustion temperature, Particulate Emission was reduced by premixed combustion and technique of Double Reflex with Spary Impingement. The reduction of NOx and PM was realized to solve the "paradox of Diesel Engine". The characteristics of this new combustion system are low cylinder pressure, rapid mixing, long ignition delay period and low combustion temperature. Double Reflex with Spary Impingement means that guide bellied arcs and little shoulders were set on surface of chamber wall, liquid spray blowout from injector and hit on surface of chamber wall, then stratified-diffusion spray was obtained, abbreviated as the Double Reflex, this combustion system is named as the Double Reflex combustion system. The reflected spray distributes at squish zone and concave zone of combustion chamber, big swirl of spray is obtained and expand to more domains. Thus, the spray to the wall can entrain more air, produce more mixture in limited ignition delay period, generate multiple ignition points and shorten duration of combustion. After the spray burst into flame, upper and lower spray make radiant heat transfer. By the effect of centrifugal force, fuel oil drops atomized insufficiently from upper spray can continue to burn in the lower spray. By the effect of reversed squish of piston, uncompleted combustion products from lower spray can continue to burn in the upper spray, too. Moreover, this reflection achieves better breaking for spray, at the same time, more homogeneous mixture can be achieved in rapid because of impingement and diffusion.
The experimental investigation on Double Reflex combustion system is carried out on a4100ZL diesel engine.The experimental test was to optimize the structural parameters for combustion system of the engine, including chamber structure, swirl ratio of head, spray angle,number and diameter of Nozzle, pressure and timing of fuel oil injection. The effect of Double Reflex combustion system on combustion and engine performance was researched to obtain the best performance indexes, and comparison to the original engine was carried out. The results show that NOx was reduced from712×10-6to487×10-6at2100r·min-1/307N·m (operating point of peak torque), from593×10-6to369×10-6at3000r·min-1/267N-m (operating point of rated power),that's31.6%and37.7%separately. The BSFC and Smoke were improved at low speed and rated load. BSFC was reduced form240.5g.(kw-h)-1to225.4g·(kw-h)-1, that's6.3%, Smoke was reduced from3.67BSU to2.1BSU, Pressure in cylinder was obviously reduced for128bar to108bar, that's15.6%at peak torque point.
The optimized Double Reflex combustion system is studied in detail and the conclusions can be given as following.
(1) Research of DI diesel engine Performance based on controlling of ROHR under high speed operating condition ensuring the best emissions and fuel economy.
The main difficulty of improving the combustion performance was the control of SOC and the combustion rate under operating conditions of high speed and heavy load, that's the control of the instantaneous ROHR. The SOC of diesel engine was postponed by reducing the geometric compression ratio,and the combustion rate of the cylinder mixture was improved by the geometric method (Double Reflex technology) for achieve the effect of reducing NOx emissions and maintaining a high indicated thermal efficiency, that is to effective control of the combustion phase and the center of gravity of the instantaneous ROHR. Double Reflex combustion system with lower compression ratio can maintain the combustion rate under the high-speed and ensure optimal emissions and economy performance of diesel engine as well as the power does not be reduced.Based on the above ideas, the experiment is carried out at speed of3000r·min-1
(2) Research of low cylinder pressure and low fuel consumption for Double Reflex combustion system of DI diesel engine based on single peak ROHR characteristics.
The results show that:The instantaneous ROHR of Double Reflex combustion system shows a trend of single peak. When the compression ratio is reduced,the peak cylinder pressure of Double Reflex combustion system was reduced at all operating point range.The fuel consumption rate characteristics is analyzed according to the cumulative ROHR, the percentage of total heat release, the single peak ROHR and the indicated thermal efficiency, the results shows that the BSFC is at a very low level.
(3) Experimental research on rapid combustion of Double Reflex combustion system of DI diesel engine based on new concept of low compression ratio.
The results showed that:When the compression ratio is reduced, the SOC was postponed for about2～3℃A, which ensures the dynamic engine performance in the same level and makes the cylinder pressure reduced greatly, the highest cylinder combustion temperature and NOx emissions reduced,too. The instantaneous ROHR showed the single peak characteristic at medium and high speed at external characteristic, the combustion of new engine had the same combustion rate at crank angle of θ5～θ70with accumulate ROHR of5%～70%as the original engine.Both phenomenon perfectly demonstrated the Double Reflex combustion system of DI diesel engine with low compression ratio can maintain rapid combustion rate indeed.
(4) Research of low soot emissions through advanced injection timing.
As the static fuel supply was increased to18℃A BTDC, the smoke emission would be reduced to0.21BSU at the operating point of rated power and peak torque.
At the same time of experimental research on the Double Reflex combustion system, the related numerical simulations on spray field at a large plate and in the combustion chamber are carried out. The fuel hits on the plate with guide arc and little shoulders, reflects in the form of vapor and forms the stratified wall jet. Taking the reflector as a center, the spray forms a high concentrated fuel zone, and constantly spreads out to form a lean mixture. In the combustion chamber, a large vortex is formed influenced by squish flow before the TDC. The vortex will be more larger when guide arc and little shoulders are adopted, and low-speed region of the bottom is smaller than that of the virtual original engine. After the piston reaches TDC, a medium-scale vortex is formed in the Double Reflex combustion chamber as the piston down, which benefits the fully mixing of fuel oil and gas. For the Double Reflex combustion chamber, the fuel locates on the sidewall of combustion chamber, and does not reach the concave, the distribution of A/F ratio on the chamber wall is small, which indicates that fuel is evaporated and lean mixture is formed.For the distribution of particles, the same conclusion can also be got. After the injection at19℃A ATDC, for the original engine and virtual original engine, there is a lot of droplets not evaporated in time on whole sidewall and concave wall, but for the Double Reflex engine there are particles not evaporated only at the touch points on combustion chamber wall.So it can also be drawn that fuel evaporation rate of the Double Reflex combustion chamber is more fast,that also proves the theory of rapid mixing.
针对“双反射”燃烧系统的特点,在一台4100ZL柴油机上进行了该燃烧系统的试验研究。对燃烧系统的结构参数优化,包括燃烧室、缸盖涡流比、喷孔夹角、喷孔直径/数目、喷射压力和喷油定时的优化,并研究了其对发动机性能和燃烧的影响,使发动机有最佳的性能指标,并与原机进行了性能对比。试验结果表明：在2100r·min-1/307N·m(扭矩点)工况NOx从712×10-6降低到487×10-6,在3000r·min-1/267N·m(功率点)工况NOx从593×10-6降低到369×10-6,分别降低了31.6%和37.7%。改善了低速全负荷的油耗率和烟度,油耗率从240.5g·(kw·h)-1降低到225.4g·(kw-h)-1,降低了6.3%；烟度从3.67BSU降低到2.1BSU。'‘双反射”柴油机的缸压较原机有很大程度的降低,扭矩点的缸压从原机的128bar降低到108bar,降低了15.6%。
对优化后的“双反射”燃烧系统进行以下几个方面深入研究并得出结论。
(1)基于高速放热率控制的直喷式柴油机性能研究,保证柴油机有最佳的排放性能和经济性能。改善燃烧性能的主要难点是高速与大负荷工况下对着火始点和燃烧速率的控制,即瞬时放热率的控制。本文通过降低几何压缩比推迟车用柴油机高速工况下的着火始点,并采用几何方法(双反射技术)提高缸内混合气的燃烧速率,达到同时降低NOx排放并保持高的热效率的效果,也就是说有效地控制燃烧相位和瞬时放热率的重心。“双反射”燃烧系统能在较低压缩比下,保持柴油机高速工况下的燃烧速率,在动力性不降低的情况下,保证了柴油机有最佳的排放性能和经济性能。基于上述思想,在柴油机3000r·min-1转速下进行了试验研究。
(2)基于单峰放热率特性的“双反射”燃烧系统的直喷柴油机低爆压低油耗的研究。试验结果表明：“双反射”燃烧系统具有单峰放热率特性。采用低压缩比后的“双反射”燃烧系统,在全工况范围内降低了气缸爆发压力。与此同时,从燃烧过程中的累计放热率、累计放热量百分比、单峰放热率和指示热效率等参数分析了油耗率特性,控制油耗率在一个很低的水平。
(3)低压缩比概念的直喷柴油机“双反射”燃烧系统快速燃烧的试验研究。试验表明：降低压缩比后,燃烧始点向后推迟2-3℃A,在保证动力性能的前提下,气缸压力大大降低,降低了缸内最高燃烧温度和NOx排放。通过外特性工况瞬时放热率在中高速呈单峰趋势以及累积放热率5%～70%对应的曲轴转角θ5～θ70范围内与原机有相同的燃烧速率,证实了低几何压缩比的“双反射”燃烧系统仍然具有快速燃烧的特性。
(4)提前喷油低碳烟排放的研究。将“双反射”燃烧系统静态供油提前角提前到18℃A BTDC,能实现扭矩点与功率点同为0.21BSU的低碳烟排放。
进行“双反射”燃烧系统试验研究的同时,分别在大平板和燃烧室中对其喷雾场进行了相关的数值模拟研究。燃油撞击到带到导向凸弧和小台阶的大平板上,以燃油蒸汽的形式反射,形成分层壁面射流。射流油束以反射物为中心,形成高浓度的燃油区域,不断向外扩散,形成稀混合气。在燃烧室中,上止点前受挤流的影响,在燃烧室中形成了大尺寸的旋涡,燃烧室壁面上设置了导向凸弧与小台阶后,旋涡的尺度会更大,而且底面凸台的低速区域与虚拟原机相比减小。活塞到达上止点后,随着活塞的下行,在“双反射”燃烧室底部形成了一个中等尺度的旋涡,有利于油气的充分混合。“双反射”燃烧室燃油分布在燃烧室的侧壁上,燃油没有到达凹坑,在壁面上的空燃比分布比例较少,说明燃油已经汽化蒸发,形成稀薄混合气。在粒子分布上也能得出相同的结论,在19°CA ATDC燃油喷射结束后,原机与虚拟原机在整个侧壁和凹坑壁面都存在大量的未来得及蒸发的液滴,而“双反射”燃烧室只有着壁点处存在还没来得及蒸发的粒子,可以得出,“双反射”燃烧室燃油蒸发的速率较快,同时也证明了快速混合理论。
According to the characteristic of spray of traditional diesel engine, a Double Reflex combustion system with spary impingement was designed based on wall-guiding, stratified-diffusion and space-dispersed on a DI Diesel Engine. NOx was reduced by low combustion temperature, Particulate Emission was reduced by premixed combustion and technique of Double Reflex with Spary Impingement. The reduction of NOx and PM was realized to solve the "paradox of Diesel Engine". The characteristics of this new combustion system are low cylinder pressure, rapid mixing, long ignition delay period and low combustion temperature. Double Reflex with Spary Impingement means that guide bellied arcs and little shoulders were set on surface of chamber wall, liquid spray blowout from injector and hit on surface of chamber wall, then stratified-diffusion spray was obtained, abbreviated as the Double Reflex, this combustion system is named as the Double Reflex combustion system. The reflected spray distributes at squish zone and concave zone of combustion chamber, big swirl of spray is obtained and expand to more domains. Thus, the spray to the wall can entrain more air, produce more mixture in limited ignition delay period, generate multiple ignition points and shorten duration of combustion. After the spray burst into flame, upper and lower spray make radiant heat transfer. By the effect of centrifugal force, fuel oil drops atomized insufficiently from upper spray can continue to burn in the lower spray. By the effect of reversed squish of piston, uncompleted combustion products from lower spray can continue to burn in the upper spray, too. Moreover, this reflection achieves better breaking for spray, at the same time, more homogeneous mixture can be achieved in rapid because of impingement and diffusion.
The experimental investigation on Double Reflex combustion system is carried out on a4100ZL diesel engine.The experimental test was to optimize the structural parameters for combustion system of the engine, including chamber structure, swirl ratio of head, spray angle,number and diameter of Nozzle, pressure and timing of fuel oil injection. The effect of Double Reflex combustion system on combustion and engine performance was researched to obtain the best performance indexes, and comparison to the original engine was carried out. The results show that NOx was reduced from712×10-6to487×10-6at2100r·min-1/307N·m (operating point of peak torque), from593×10-6to369×10-6at3000r·min-1/267N-m (operating point of rated power),that's31.6%and37.7%separately. The BSFC and Smoke were improved at low speed and rated load. BSFC was reduced form240.5g.(kw-h)-1to225.4g·(kw-h)-1, that's6.3%, Smoke was reduced from3.67BSU to2.1BSU, Pressure in cylinder was obviously reduced for128bar to108bar, that's15.6%at peak torque point.
The optimized Double Reflex combustion system is studied in detail and the conclusions can be given as following.
(1) Research of DI diesel engine Performance based on controlling of ROHR under high speed operating condition ensuring the best emissions and fuel economy.
The main difficulty of improving the combustion performance was the control of SOC and the combustion rate under operating conditions of high speed and heavy load, that's the control of the instantaneous ROHR. The SOC of diesel engine was postponed by reducing the geometric compression ratio,and the combustion rate of the cylinder mixture was improved by the geometric method (Double Reflex technology) for achieve the effect of reducing NOx emissions and maintaining a high indicated thermal efficiency, that is to effective control of the combustion phase and the center of gravity of the instantaneous ROHR. Double Reflex combustion system with lower compression ratio can maintain the combustion rate under the high-speed and ensure optimal emissions and economy performance of diesel engine as well as the power does not be reduced.Based on the above ideas, the experiment is carried out at speed of3000r·min-1
(2) Research of low cylinder pressure and low fuel consumption for Double Reflex combustion system of DI diesel engine based on single peak ROHR characteristics.
The results show that:The instantaneous ROHR of Double Reflex combustion system shows a trend of single peak. When the compression ratio is reduced,the peak cylinder pressure of Double Reflex combustion system was reduced at all operating point range.The fuel consumption rate characteristics is analyzed according to the cumulative ROHR, the percentage of total heat release, the single peak ROHR and the indicated thermal efficiency, the results shows that the BSFC is at a very low level.
(3) Experimental research on rapid combustion of Double Reflex combustion system of DI diesel engine based on new concept of low compression ratio.
The results showed that:When the compression ratio is reduced, the SOC was postponed for about2～3℃A, which ensures the dynamic engine performance in the same level and makes the cylinder pressure reduced greatly, the highest cylinder combustion temperature and NOx emissions reduced,too. The instantaneous ROHR showed the single peak characteristic at medium and high speed at external characteristic, the combustion of new engine had the same combustion rate at crank angle of θ5～θ70with accumulate ROHR of5%～70%as the original engine.Both phenomenon perfectly demonstrated the Double Reflex combustion system of DI diesel engine with low compression ratio can maintain rapid combustion rate indeed.
(4) Research of low soot emissions through advanced injection timing.
As the static fuel supply was increased to18℃A BTDC, the smoke emission would be reduced to0.21BSU at the operating point of rated power and peak torque.
At the same time of experimental research on the Double Reflex combustion system, the related numerical simulations on spray field at a large plate and in the combustion chamber are carried out. The fuel hits on the plate with guide arc and little shoulders, reflects in the form of vapor and forms the stratified wall jet. Taking the reflector as a center, the spray forms a high concentrated fuel zone, and constantly spreads out to form a lean mixture. In the combustion chamber, a large vortex is formed influenced by squish flow before the TDC. The vortex will be more larger when guide arc and little shoulders are adopted, and low-speed region of the bottom is smaller than that of the virtual original engine. After the piston reaches TDC, a medium-scale vortex is formed in the Double Reflex combustion chamber as the piston down, which benefits the fully mixing of fuel oil and gas. For the Double Reflex combustion chamber, the fuel locates on the sidewall of combustion chamber, and does not reach the concave, the distribution of A/F ratio on the chamber wall is small, which indicates that fuel is evaporated and lean mixture is formed.For the distribution of particles, the same conclusion can also be got. After the injection at19℃A ATDC, for the original engine and virtual original engine, there is a lot of droplets not evaporated in time on whole sidewall and concave wall, but for the Double Reflex engine there are particles not evaporated only at the touch points on combustion chamber wall.So it can also be drawn that fuel evaporation rate of the Double Reflex combustion chamber is more fast,that also proves the theory of rapid mixing.
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