高性能车用磁粉离合器的研究
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摘要
磁粉离合器具有接合平顺、可控性好、响应迅速、转矩传递范围广且与滑差率无关、传动效率高等优点,决定其在车辆行业有着广阔的应用前景。但是由于国外技术封锁,国内缺少相关研究,目前国产车用磁粉离合器存在传递转矩容量低,工作过程激磁线圈温升过高等问题,无法满足车辆传动的使用要求。为此,本文以一种适用于经济型乘用车自动变速或半自动变速系统中使用的,具有高转矩传递、高可靠性、低能耗的高性能车用磁粉离合器为研究对象,运用理论分析、仿真计算、样件试制与试验测试相结合的研究方法,紧密把握材料与结构设计两条研究主线,对磁粉离合器转矩传递机理、基于电磁场分析的磁粉离合器性能评价及设计方法、材料性能及结构参数对磁粉离合器性能的影响关系、温度场分析模型、应用永磁材料的磁粉离合器设计及可行性等一系列关键问题展开了深入研究,旨在通过本文的研究提高国产磁粉离合器及汽车产品的档次和市场竞争力。主要内容包括以下几个方面：
(1)从能量守恒角度出发,建立了磁粉离合器转矩传递机理模型,揭示其利用能量变换实现转矩传递的内在规律。建立了磁粉离合器工作间隙电磁场与其转矩传递间关系,提出了通过电磁场分析得到磁粉离合器性能的方法。
(2)利用现有磁粉离合器的设计方法与经验,综合考虑车辆变速器型腔空间对磁粉离合器几何尺寸的限定,对车用磁粉离合器结构与电磁参数进行了设计,建立了设计车用磁粉离合器的电磁场分析模型,并对其性能进行了分析研究。
(3)在设计的车用磁粉离合器分析模型和分析结果的基础上,从离合器结构及参数的改进与优化、离合器材料对其性能影响两个角度,分析提升磁粉离合器转矩传递性能的方法与途径,分析建立了磁粉离合器工作间隙宽度、非工作间隙宽度、工作间隙数目、磁路材料磁性能、磁粉材料等主要设计参数与其性能间的定量关系。通过储粉腔、磁粉导槽的合理设计,改善了磁粉离合器磁场分布,实现了磁粉离合器高转矩传递的高性能。
(4)针对车用磁粉离合器的工作特点,利用永磁材料在工作中不消耗能量的优良特性,提出了一种基于永磁体产生的和由激磁线圈产生的两磁场叠加原理的磁粉离合器,对其结构方案、工作过程及结构参数进行了设计分析。确定了满足设计要求车用永磁磁粉离合器的设计方案,并对其性能进行分析,与常规电磁磁粉离合器相比,能耗得到有效降低。
(5)为评价设计的磁粉离合器的工作能力和可行性,指导其设计与优化,建立了磁粉离合器温度场分析模型,研究了三种典型稳定工况下的磁粉离合器温度分布及其变化情况。分析结果表明,本文设计的车用磁粉离合器具有高的工作可靠性。
(6)研制了磁粉离合器试验样机,建立了试验平台,进行了试验样机表面静态电磁场、转矩-激磁电流特性、表面温升的试验研究。试验验证了本文设计、计算等工作的正确性,结果表明本文所研究的车用磁粉离合器的具有高转矩传递、高可靠性及低能耗的特点,达到预期研究效果。
Magnetic powder clutch has the advantages of smooth separation and joint, good controllability, quick response, wide torque transmission range independent of the slip ratio, high transmission efficiency and so on, which determined that it has a broad application prospect in the vehicle industry. However, because of the technical blockage of foreign enterprise and very few people engaged in the research of the magnetic powder clutch, the present domestic magnetic powder clutch has shortcomings of the low transferring torque capacity, heating seriously during its working process etc. As a result, it can't satisfy the requirements of vehicle transmission system. Therefore, a kind of the high-performance vehicle magnetic powder clutch with high torque transmission performance, high reliability and low energy consumption was studied. And it is suitable for automatic transmission system or semi-automatic transmission system of the economical car. In order to improve the torque transmission performance of the magnetic powder clutch, raise the grade of the domestic magnetic powder clutch and its car product and have a better competitive, some key topics such as the torque transmission mechanism of the magnetic powder clutch, research on the methods of the performance evaluation and design of the magnetic powder clutch based on electromagnetic field analysis, influence of the material properties and structural parameters on the performance of the magnetic powder clutch, temperature field analysis model, magnetic powder clutch applied permanent magnet and so on were studied using research methods such as theoretical analysis, simulation calculation, prototype develop and test. The major contributions of this paper were as follows:
(1)From the perspective of energy conservation, the torque transmission performance evaluation mathematical model of the magnetic powder clutch was established. The inherent law of its torque transmission based on energy conversion was revealed. The relation between the electromagnetic field of the working gap and the torque transmission of the magnetic powder clutch was established. The performance evaluation method for the magnetic powder clutch based on the electromagnetic field analysis was presented.
(2) A further study on analysis and design methods of the magnetic powder clutch electromagnetic field was carried out. The structural and electromagnetic parameters of the vehicle magnetic powder clutch were initially designed based on the existing design methods and experiences of the magnetic powder clutch, and at the same time, it was comprehensively considered that the geometry size of the magnetic powder clutch was limited by the vehicle transmission cavity space. Electromagnetic field simulation model of the designed vehicle magnetic powder clutch was created. The performance of the vehicle magnetic powder clutch was simulated based on the simulation model.
(3)According to the influences of the clutch material properties and its structural parameters on the performance of the clutch, the ways and means to improve the torque transmission performance of the magnetic powder clutch were analyzed, and the quantitative relationship was determined between its performance and its main design parameters such as working gap width, nonworking gap width, number of working gap, magnetic circuit material properties based on the designed model of the vehicle magnetic powder clutch and the analysis results. The magnetic field distribution of the magnetic powder clutch was improved by the reasonable design on powder storage chamber and magnetic powder guidance channel. And the performance of high torque transmission was realized.
(4)According to the working characteristics of the vehicle magnetic powder clutch and the excellent characteristic of the permanent magnetic materials that it does not consume energy throughout the work, a kind of magnetic powder clutch was proposed with superposition principle of two magnetic fields generated by permanent magnet and the excitation coil. And its structure scheme, working process and structural parameters were designed and analyzed. The design scheme of the vehicle magnetic powder clutch that can meet the design requirements was determined. And the performance of the designed vehicle magnetic powder clutch was analyzed. And the performance of low energy consumption was realized.
(5)In order to evaluate the working ability and the feasibility and to guide the design and optimization of the designed magnetic powder clutch, the simulation model of the temperature field was created. Based on the simulation model, the temperature distribution and the variation of the magnetic powder clutch under three typical stable conditions were studied. The results showed that the designed vehicle magnetic powder clutch in this paper had high working reliability.
(6)The test prototype was developed and the test platform was established to test a study of static electromagnetic field on the surface of this test prototype, torque-exciting current characteristics and temperature rise. This study has verified the correctness of the design and calculations for this article and the feasibility of this designed magnetic powder clutch. The design and the calculations were verified by the test. The test results showed that the designed vehicle magnetic powder clutch in this article has advantages of high torque transmission,high working stablity and low energy consumption and that the research results reached the reached the expected requirement.
(1)从能量守恒角度出发,建立了磁粉离合器转矩传递机理模型,揭示其利用能量变换实现转矩传递的内在规律。建立了磁粉离合器工作间隙电磁场与其转矩传递间关系,提出了通过电磁场分析得到磁粉离合器性能的方法。
(2)利用现有磁粉离合器的设计方法与经验,综合考虑车辆变速器型腔空间对磁粉离合器几何尺寸的限定,对车用磁粉离合器结构与电磁参数进行了设计,建立了设计车用磁粉离合器的电磁场分析模型,并对其性能进行了分析研究。
(3)在设计的车用磁粉离合器分析模型和分析结果的基础上,从离合器结构及参数的改进与优化、离合器材料对其性能影响两个角度,分析提升磁粉离合器转矩传递性能的方法与途径,分析建立了磁粉离合器工作间隙宽度、非工作间隙宽度、工作间隙数目、磁路材料磁性能、磁粉材料等主要设计参数与其性能间的定量关系。通过储粉腔、磁粉导槽的合理设计,改善了磁粉离合器磁场分布,实现了磁粉离合器高转矩传递的高性能。
(4)针对车用磁粉离合器的工作特点,利用永磁材料在工作中不消耗能量的优良特性,提出了一种基于永磁体产生的和由激磁线圈产生的两磁场叠加原理的磁粉离合器,对其结构方案、工作过程及结构参数进行了设计分析。确定了满足设计要求车用永磁磁粉离合器的设计方案,并对其性能进行分析,与常规电磁磁粉离合器相比,能耗得到有效降低。
(5)为评价设计的磁粉离合器的工作能力和可行性,指导其设计与优化,建立了磁粉离合器温度场分析模型,研究了三种典型稳定工况下的磁粉离合器温度分布及其变化情况。分析结果表明,本文设计的车用磁粉离合器具有高的工作可靠性。
(6)研制了磁粉离合器试验样机,建立了试验平台,进行了试验样机表面静态电磁场、转矩-激磁电流特性、表面温升的试验研究。试验验证了本文设计、计算等工作的正确性,结果表明本文所研究的车用磁粉离合器的具有高转矩传递、高可靠性及低能耗的特点,达到预期研究效果。
Magnetic powder clutch has the advantages of smooth separation and joint, good controllability, quick response, wide torque transmission range independent of the slip ratio, high transmission efficiency and so on, which determined that it has a broad application prospect in the vehicle industry. However, because of the technical blockage of foreign enterprise and very few people engaged in the research of the magnetic powder clutch, the present domestic magnetic powder clutch has shortcomings of the low transferring torque capacity, heating seriously during its working process etc. As a result, it can't satisfy the requirements of vehicle transmission system. Therefore, a kind of the high-performance vehicle magnetic powder clutch with high torque transmission performance, high reliability and low energy consumption was studied. And it is suitable for automatic transmission system or semi-automatic transmission system of the economical car. In order to improve the torque transmission performance of the magnetic powder clutch, raise the grade of the domestic magnetic powder clutch and its car product and have a better competitive, some key topics such as the torque transmission mechanism of the magnetic powder clutch, research on the methods of the performance evaluation and design of the magnetic powder clutch based on electromagnetic field analysis, influence of the material properties and structural parameters on the performance of the magnetic powder clutch, temperature field analysis model, magnetic powder clutch applied permanent magnet and so on were studied using research methods such as theoretical analysis, simulation calculation, prototype develop and test. The major contributions of this paper were as follows:
(1)From the perspective of energy conservation, the torque transmission performance evaluation mathematical model of the magnetic powder clutch was established. The inherent law of its torque transmission based on energy conversion was revealed. The relation between the electromagnetic field of the working gap and the torque transmission of the magnetic powder clutch was established. The performance evaluation method for the magnetic powder clutch based on the electromagnetic field analysis was presented.
(2) A further study on analysis and design methods of the magnetic powder clutch electromagnetic field was carried out. The structural and electromagnetic parameters of the vehicle magnetic powder clutch were initially designed based on the existing design methods and experiences of the magnetic powder clutch, and at the same time, it was comprehensively considered that the geometry size of the magnetic powder clutch was limited by the vehicle transmission cavity space. Electromagnetic field simulation model of the designed vehicle magnetic powder clutch was created. The performance of the vehicle magnetic powder clutch was simulated based on the simulation model.
(3)According to the influences of the clutch material properties and its structural parameters on the performance of the clutch, the ways and means to improve the torque transmission performance of the magnetic powder clutch were analyzed, and the quantitative relationship was determined between its performance and its main design parameters such as working gap width, nonworking gap width, number of working gap, magnetic circuit material properties based on the designed model of the vehicle magnetic powder clutch and the analysis results. The magnetic field distribution of the magnetic powder clutch was improved by the reasonable design on powder storage chamber and magnetic powder guidance channel. And the performance of high torque transmission was realized.
(4)According to the working characteristics of the vehicle magnetic powder clutch and the excellent characteristic of the permanent magnetic materials that it does not consume energy throughout the work, a kind of magnetic powder clutch was proposed with superposition principle of two magnetic fields generated by permanent magnet and the excitation coil. And its structure scheme, working process and structural parameters were designed and analyzed. The design scheme of the vehicle magnetic powder clutch that can meet the design requirements was determined. And the performance of the designed vehicle magnetic powder clutch was analyzed. And the performance of low energy consumption was realized.
(5)In order to evaluate the working ability and the feasibility and to guide the design and optimization of the designed magnetic powder clutch, the simulation model of the temperature field was created. Based on the simulation model, the temperature distribution and the variation of the magnetic powder clutch under three typical stable conditions were studied. The results showed that the designed vehicle magnetic powder clutch in this paper had high working reliability.
(6)The test prototype was developed and the test platform was established to test a study of static electromagnetic field on the surface of this test prototype, torque-exciting current characteristics and temperature rise. This study has verified the correctness of the design and calculations for this article and the feasibility of this designed magnetic powder clutch. The design and the calculations were verified by the test. The test results showed that the designed vehicle magnetic powder clutch in this article has advantages of high torque transmission,high working stablity and low energy consumption and that the research results reached the reached the expected requirement.
引文
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