可变负荷率往复式内燃机设计理论与关键技术研究
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摘要
各种技术的融合与协作逐渐成为车用往复式内燃机(简称发动机)发展的必然趋势。若能利用先进发动机技术，根据具体工况动态调节发动机的负荷率，使其一直处于最佳负荷率区间，则有望实现全转速各工况综合性能的提升。世界著名汽车公司基于变负荷率理念，已分别研制出具备可变压缩比、可变排量与可变循环等技术特征的发动机，并得到业界和市场的一致认可，但国内对相关技术的研究几乎处于空白，所以此方面研究具有实际意义和广阔前景。本文设计出一种兼具二冲程和四冲程两种机型工作循环的发动机平台，主要对其工作原理、设计理论、参数优化及可行性试验验证等方面进行了研究，为设计具有自主知识产权的先进车用发动机及其实用化奠定理论和试验基础。主要研究内容如下：
提出一种能同时具备可变配气、可变排量、可变压缩比、可变循环与HCCI燃烧等技术的可变负荷率发动机(Variable Load Rate Engine, VLRE)，应用热力循环理论，分析了不同工作循环模式、可变压缩比与可变排量的工作原理，并确定出最佳模式切换时机为压缩上止点附近区域。分别基于发动机循环功频和有效压缩比概念，分析了VLRE循环功频多样性和其可变压缩比与可变排量技术相互依存的特点。依据二冲程发动机换气理论，确定了VLRE二冲程模式(VLRE-T)顶进-侧排的换气方案。最后分析了VLRE研发的可行性优势。
依据原型机Honda WH125-6构建了VLRE四冲程模式(VLRE-F)性能仿真模型，采用正交试验仿真得出了最大扭矩转速的最佳配气相位。仅利用七个发动机参数，建立了完整的二冲程机气口参数与配气相位程序化封闭求解数学模型，在初步确定VLRE缸侧排气口参数及VLRE-T模式设计最大功率转速配气相位后，利用VLRE-T模式性能仿真模型，优化了缸侧排气口及配气相位参数。
基于VLRE各配气凸轮的不同驱动功能，依据双质量当量模型和凸轮阀系设计理论，利用Excite_TD搭建了VLRE配气机构运动学和动力学模型。在凸轮廓线优化设计过程中，为提高计算参量的获取与调整效率，编写了凸轮参数计算与指标检验程序。基于配气机构运动学和动力学模型，优化设计出了VLRE各配气凸轮廓线。
提出了VLRE可变配气机构的总体设计方案，分析了其中可变配气凸轮廓线机构的结构特征与工作原理。利用数值转化建模方法，设计出了VLRE-T进气双峰凸轮廓线。基于VLRE的配气相位，研究了复合凸轮各凸峰相对位置的确定方法，并对模式切换过程的复合凸轮进行了驱动力分析。通过构建可变配气凸轮廓线机构三维虚拟样机，进行机构多体动力学分析，进一步验证了凸轮廓线设计的正确性与合理性。
基于VLRE凸轮轴驱动机构功能需求，提出利用双排行星轮系架构实现相位与速比同时可变的驱动机构方案。为快速辨识不同构型并从中优选合理的VLRE凸轮轴驱动机构方案，以功能实现为目标，采用粗糙集理论和聚类分析法进行机构方案的型综合与分类研究，确定出一类符合VLRE应用需求的机构方案。
为实现全转速综合性能最佳的VLRE设计参数优化，提出并构建了复合性能系数。复合性能系数的构造特点及引入的额定值无量纲法，决定了其参数权重和无量纲化结果对评价效果无本质影响，并通过考题与模糊物元法验证了其合理性。与传统发动机综合性能评价方法相比，该方法计算高效且能实现发动机不同机型或不同模式全转速综合性能的评价与比较。基于复合性能系数坎贝尔图，优化了全转速下VLRE-T模式的配气相位，确定了VLRE缸侧排气口的形状、尺寸及位置参数。依据复合性能系数与负荷率最优原则，分别制定了VLRE“综合性能模式”与“经济模式”两种工作模式切换策略。
搭建了VLRE台架试验平台，根据原型机的具体结构与布置特征，设计了VLRE配气凸轮机构试验方案，确定了缸侧排气口加工位置与增压器驱动方案，基于实践找到了一种快速调校VLRE-T模式配气正时的方法，并设计出具备排气缓冲功能的排气管路系统，解决了小排量发动机台架试验因管路过长导致的排气背压过高问题。最后完成了对WH125-6、VLRE-F模式和VLRE-T模式的台架试验，试验测试数据的分析结果，论证了VLRE设计思想的可行性。
The integration and collaboration of various technologies gradually become the inevitable trendfor vehicle reciprocating internal combustion engine(engine for short) development. If the engine loadrate is adjusted dynamically by using advanced engine technology according to specific workingcondition, it can stay in the range of optimum load rate, and the engine over-all performance at allspeed working conditions is expected to enhance. Based on the concept of variable load rate, the worldfamous auto companies have developed the engines with variable compression ratio, variabledisplacement and variable cycle etc. separately, which are unanimously approved by the industry andthe market. However, the domestic research on such area is almost blank, so research in this area haspractical and broad prospect. This paper designed a engine platform which combines both two-strokeand four-stroke working cycle, mainly focus on operating principle, design theory, parameteroptimization and feasibility test verification, which also lay a theoretical and experimental basis forself-developed high-tech advanced vehicle engine. The main research contents are as follows:
A variable load rate engine(VLRE) which can combine the variable valve, variable compressionratio, variable displacement, variable cycle and HCCI combustion technology simultaneity is proposed.The VLRE working principle of different work cycle mode, variable compression ratio and variabledisplacement by applying thermodynamic cycle theory are analyzed, and finally determined the bestmode switch timing is near the compression top dead center. Based on the engine cycle powerfrequency and effective compression ratio concept respectively, the diversity of cycle power frequencyand the interdependence characteristics between VLRE variable compression ratio and variabledisplacement technology are analyzed. According to the ventilation theory for two-stroke engine,VLRE’s two-stroke mode (VLRE-T) top intake-side exhaust ventilation program is determined. Finally,the feasibility advantage of developing VLRE is analyzed.
Based on the prototype Honda WH125-6, VLRE’s four-stroke mode (VLRE-F) performancesimulation model is built, and the best valve timing for VLRE-F in maximum torque speed is obtainedby using orthogonal test simulation. Using only seven engine parameters, a programmablemathematical model for getting the closed-form solution of two-stroke engine port parameters and valve timing is established. After initially identifying the cylinder exhaust port parameters and valvetiming of VLRE-T mode in design maximum power speed by programmable mathematical model, theparameters of cylinder exhaust port and valve timing are optimized again by using VLRE-T modeperformance simulation model.
Based on different drive functions of each VLRE valve cam, the kinematics and dynamics modelsof VLRE distribution device are built up according to the dual mass equivalent model and cam valvedesign theory by using Excite_TD. During the cam profile optimization and design process, a programis written for the cam parameters calculation and indicators inspection in order to improve theefficiency of the access and adjustment of calculated parameters. Each VLRE cam profile is optimizeddesign base on the kinematics and dynamics models of distribution device.
Variable distribution device overall design plan of VLRE is proposed, and the structural featuresand working principle of variable cam profile mechanism are analyzed. Using numerical transformationmodeling, the VLRE-T intake cam bimodal profile is worked out. Then the method of determining therelative position of multiple mounted cam each hump is studied base on the valve timing of VLRE, andthe driving forces of multiple mounted cam is analyzed during the mode switching process. By buildingthe three-dimensional virtual prototype of variable cam profile mechanism and carrying out multi-bodydynamics analysis, further validate the correctness and reasonableness of cam profile design.
Based on the functional requirements of the VLRE camshaft drive mechanism, a drive mechanismscheme that the double-planetary gear train structure are used to realize the phase and speed ratiochanging at the same time is proposed. In order to identify the different configurations quickly andoptimize the reasonable VLRE camshaft drive mechanism program, the rough set theory and clusteranalysis were applied to do the type synthesis and classification research on mechanism schemes withthe target of realize the function, so as to find out those mechanism schemes which can meet theapplication requirements of VLRE.
In order to achieve the best over-all performance at all speed, so as to optimize the designparameters of VLRE, the composite performance coefficient is proposed and constructed. Thestructural characteristics of the composite performance coefficient and the rating valuenon-dimensional method determined the parameter weight and non-dimensional results have noessential impact on effect of the evaluation, and its reasonableness is verified with examples calculationand the method of fuzzy matter element. Compared with the traditional engine over-all performance evaluation method, the method is not only computationally efficient, but also can evaluate and comparethe over-all performance at all speed under different engine types or different mode. Based on theCampbell diagram of composite performance coefficient, the valve timing of VLRE-T mode at allspeed are optimized, and the optimum shape, size dimension and position parameters of VLRE cylinderexhaust port are determined. Base on the optimal principle of composite performance coefficient andload rate, the two switching strategy of "over-all performance mode" and "economy mode" for VLRE’stwo operating mode are established respectively.
According to the specific structure and layout characteristics of the prototype, VLRE bench testplatform is built up, and the testing program about VLRE distribution device is designed, theprocessing position of the cylinder exhaust port and the supercharger drive scheme are determined. Amethod for rapidly adjusting the valve timing of VLRE-T mode is found out based on the practice, andthe exhaust piping system with exhaust buffer function is designed, which can solve problems ofsmall-displacement engine exhaust back pressure is too high when bench test. Finally, the bench test ofWH125-6, VLRE-F mode and VLRE-T mode is carried out, the analysis result of test datademonstrated the feasibility of VLRE design idea.
提出一种能同时具备可变配气、可变排量、可变压缩比、可变循环与HCCI燃烧等技术的可变负荷率发动机(Variable Load Rate Engine, VLRE)，应用热力循环理论，分析了不同工作循环模式、可变压缩比与可变排量的工作原理，并确定出最佳模式切换时机为压缩上止点附近区域。分别基于发动机循环功频和有效压缩比概念，分析了VLRE循环功频多样性和其可变压缩比与可变排量技术相互依存的特点。依据二冲程发动机换气理论，确定了VLRE二冲程模式(VLRE-T)顶进-侧排的换气方案。最后分析了VLRE研发的可行性优势。
依据原型机Honda WH125-6构建了VLRE四冲程模式(VLRE-F)性能仿真模型，采用正交试验仿真得出了最大扭矩转速的最佳配气相位。仅利用七个发动机参数，建立了完整的二冲程机气口参数与配气相位程序化封闭求解数学模型，在初步确定VLRE缸侧排气口参数及VLRE-T模式设计最大功率转速配气相位后，利用VLRE-T模式性能仿真模型，优化了缸侧排气口及配气相位参数。
基于VLRE各配气凸轮的不同驱动功能，依据双质量当量模型和凸轮阀系设计理论，利用Excite_TD搭建了VLRE配气机构运动学和动力学模型。在凸轮廓线优化设计过程中，为提高计算参量的获取与调整效率，编写了凸轮参数计算与指标检验程序。基于配气机构运动学和动力学模型，优化设计出了VLRE各配气凸轮廓线。
提出了VLRE可变配气机构的总体设计方案，分析了其中可变配气凸轮廓线机构的结构特征与工作原理。利用数值转化建模方法，设计出了VLRE-T进气双峰凸轮廓线。基于VLRE的配气相位，研究了复合凸轮各凸峰相对位置的确定方法，并对模式切换过程的复合凸轮进行了驱动力分析。通过构建可变配气凸轮廓线机构三维虚拟样机，进行机构多体动力学分析，进一步验证了凸轮廓线设计的正确性与合理性。
基于VLRE凸轮轴驱动机构功能需求，提出利用双排行星轮系架构实现相位与速比同时可变的驱动机构方案。为快速辨识不同构型并从中优选合理的VLRE凸轮轴驱动机构方案，以功能实现为目标，采用粗糙集理论和聚类分析法进行机构方案的型综合与分类研究，确定出一类符合VLRE应用需求的机构方案。
为实现全转速综合性能最佳的VLRE设计参数优化，提出并构建了复合性能系数。复合性能系数的构造特点及引入的额定值无量纲法，决定了其参数权重和无量纲化结果对评价效果无本质影响，并通过考题与模糊物元法验证了其合理性。与传统发动机综合性能评价方法相比，该方法计算高效且能实现发动机不同机型或不同模式全转速综合性能的评价与比较。基于复合性能系数坎贝尔图，优化了全转速下VLRE-T模式的配气相位，确定了VLRE缸侧排气口的形状、尺寸及位置参数。依据复合性能系数与负荷率最优原则，分别制定了VLRE“综合性能模式”与“经济模式”两种工作模式切换策略。
搭建了VLRE台架试验平台，根据原型机的具体结构与布置特征，设计了VLRE配气凸轮机构试验方案，确定了缸侧排气口加工位置与增压器驱动方案，基于实践找到了一种快速调校VLRE-T模式配气正时的方法，并设计出具备排气缓冲功能的排气管路系统，解决了小排量发动机台架试验因管路过长导致的排气背压过高问题。最后完成了对WH125-6、VLRE-F模式和VLRE-T模式的台架试验，试验测试数据的分析结果，论证了VLRE设计思想的可行性。
The integration and collaboration of various technologies gradually become the inevitable trendfor vehicle reciprocating internal combustion engine(engine for short) development. If the engine loadrate is adjusted dynamically by using advanced engine technology according to specific workingcondition, it can stay in the range of optimum load rate, and the engine over-all performance at allspeed working conditions is expected to enhance. Based on the concept of variable load rate, the worldfamous auto companies have developed the engines with variable compression ratio, variabledisplacement and variable cycle etc. separately, which are unanimously approved by the industry andthe market. However, the domestic research on such area is almost blank, so research in this area haspractical and broad prospect. This paper designed a engine platform which combines both two-strokeand four-stroke working cycle, mainly focus on operating principle, design theory, parameteroptimization and feasibility test verification, which also lay a theoretical and experimental basis forself-developed high-tech advanced vehicle engine. The main research contents are as follows:
A variable load rate engine(VLRE) which can combine the variable valve, variable compressionratio, variable displacement, variable cycle and HCCI combustion technology simultaneity is proposed.The VLRE working principle of different work cycle mode, variable compression ratio and variabledisplacement by applying thermodynamic cycle theory are analyzed, and finally determined the bestmode switch timing is near the compression top dead center. Based on the engine cycle powerfrequency and effective compression ratio concept respectively, the diversity of cycle power frequencyand the interdependence characteristics between VLRE variable compression ratio and variabledisplacement technology are analyzed. According to the ventilation theory for two-stroke engine,VLRE’s two-stroke mode (VLRE-T) top intake-side exhaust ventilation program is determined. Finally,the feasibility advantage of developing VLRE is analyzed.
Based on the prototype Honda WH125-6, VLRE’s four-stroke mode (VLRE-F) performancesimulation model is built, and the best valve timing for VLRE-F in maximum torque speed is obtainedby using orthogonal test simulation. Using only seven engine parameters, a programmablemathematical model for getting the closed-form solution of two-stroke engine port parameters and valve timing is established. After initially identifying the cylinder exhaust port parameters and valvetiming of VLRE-T mode in design maximum power speed by programmable mathematical model, theparameters of cylinder exhaust port and valve timing are optimized again by using VLRE-T modeperformance simulation model.
Based on different drive functions of each VLRE valve cam, the kinematics and dynamics modelsof VLRE distribution device are built up according to the dual mass equivalent model and cam valvedesign theory by using Excite_TD. During the cam profile optimization and design process, a programis written for the cam parameters calculation and indicators inspection in order to improve theefficiency of the access and adjustment of calculated parameters. Each VLRE cam profile is optimizeddesign base on the kinematics and dynamics models of distribution device.
Variable distribution device overall design plan of VLRE is proposed, and the structural featuresand working principle of variable cam profile mechanism are analyzed. Using numerical transformationmodeling, the VLRE-T intake cam bimodal profile is worked out. Then the method of determining therelative position of multiple mounted cam each hump is studied base on the valve timing of VLRE, andthe driving forces of multiple mounted cam is analyzed during the mode switching process. By buildingthe three-dimensional virtual prototype of variable cam profile mechanism and carrying out multi-bodydynamics analysis, further validate the correctness and reasonableness of cam profile design.
Based on the functional requirements of the VLRE camshaft drive mechanism, a drive mechanismscheme that the double-planetary gear train structure are used to realize the phase and speed ratiochanging at the same time is proposed. In order to identify the different configurations quickly andoptimize the reasonable VLRE camshaft drive mechanism program, the rough set theory and clusteranalysis were applied to do the type synthesis and classification research on mechanism schemes withthe target of realize the function, so as to find out those mechanism schemes which can meet theapplication requirements of VLRE.
In order to achieve the best over-all performance at all speed, so as to optimize the designparameters of VLRE, the composite performance coefficient is proposed and constructed. Thestructural characteristics of the composite performance coefficient and the rating valuenon-dimensional method determined the parameter weight and non-dimensional results have noessential impact on effect of the evaluation, and its reasonableness is verified with examples calculationand the method of fuzzy matter element. Compared with the traditional engine over-all performance evaluation method, the method is not only computationally efficient, but also can evaluate and comparethe over-all performance at all speed under different engine types or different mode. Based on theCampbell diagram of composite performance coefficient, the valve timing of VLRE-T mode at allspeed are optimized, and the optimum shape, size dimension and position parameters of VLRE cylinderexhaust port are determined. Base on the optimal principle of composite performance coefficient andload rate, the two switching strategy of "over-all performance mode" and "economy mode" for VLRE’stwo operating mode are established respectively.
According to the specific structure and layout characteristics of the prototype, VLRE bench testplatform is built up, and the testing program about VLRE distribution device is designed, theprocessing position of the cylinder exhaust port and the supercharger drive scheme are determined. Amethod for rapidly adjusting the valve timing of VLRE-T mode is found out based on the practice, andthe exhaust piping system with exhaust buffer function is designed, which can solve problems ofsmall-displacement engine exhaust back pressure is too high when bench test. Finally, the bench test ofWH125-6, VLRE-F mode and VLRE-T mode is carried out, the analysis result of test datademonstrated the feasibility of VLRE design idea.
引文
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