柴油机低噪声结构动态设计方法的研究
摘要
本文运用机械产品动态设计的理论和方法,系统研究了以低结构噪声为目标的柴油机动态设计流程。在设计阶段建立柴油机主要部件的动力学分析模型,得到了结构的动态特性;计算并分析结构动态响应,实现了柴油机振动及噪声性能的预测;依据所获得的预测结果、结构动态特性、系统激励等信息对结构进行修改,最终达到了低结构噪声柴油机的设计目的。
通过理论分析与实验研究两种不同的手段,建立一台车用六缸柴油机的两个主要部件机体和曲轴的动力学模型,经过实验模态分析与有限元分析结果的对比,验证了所建立的有限元模型的合理性。分析了机体和曲轴的动态特性,得到它们的主要振动模态及模态频率。
根据柔体多体动力学的基本理论,推导了柔性旋转轴的有限元模型,借助大型结构动态分析的子结构方法,将柔性曲轴看作一个子结构,采用子结构综合方法将柔性曲轴与发动机其它构件连接,进行了发动机曲柄连杆机构动力学分析。
建立机体结构动态响应模型,得到了发动机主要激励力对机体表面振动的传递特性以及表面振动速度。推导结构表面振动速度与辐射噪声之间的关系,并算出机体表面噪声辐射声功率,实现了机体结构动态响应预测。
设计不同的实验方案,分离出柴油机的进气噪声、风扇噪声、机械噪声和燃烧噪声,得到了它们对整机噪声声功率的贡献度。通过对实验结果的整理分析,发现了柴油机负荷、转速对上述噪声的影响规律。为后期的设计改进提供了指导。
进行机体结构的改进设计的实际应用研究。根据结构动态特性及动态响应分析结果,针对激励源、载荷承受体结构动态响应、振动表面振声辐射等环节,采取了不同的方法和手段。优化活塞重心及销孔中心偏置参数,减小了活塞对缸套的冲击载荷。改变主轴承隔板刚度及机体裙部结构方案,降低了机体裙部表面振动。研究了油底壳不同的结构修改方案,以及用减振钢板来改善结构声辐射性能。对样机开展综合设计改进,取得了整机声功率级降低4.1dB(A)的显著效果。
Based on the theory of machinery dynamic design, a systemic dynamic design procedure was practiced aiming to achieve a low structure-borne noise diesel engine. After modeling the major parts of the diesel, their dynamical characteristics were obtained. Engine block dynamic behavior, namely its vibration and noise radiation, can be predicted by computing its dynamic response. Analyzing such prediction result, structure dynamical characteristics and the external load applied on it, structural modification of engine block was conducted and proved to be effective to reduce engine noise radiation.
Both engine block and crank shaft dynamic models for an inline 6-cylinder-diesel were established by theoretical and experimental method. Model shape and frequency were obtained and compared, the results from EMA and FEA revealed the reliability of the FEA model.
A formulation for modeling a rotating flexible crankshaft coupling with its elastic deformation and component mode synthesis were presented. Crank train kinematical simulation was performed by combining the flexible crankshaft with con-rod, piston and main bearing journal.
Structural dynamic response model yielded transfer behavior from major exciting force to surface vibration as well as surface vibrating velocity. Deduction the methodology from surface velocity to noise radiation realized noise power prediction of the engine block.
Designing different noise source identification strategy, the intake noise, fan noise, mechanical noise and combustion noise were separated successfully. Their contribution to entire engine noise and correlation to engine load, engine speed were also found.
Different modification was made against the noise generation loop. To the exciting force, piston kinematical modeling helps to optimize piston gravity center offset and pin offset, resulted in a minimizing piston slap force. To the load bearing structure, main journal supporting plate and crank case modification reduced engine block skirt vibration. Geometrical shape variation and application of vibration-damping steel plate to the oil pan was attempted. Applying a kit of noise reduction solutions to the sample diesel engine, a 4.1dB(A) overall noise power level reduction was achieved.
通过理论分析与实验研究两种不同的手段,建立一台车用六缸柴油机的两个主要部件机体和曲轴的动力学模型,经过实验模态分析与有限元分析结果的对比,验证了所建立的有限元模型的合理性。分析了机体和曲轴的动态特性,得到它们的主要振动模态及模态频率。
根据柔体多体动力学的基本理论,推导了柔性旋转轴的有限元模型,借助大型结构动态分析的子结构方法,将柔性曲轴看作一个子结构,采用子结构综合方法将柔性曲轴与发动机其它构件连接,进行了发动机曲柄连杆机构动力学分析。
建立机体结构动态响应模型,得到了发动机主要激励力对机体表面振动的传递特性以及表面振动速度。推导结构表面振动速度与辐射噪声之间的关系,并算出机体表面噪声辐射声功率,实现了机体结构动态响应预测。
设计不同的实验方案,分离出柴油机的进气噪声、风扇噪声、机械噪声和燃烧噪声,得到了它们对整机噪声声功率的贡献度。通过对实验结果的整理分析,发现了柴油机负荷、转速对上述噪声的影响规律。为后期的设计改进提供了指导。
进行机体结构的改进设计的实际应用研究。根据结构动态特性及动态响应分析结果,针对激励源、载荷承受体结构动态响应、振动表面振声辐射等环节,采取了不同的方法和手段。优化活塞重心及销孔中心偏置参数,减小了活塞对缸套的冲击载荷。改变主轴承隔板刚度及机体裙部结构方案,降低了机体裙部表面振动。研究了油底壳不同的结构修改方案,以及用减振钢板来改善结构声辐射性能。对样机开展综合设计改进,取得了整机声功率级降低4.1dB(A)的显著效果。
Based on the theory of machinery dynamic design, a systemic dynamic design procedure was practiced aiming to achieve a low structure-borne noise diesel engine. After modeling the major parts of the diesel, their dynamical characteristics were obtained. Engine block dynamic behavior, namely its vibration and noise radiation, can be predicted by computing its dynamic response. Analyzing such prediction result, structure dynamical characteristics and the external load applied on it, structural modification of engine block was conducted and proved to be effective to reduce engine noise radiation.
Both engine block and crank shaft dynamic models for an inline 6-cylinder-diesel were established by theoretical and experimental method. Model shape and frequency were obtained and compared, the results from EMA and FEA revealed the reliability of the FEA model.
A formulation for modeling a rotating flexible crankshaft coupling with its elastic deformation and component mode synthesis were presented. Crank train kinematical simulation was performed by combining the flexible crankshaft with con-rod, piston and main bearing journal.
Structural dynamic response model yielded transfer behavior from major exciting force to surface vibration as well as surface vibrating velocity. Deduction the methodology from surface velocity to noise radiation realized noise power prediction of the engine block.
Designing different noise source identification strategy, the intake noise, fan noise, mechanical noise and combustion noise were separated successfully. Their contribution to entire engine noise and correlation to engine load, engine speed were also found.
Different modification was made against the noise generation loop. To the exciting force, piston kinematical modeling helps to optimize piston gravity center offset and pin offset, resulted in a minimizing piston slap force. To the load bearing structure, main journal supporting plate and crank case modification reduced engine block skirt vibration. Geometrical shape variation and application of vibration-damping steel plate to the oil pan was attempted. Applying a kit of noise reduction solutions to the sample diesel engine, a 4.1dB(A) overall noise power level reduction was achieved.
引文
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