柱塞泵流量脉动测试方法和大范围工况降噪结构优化的研究
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摘要
噪声污染成为世界范围内的环境问题,在工业领域尤为严重。轴向柱塞泵是液压系统主要噪声源,其流体噪声能够激发相连管道、阀等相关元件振动,致使整个液压系统气动噪声加剧。泵源流量脉动是轴向柱塞泵流体噪声的主要激振源,具有高频、大流量的特点,由于现有高频动态流量计不能直接测试,只能采用间接方法测量。ISO标准“二次源”法是测试容积泵泵源流量脉动的间接方法,该方法基于波的传递理论和管道压力动态特性,应用频率特性已知的辅助泵、阀等改变被测泵所在测试系统的终端阻抗,通过传感器同步测试被测泵和辅助泵、阀之间相连管道不同位置处动态压力推导泵源流量脉动。这一方法适用于多种类型容积泵,测试精度较高,但是系统构成复杂,当传感器距离是压力波波长的整数倍时,不能准确测试泵源流量脉动。因此本文主要针对轴向柱塞泵泵源流量脉动进行研究,以获得一种系统构成简单与全工况精度较高的测试方法,为低敏感度柱塞泵设计提供支撑,选题具有重要的理论意义和工程价值。
本文首先建立了柱塞泵流动特性的多场耦合数值模型,该模型首次引入油膜运动的柱塞副、滑靴副泄漏流量对流量脉动的影响,提高了柱塞泵流量脉动模型的精度。在出口压力15MPa、缸体转速1000rpm和斜盘倾角13°时的试验结果证实,与传统数值模型相比,该模型对泵源流量脉动率预测精度提高了22.7%。因此该模型计算结果可以作为分析泵源流量脉动和优化降噪结构的参考。然后提出了新的泵源阻抗估值算法和非等径管道特征参数计算方法,解决了应用辅助泵测试被测泵泵源流量脉动的ISO标准“二次源”法不能准确测试压力传感器距离是压力谐波频整数倍工况下泵源流量脉动,将出口管道等效成长直管道的“实用近似”法不能准确测试带有非等径管道容积泵泵源流量脉动的问题。通过出口压力为5MPa-22MPa,转速为400rpm-1500rpm的试验证实,与ISO提供阻抗估值算法相比,新的阻抗估值算法能估测任意工况下泵源流量脉动,且阻抗估值精度提高了20%；同时修正的“实用近似”法测试精度达到92%以上。因此这些方法提高了测试方法的精度,拓展了现有测试方法的使用范围。最后提出了与配流盘缓冲槽结合的预压缩容腔和斜盘交错角降噪结构的优选准则。首次应用泵源流量脉动变化率差值对预压缩容腔边长差值之比选择了预压缩容腔体积大小,应用配流盘对泵源流量脉动峰值和柱塞腔压力峰值敏感区初选了预压缩容腔引入孔角度和斜盘交错角。针对排量56的斜盘式轴向柱塞泵仿真研究表明,这两个优化准则简化了大范围工况、多部件结合降噪结构优化过程。
论文主要研究内容如下：
第一章给出了柱塞泵流量脉动研究的目的和意义。针对现有柱塞泵流量脉动仿真模型精度低、测试方法复杂等问题,确定了课题的研究内容、技术路线,并总结了课题的技术难点,给出了课题研究的目标。
第二章根据柱塞泵运行原理,搭建了柱塞泵油液流动特性的多场耦合数值模型。该模型首次考虑引入油膜运动的柱塞副、滑靴副泄漏流量对流量脉动的影响,提高了柱塞泵流量脉动模型的精度；模型考虑了温度和压力对油液粘度的影响,通过质量、动量和能量守恒方程计算了柱塞泵关键油模的压力场和温度场；搭建了柱塞泵测试系统有限元模型。
第三章详述了柱塞泵流量脉动测试原理和测试平台搭建需要注意的问题。针对现有“实用近似”法不能准确测试带有非等径出口管道柱塞泵流量脉动的问题,应用第二章建立的有限元模型和动边界理论,计算非等径管道特征参数,修正了“实用近似”法,以拓展拓展其使用范围。
第四章给出了ISO标准“二次源”法测试数据处理过程,获得了较精确的测试结果,并实验验证了第二章所建立的柱塞泵流量脉动仿真模型的准确性；提出应用阻抗估值带宽估算泵源阻抗,应用线性衰减技术计算估值带宽,试验证实,该方法能够获得全工况范围泵源阻抗。针对第三章提出的修正方法进行了实验验证,结果表明：通过出口压力为5MPa-22MPa,转速为400rpm-1500rpm时试验证实：新的阻抗估值算法能估测任意工况下泵源流量脉动,且阻抗估值精度提高了20%。
第五章分析了运行工况(包括稳态、瞬态工况)和油液特性对柱塞泵流量脉动的影响,给出了不同参数的影响程度,为降噪结构的优化提供依据。针对柱塞泵流量脉动有限元模型巨大,求解时间过长的问题,应用并行求解器快速获得仿真结果；引入动边界理论模拟瞬态工况下柱塞泵流量脉动,分析了柱塞泵流量脉动瞬态变化。
第六章研究了缓冲槽、预压缩容腔和交错角对柱塞泵流量脉动的影响,给出了配流盘结构与流量脉动峰值对应关系,并提出了带有配流盘缓冲槽的预压缩容腔和交错角结构优化准则。
第七章总结了论文研究内容,给出了柱塞泵流体噪声研究结论,引出了本文创新点,最后展望了进一步研究内容。
Noise pollution has become one of the most serious environmental problems in the world, especially in industry. Axial piston pump is one of the main noise sources in hydraulic system, and the air-borne noise of the whole hydraulic system is aggravated by the pump fluid-borne noise. The pump output flow, which is characterized by high frequency, is the main source of the fluid-borne noise, and it is impossible to measure this high frequency flow ripple with traditional flow meters, so some indirect methods have been developed. The Secondary Source Method is a well-known indirect method to measure the pump source flow rate, which is of high precision in most case and can be used for many types of hydraulic pumps. However, the test system is complicated and the accuracy of the measured source flow rate is low when the test pipe length is multiple of the pressure wave length. A new test method, which is simpler and more accurate than traditional ones, has been proposed and discussed in this paper, so that those weaknesses mentioned above have been overcome.
A numerical simulation model has been developed based on the operating principle of the axial piston pump, and the influence of the pressure and temperature as well as the movement of the oil film has been considered simultaneously in the model. Then this simulation model was validated by the test results obtained with the Secondary Source method. According to experimental test, when the pump output pressure was15MPa, the pump speed1000rpm and the swash plate angle13deg, the computational accuracy was improved22.7%compared to the traditional model. So this numerical simulation model can be used to analyze the source flow rate and optimize the structure of the axial piston pump. A new estimation algorithm of the pump source impedance has been designed to deal with the case when the test pipe length is multiple of the pressure wave length, a new computational algorithm to solve the problem of the source flow rate with unequal diameter discharge pipe has also been developed. It can be seen from the results that the pump source impedance can be obtained with the new estimation algorithm over following operating conditions:the pump output pressure was between5MPa and22MPa, the pump speed was between400rpm and1500rpm. In addition, the92%test accuracy of source flow rate has been reached by the modified Practical Approximate Method with the computational algorithm. So the application of the current test method is expanded. The parameter selection criteria of the pre-compression volume and the swash plate cross angle with relief groove has been developed, the ratio of the non-uniformity grade difference of flow ripple and the volume difference of the pre-compression volume is used to determine the size of pre-compression volume, the position of the sensitive zone of the port plate where the peak value of the source flow rate and cylinder pressure occur was used to choose degrees of both the angle connecting the port plate and the pre-compression volume and the swash plate cross angle. It can be seen from the simulation result that the optimization procedure for the pre-compression volume and the swash plate cross angle with relief groove has been greatly simplified by adopting the developed parameter selection criteria. The results given in this paper help potential researchers to better understand both the development of flow ripple model and the procedure of performing flow ripple test for piston pump, structure optimization criteria for obtaining quieter piston pump are also proposed and validated by simulation, nevertheless, further experiments are required to approve its effectiveness. The structure of this thesis is illustrated in the following:
In chapter1, the research purpose and the research significance of this thesis are discussed. The research content and the technical route are given, and the technical issues are presented accordingly.
In chapter2, a newly built numerical simulation model for axial piston pump which is based on the operation principle of the axial piston pump is presented. The computation for the leakage flow rate from all three key oil films is modified, and the calculation accuracy is improved compared to the traditional ones. The energy equation is introduced, and the pressure field and temperature field of the three oil films can be computed simultaneously. The simulation model of the whole hydraulic system connected to the axial piston pump is also built.
In chapter3, the testing principle of the pump source flow rate is depicted in detail, and problems which are met in building the test apparatus are provided. Because the current test method is difficult to test the source flow rate of the pump with complicated pump discharge pipe, the finite element method and the dynamic boundary condition is used to compute the characteristic of the discharge pipe. Then according to the different test principle, the relationship between the characteristic of the discharge pipe and the source flow rate is presented, and the corresponding test method is modified.
In chapter4, the signal processing of the Secondary Source Method is presented, the precise test results are obtained, and the simulation model built in chapter2is validated. It can be seen from the test results that the new estimation algorithm of the pump source impedance can get the result over the whole operating conditions and the accuracy increased20%over the following operating conditions:pump delivery pressure is5MPa,15MPa and22MPa, the pump speed is400rpm,1000rpm and1500rpm. The signal processing for the Practical Approximate Method is simplified with the high precision. Therefore, the application of the test method is extending.
In chapter5, the effect of operating conditions and the fluid characteristic on flow ripple is analyzed, and their influencing degree is concluded, which is the guideline for optimization of the axial piston pump. The parallel solution is used to obtain the simulation result as fast as possible. The dynamic boundary condition is used to define the time-depended pump delivery pressure and pump speed, and the effect of transient operating condition is also provided.
In chapter6, the structure of the pre-compression volume and the swash plate cross angle with relief groove have been optimized with the built simulation method. The selection criteria of the Pre-compression volume and the swash plate cross angle with relief groove is presented.
In chapter7, the conclusion of this thesis is provided and the further research is analyzed.
本文首先建立了柱塞泵流动特性的多场耦合数值模型,该模型首次引入油膜运动的柱塞副、滑靴副泄漏流量对流量脉动的影响,提高了柱塞泵流量脉动模型的精度。在出口压力15MPa、缸体转速1000rpm和斜盘倾角13°时的试验结果证实,与传统数值模型相比,该模型对泵源流量脉动率预测精度提高了22.7%。因此该模型计算结果可以作为分析泵源流量脉动和优化降噪结构的参考。然后提出了新的泵源阻抗估值算法和非等径管道特征参数计算方法,解决了应用辅助泵测试被测泵泵源流量脉动的ISO标准“二次源”法不能准确测试压力传感器距离是压力谐波频整数倍工况下泵源流量脉动,将出口管道等效成长直管道的“实用近似”法不能准确测试带有非等径管道容积泵泵源流量脉动的问题。通过出口压力为5MPa-22MPa,转速为400rpm-1500rpm的试验证实,与ISO提供阻抗估值算法相比,新的阻抗估值算法能估测任意工况下泵源流量脉动,且阻抗估值精度提高了20%；同时修正的“实用近似”法测试精度达到92%以上。因此这些方法提高了测试方法的精度,拓展了现有测试方法的使用范围。最后提出了与配流盘缓冲槽结合的预压缩容腔和斜盘交错角降噪结构的优选准则。首次应用泵源流量脉动变化率差值对预压缩容腔边长差值之比选择了预压缩容腔体积大小,应用配流盘对泵源流量脉动峰值和柱塞腔压力峰值敏感区初选了预压缩容腔引入孔角度和斜盘交错角。针对排量56的斜盘式轴向柱塞泵仿真研究表明,这两个优化准则简化了大范围工况、多部件结合降噪结构优化过程。
论文主要研究内容如下：
第一章给出了柱塞泵流量脉动研究的目的和意义。针对现有柱塞泵流量脉动仿真模型精度低、测试方法复杂等问题,确定了课题的研究内容、技术路线,并总结了课题的技术难点,给出了课题研究的目标。
第二章根据柱塞泵运行原理,搭建了柱塞泵油液流动特性的多场耦合数值模型。该模型首次考虑引入油膜运动的柱塞副、滑靴副泄漏流量对流量脉动的影响,提高了柱塞泵流量脉动模型的精度；模型考虑了温度和压力对油液粘度的影响,通过质量、动量和能量守恒方程计算了柱塞泵关键油模的压力场和温度场；搭建了柱塞泵测试系统有限元模型。
第三章详述了柱塞泵流量脉动测试原理和测试平台搭建需要注意的问题。针对现有“实用近似”法不能准确测试带有非等径出口管道柱塞泵流量脉动的问题,应用第二章建立的有限元模型和动边界理论,计算非等径管道特征参数,修正了“实用近似”法,以拓展拓展其使用范围。
第四章给出了ISO标准“二次源”法测试数据处理过程,获得了较精确的测试结果,并实验验证了第二章所建立的柱塞泵流量脉动仿真模型的准确性；提出应用阻抗估值带宽估算泵源阻抗,应用线性衰减技术计算估值带宽,试验证实,该方法能够获得全工况范围泵源阻抗。针对第三章提出的修正方法进行了实验验证,结果表明：通过出口压力为5MPa-22MPa,转速为400rpm-1500rpm时试验证实：新的阻抗估值算法能估测任意工况下泵源流量脉动,且阻抗估值精度提高了20%。
第五章分析了运行工况(包括稳态、瞬态工况)和油液特性对柱塞泵流量脉动的影响,给出了不同参数的影响程度,为降噪结构的优化提供依据。针对柱塞泵流量脉动有限元模型巨大,求解时间过长的问题,应用并行求解器快速获得仿真结果；引入动边界理论模拟瞬态工况下柱塞泵流量脉动,分析了柱塞泵流量脉动瞬态变化。
第六章研究了缓冲槽、预压缩容腔和交错角对柱塞泵流量脉动的影响,给出了配流盘结构与流量脉动峰值对应关系,并提出了带有配流盘缓冲槽的预压缩容腔和交错角结构优化准则。
第七章总结了论文研究内容,给出了柱塞泵流体噪声研究结论,引出了本文创新点,最后展望了进一步研究内容。
Noise pollution has become one of the most serious environmental problems in the world, especially in industry. Axial piston pump is one of the main noise sources in hydraulic system, and the air-borne noise of the whole hydraulic system is aggravated by the pump fluid-borne noise. The pump output flow, which is characterized by high frequency, is the main source of the fluid-borne noise, and it is impossible to measure this high frequency flow ripple with traditional flow meters, so some indirect methods have been developed. The Secondary Source Method is a well-known indirect method to measure the pump source flow rate, which is of high precision in most case and can be used for many types of hydraulic pumps. However, the test system is complicated and the accuracy of the measured source flow rate is low when the test pipe length is multiple of the pressure wave length. A new test method, which is simpler and more accurate than traditional ones, has been proposed and discussed in this paper, so that those weaknesses mentioned above have been overcome.
A numerical simulation model has been developed based on the operating principle of the axial piston pump, and the influence of the pressure and temperature as well as the movement of the oil film has been considered simultaneously in the model. Then this simulation model was validated by the test results obtained with the Secondary Source method. According to experimental test, when the pump output pressure was15MPa, the pump speed1000rpm and the swash plate angle13deg, the computational accuracy was improved22.7%compared to the traditional model. So this numerical simulation model can be used to analyze the source flow rate and optimize the structure of the axial piston pump. A new estimation algorithm of the pump source impedance has been designed to deal with the case when the test pipe length is multiple of the pressure wave length, a new computational algorithm to solve the problem of the source flow rate with unequal diameter discharge pipe has also been developed. It can be seen from the results that the pump source impedance can be obtained with the new estimation algorithm over following operating conditions:the pump output pressure was between5MPa and22MPa, the pump speed was between400rpm and1500rpm. In addition, the92%test accuracy of source flow rate has been reached by the modified Practical Approximate Method with the computational algorithm. So the application of the current test method is expanded. The parameter selection criteria of the pre-compression volume and the swash plate cross angle with relief groove has been developed, the ratio of the non-uniformity grade difference of flow ripple and the volume difference of the pre-compression volume is used to determine the size of pre-compression volume, the position of the sensitive zone of the port plate where the peak value of the source flow rate and cylinder pressure occur was used to choose degrees of both the angle connecting the port plate and the pre-compression volume and the swash plate cross angle. It can be seen from the simulation result that the optimization procedure for the pre-compression volume and the swash plate cross angle with relief groove has been greatly simplified by adopting the developed parameter selection criteria. The results given in this paper help potential researchers to better understand both the development of flow ripple model and the procedure of performing flow ripple test for piston pump, structure optimization criteria for obtaining quieter piston pump are also proposed and validated by simulation, nevertheless, further experiments are required to approve its effectiveness. The structure of this thesis is illustrated in the following:
In chapter1, the research purpose and the research significance of this thesis are discussed. The research content and the technical route are given, and the technical issues are presented accordingly.
In chapter2, a newly built numerical simulation model for axial piston pump which is based on the operation principle of the axial piston pump is presented. The computation for the leakage flow rate from all three key oil films is modified, and the calculation accuracy is improved compared to the traditional ones. The energy equation is introduced, and the pressure field and temperature field of the three oil films can be computed simultaneously. The simulation model of the whole hydraulic system connected to the axial piston pump is also built.
In chapter3, the testing principle of the pump source flow rate is depicted in detail, and problems which are met in building the test apparatus are provided. Because the current test method is difficult to test the source flow rate of the pump with complicated pump discharge pipe, the finite element method and the dynamic boundary condition is used to compute the characteristic of the discharge pipe. Then according to the different test principle, the relationship between the characteristic of the discharge pipe and the source flow rate is presented, and the corresponding test method is modified.
In chapter4, the signal processing of the Secondary Source Method is presented, the precise test results are obtained, and the simulation model built in chapter2is validated. It can be seen from the test results that the new estimation algorithm of the pump source impedance can get the result over the whole operating conditions and the accuracy increased20%over the following operating conditions:pump delivery pressure is5MPa,15MPa and22MPa, the pump speed is400rpm,1000rpm and1500rpm. The signal processing for the Practical Approximate Method is simplified with the high precision. Therefore, the application of the test method is extending.
In chapter5, the effect of operating conditions and the fluid characteristic on flow ripple is analyzed, and their influencing degree is concluded, which is the guideline for optimization of the axial piston pump. The parallel solution is used to obtain the simulation result as fast as possible. The dynamic boundary condition is used to define the time-depended pump delivery pressure and pump speed, and the effect of transient operating condition is also provided.
In chapter6, the structure of the pre-compression volume and the swash plate cross angle with relief groove have been optimized with the built simulation method. The selection criteria of the Pre-compression volume and the swash plate cross angle with relief groove is presented.
In chapter7, the conclusion of this thesis is provided and the further research is analyzed.
引文
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