16V280ZJ型柴油机燃油喷射系统改进及模拟仿真研究
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摘要
自从铁路机车提速以后,干线机车装用的16V280ZJ型柴油机燃油系统故障率上升32%,临修率上升40%,其燃油系统出现问题是:针阀偶件使用寿命短,喷油器在短时间使用后出现雾化不良现象,喷油泵出油阀穴蚀现象严重,柱塞偶件卡死等现象。上述现象直接导致柴油机敲缸,油耗率偏高,排气管红热、冒黑烟。情况严重甚至可以导致柴油机零部件损坏。因此对燃油喷射系统的设计必须给予足够重视。
本文主要是对燃油喷射系统三大偶件(针阀偶件、出油阀偶件、柱塞偶件)进行改进。首先运用先进的冲击应力理论,通过理论计算,发现采用质量较小的短针阀可以减小针阀对密封座面的冲击应力,同时对喷油器偶件密封座面、压力室容积、喷孔数目等结构进行改进,提高喷油器的使用寿命;其次对柱塞偶件头部螺旋线进行改进,把原柱塞定时螺旋边加工成一个三段螺旋边,改善柴油机在部分负荷工况下的经济性;出油阀改进采用两种方案,方案1采用等压式出油阀(包括主阀与副阀)代替原等容式出油阀,可以减少燃油喷射系统穴蚀现象;方案2采用密封座面下置式出油阀代替原等容式出油阀,可以减缓出油阀对其座面的冲击。
为了保证改进后柴油机燃油喷射系统动力性、经济性有所提高,本论文采用先进商业软件GT-SUITE对其改进前后燃油喷射泵-管-嘴系统进行模拟仿真计算,通过上述步骤可以大大加快开发过程,减少开发费用。论文首先利用GT软件中FUEL模块,结合实际燃油喷射系统零件图纸,建立了16V280ZJ型柴油机泵-管-嘴模型,得到循环喷油量、针阀升程、高压油管压力等计算结果。并利用GT软件中POWER模块建立改进前后单缸机模型,预测不同工况下缸内爆发压力,燃油消耗率等曲线。改进后的燃油喷射系统目前在郑州铁路局新乡机务段配属5585号东风8B内燃机车上进行装车试验,目前运行状况良好。
Since the speeding up of railway, the malfunction rate of 16V280ZJ diesel engine has increased by 32%, the repair rate has also increased by 40%, the malfunctions of fuel injection system are followed: the service life of needle valve is short after short time use, the spray and flow quality of fuel injector is bad, delivery valve has serious cavitations, plunger matching parts is blocked down and so on.above phenomenon lead to cylinder knocked,the fuel consumption rate become high. ventpipe is too hot, emit black smoke.some serious phenomenon can lead to parts of diesel engine broken, therefore we should pay attention the design of fuel injection system.
This paper mainly improves three matching parts (needle valve, delivery valve, plunger). firstly,we use the advance impact stress theory, through calculating,adopting short needle valve with small mass can reduce the impact stress of needle valve on sealing surface of valve seat.accordingly,we take some improvements to sealed coniacal surface, injection holes, whic h increase the service life of fuel injector;secondly,we change the head of sect of helix instead of only one helix,which can improve the economy of disel engine in part load work conditi ons.There are two improved programmes of delivery valve. The first improved programme is using the constant pressure delivery valve(including main valve and auxiliary valve ) instead of constant volume ,which can reduce the cavation phenomenon; The second improved progra mme is using delivery valve with under seal seat instead of constant volume, which can slow up the impulse of delivery valve.
In order to ensure the advance of dynamics and economy of improved fuel injection system,this paper adopt business soft GT-SUITE to simulate the pump-line-injector of fuel injection system.with above steps, quicken empolder process and reduce expense of empold er.this paper make use of FUEL model of GT-SUITE soft,with parts drawings of actural inject ion system.,modeling pump-line-injector of 16V280 type, get cycle injected mass,the lift of needle valve, the pressure of high pressure line and so on results.then we make use of power model of GT-SUITE soft, modeling the singal cylinder engine,predict the maximum pressure in cylinder,fuel consumption rate,the improved fuel injection system is carried on the load experiment of NO.5585 DF8B diesel locomotive in the Xin Xiang mechanical section of Zheng Zhou rail bureau , and now it runs well.
本文主要是对燃油喷射系统三大偶件(针阀偶件、出油阀偶件、柱塞偶件)进行改进。首先运用先进的冲击应力理论,通过理论计算,发现采用质量较小的短针阀可以减小针阀对密封座面的冲击应力,同时对喷油器偶件密封座面、压力室容积、喷孔数目等结构进行改进,提高喷油器的使用寿命;其次对柱塞偶件头部螺旋线进行改进,把原柱塞定时螺旋边加工成一个三段螺旋边,改善柴油机在部分负荷工况下的经济性;出油阀改进采用两种方案,方案1采用等压式出油阀(包括主阀与副阀)代替原等容式出油阀,可以减少燃油喷射系统穴蚀现象;方案2采用密封座面下置式出油阀代替原等容式出油阀,可以减缓出油阀对其座面的冲击。
为了保证改进后柴油机燃油喷射系统动力性、经济性有所提高,本论文采用先进商业软件GT-SUITE对其改进前后燃油喷射泵-管-嘴系统进行模拟仿真计算,通过上述步骤可以大大加快开发过程,减少开发费用。论文首先利用GT软件中FUEL模块,结合实际燃油喷射系统零件图纸,建立了16V280ZJ型柴油机泵-管-嘴模型,得到循环喷油量、针阀升程、高压油管压力等计算结果。并利用GT软件中POWER模块建立改进前后单缸机模型,预测不同工况下缸内爆发压力,燃油消耗率等曲线。改进后的燃油喷射系统目前在郑州铁路局新乡机务段配属5585号东风8B内燃机车上进行装车试验,目前运行状况良好。
Since the speeding up of railway, the malfunction rate of 16V280ZJ diesel engine has increased by 32%, the repair rate has also increased by 40%, the malfunctions of fuel injection system are followed: the service life of needle valve is short after short time use, the spray and flow quality of fuel injector is bad, delivery valve has serious cavitations, plunger matching parts is blocked down and so on.above phenomenon lead to cylinder knocked,the fuel consumption rate become high. ventpipe is too hot, emit black smoke.some serious phenomenon can lead to parts of diesel engine broken, therefore we should pay attention the design of fuel injection system.
This paper mainly improves three matching parts (needle valve, delivery valve, plunger). firstly,we use the advance impact stress theory, through calculating,adopting short needle valve with small mass can reduce the impact stress of needle valve on sealing surface of valve seat.accordingly,we take some improvements to sealed coniacal surface, injection holes, whic h increase the service life of fuel injector;secondly,we change the head of sect of helix instead of only one helix,which can improve the economy of disel engine in part load work conditi ons.There are two improved programmes of delivery valve. The first improved programme is using the constant pressure delivery valve(including main valve and auxiliary valve ) instead of constant volume ,which can reduce the cavation phenomenon; The second improved progra mme is using delivery valve with under seal seat instead of constant volume, which can slow up the impulse of delivery valve.
In order to ensure the advance of dynamics and economy of improved fuel injection system,this paper adopt business soft GT-SUITE to simulate the pump-line-injector of fuel injection system.with above steps, quicken empolder process and reduce expense of empold er.this paper make use of FUEL model of GT-SUITE soft,with parts drawings of actural inject ion system.,modeling pump-line-injector of 16V280 type, get cycle injected mass,the lift of needle valve, the pressure of high pressure line and so on results.then we make use of power model of GT-SUITE soft, modeling the singal cylinder engine,predict the maximum pressure in cylinder,fuel consumption rate,the improved fuel injection system is carried on the load experiment of NO.5585 DF8B diesel locomotive in the Xin Xiang mechanical section of Zheng Zhou rail bureau , and now it runs well.
引文
[1]许峰,满长忠.内燃机制造工艺教程.第1版.大连理工大学出版社,2006:176-177
[2]贾锡印.柴油机燃油喷射及调节.第2版.哈尔滨工程技术大学出版社,2002:47-54
[3]杨兆昆.东风8B型内燃机车.中国铁道出版社,2001:91-92
[4]解茂昭.内燃机计算燃烧学.大连理工大学出版社,2005:137-138
[5]史绍熙.柴油机设计手册(中册).第1版.中国农业机械出版社,1984:228-229
[6]高书堂,高国强.柴油机燃油系统和匹配.第1版.北京理工大学出版社,2005:173-174
[7]李明海,柳崮.机车柴油机燃油喷射系统新技术的研究.内燃机车.2003(1):14-14
[8]李明海,柳崮.16V280ZJ柴油机燃油系统可靠性研究.内燃机工程.2002(2):72-72
[9]柳崮,李明海,张岩.内燃机车用新型短针阀喷油器的研究.内燃机车.2006(7):1-2
[10]北方交通大学.机车柴油机原理.第1版.中国铁道出版社,1980:72-73
[11]徐家龙.柴油机电控喷油技术.第1版.人民交通出版社,2004:176-178
[12]史绍熙.柴油机设计手册(下册).第1版.中国农业机械出版社,1984:228-229
[13]周龙保.内燃机学.第1版.机械工业出版社,2005:143-144
[14]冒晓建,肖文雍,徐美玲等.提高泵-管-嘴供油系统喷射压力的研究.内燃机工程.2001,22(3)
[15]朱晓东,赵伟等.大功率柴油机常规喷射系统的发展方向.柴油机.2004(5):33-34
[16]程财鹤,高强化柴油机燃油喷射系统防穴蚀研究.柴油机.2001(4):11-12
[17]赵昌普,张青霞.出油阀结构对小型柴油机喷油量影响的研究.农业机械学报.2001(6):16-17
[18]谭杰,周虹伟等.喷油泵螺旋槽对柴油机燃油消耗率影响的试验研究.铁道机车车辆.2003(23): 111-112
[19]李明海.调车机车用柴油机燃油喷射系统改进.内燃机工程.2004(2):68-69
[20]姚春德.闭式柴油喷嘴阀体座面的冲击应力计算.力学与实践.1999(4):57-59
[21]陆卫东.柴油机喷油器精密偶件的材料选择及热处理.柴油机.1996(5):21-23
[22]谭丕强,陆家祥,邓康耀等.喷油提前角对柴油机排放影响的研究.内燃机工程.2004,25(2):11
[23]史成良.机车柴油机现代技术与发展.铁道机车车辆.2003,23(11):7
[24]胡严.280柴油机喷射系统的改进.内燃机车.2003(2):46-47
[25]曹京刚.提高国产机车喷油器使用寿命问题的研究.铁道机车车辆.2002(4):8
[26]金江善,平涛,赵伟等.柴油机燃油喷射系统仿真研究.柴油机.2004(2):12-13
[27]章艳林,倪弘,江哲等.柴油机燃油喷射系统出油阀偶件的试验研究.现代车用动力.2004(3):20
[28]刘建伟,李明海,姜培良等.国产机车柴油机燃油喷射系统的改进.内燃机车.2000(8):11-12
[29]朱晓东,赵伟,平涛.大功率柴油机常规喷射系统的发展方向.柴油机.2004(5):33-34
[30]虞金霞,胡先富.柴油机喷油喷射系统的仿真计算及分析.上海海运学院学报.2001(2):11-12
[31]姜培良,李明海.机车柴油机喷油嘴流通座面结构设计与对比.内燃机车.1998(4):9-10
[32]李友峰.大功率柴油机燃油喷射系统的模拟计算与试验研究.柴油机.2006(2):9-10
[33]沈海元.徐智岚.关于DF11型机车装用LSD280型柴油机喷油器针阀偶件的试验分析.上海海运学院学报.2001(1):4-5
[34]袁永先.喷油器结构对柴油机性能影响的研究.车用发动机.2004(1):24-25
[35]大连机车车辆厂.东风4D型内燃机车(2).1999:82-105
[36]Babajide Kolade and Michael E. Boghosian.Development of a General Purpose Thermal-H ydraulic So ftware and its Application to Fuel Injection Systems.Society of Automotive Engineers.2003(1):3-6
[37]Takeshi Imahashi,Eiji Tomita,Taizo Kimoto.Experimental analysis on the combustion rate due to interf erence of the burned gas in slow speeddiesel engine with a side fuel injection nozzle system.INTERNATIO NAL COUNCILON COMBUSTION ENGINES.(NO 177):1-4
[38]WU Jinjun,HAI Jingtao,SHI Jianzhong.Strategy for diesel rotary engine with common rail injection system.CHINESE JOURNAL OF MECHANICAL ENGINEERING.2006(3):412-414
[39]Tan Wenchun ,Yu Shitao and so on..Application of circuit simulation in hardware design for electronic al control high pressure common-rail fuel system of diesel engine.CHINESE JOURNAL OF MECHANIC AL ENGINEERING,2005(4):613-616
[2]贾锡印.柴油机燃油喷射及调节.第2版.哈尔滨工程技术大学出版社,2002:47-54
[3]杨兆昆.东风8B型内燃机车.中国铁道出版社,2001:91-92
[4]解茂昭.内燃机计算燃烧学.大连理工大学出版社,2005:137-138
[5]史绍熙.柴油机设计手册(中册).第1版.中国农业机械出版社,1984:228-229
[6]高书堂,高国强.柴油机燃油系统和匹配.第1版.北京理工大学出版社,2005:173-174
[7]李明海,柳崮.机车柴油机燃油喷射系统新技术的研究.内燃机车.2003(1):14-14
[8]李明海,柳崮.16V280ZJ柴油机燃油系统可靠性研究.内燃机工程.2002(2):72-72
[9]柳崮,李明海,张岩.内燃机车用新型短针阀喷油器的研究.内燃机车.2006(7):1-2
[10]北方交通大学.机车柴油机原理.第1版.中国铁道出版社,1980:72-73
[11]徐家龙.柴油机电控喷油技术.第1版.人民交通出版社,2004:176-178
[12]史绍熙.柴油机设计手册(下册).第1版.中国农业机械出版社,1984:228-229
[13]周龙保.内燃机学.第1版.机械工业出版社,2005:143-144
[14]冒晓建,肖文雍,徐美玲等.提高泵-管-嘴供油系统喷射压力的研究.内燃机工程.2001,22(3)
[15]朱晓东,赵伟等.大功率柴油机常规喷射系统的发展方向.柴油机.2004(5):33-34
[16]程财鹤,高强化柴油机燃油喷射系统防穴蚀研究.柴油机.2001(4):11-12
[17]赵昌普,张青霞.出油阀结构对小型柴油机喷油量影响的研究.农业机械学报.2001(6):16-17
[18]谭杰,周虹伟等.喷油泵螺旋槽对柴油机燃油消耗率影响的试验研究.铁道机车车辆.2003(23): 111-112
[19]李明海.调车机车用柴油机燃油喷射系统改进.内燃机工程.2004(2):68-69
[20]姚春德.闭式柴油喷嘴阀体座面的冲击应力计算.力学与实践.1999(4):57-59
[21]陆卫东.柴油机喷油器精密偶件的材料选择及热处理.柴油机.1996(5):21-23
[22]谭丕强,陆家祥,邓康耀等.喷油提前角对柴油机排放影响的研究.内燃机工程.2004,25(2):11
[23]史成良.机车柴油机现代技术与发展.铁道机车车辆.2003,23(11):7
[24]胡严.280柴油机喷射系统的改进.内燃机车.2003(2):46-47
[25]曹京刚.提高国产机车喷油器使用寿命问题的研究.铁道机车车辆.2002(4):8
[26]金江善,平涛,赵伟等.柴油机燃油喷射系统仿真研究.柴油机.2004(2):12-13
[27]章艳林,倪弘,江哲等.柴油机燃油喷射系统出油阀偶件的试验研究.现代车用动力.2004(3):20
[28]刘建伟,李明海,姜培良等.国产机车柴油机燃油喷射系统的改进.内燃机车.2000(8):11-12
[29]朱晓东,赵伟,平涛.大功率柴油机常规喷射系统的发展方向.柴油机.2004(5):33-34
[30]虞金霞,胡先富.柴油机喷油喷射系统的仿真计算及分析.上海海运学院学报.2001(2):11-12
[31]姜培良,李明海.机车柴油机喷油嘴流通座面结构设计与对比.内燃机车.1998(4):9-10
[32]李友峰.大功率柴油机燃油喷射系统的模拟计算与试验研究.柴油机.2006(2):9-10
[33]沈海元.徐智岚.关于DF11型机车装用LSD280型柴油机喷油器针阀偶件的试验分析.上海海运学院学报.2001(1):4-5
[34]袁永先.喷油器结构对柴油机性能影响的研究.车用发动机.2004(1):24-25
[35]大连机车车辆厂.东风4D型内燃机车(2).1999:82-105
[36]Babajide Kolade and Michael E. Boghosian.Development of a General Purpose Thermal-H ydraulic So ftware and its Application to Fuel Injection Systems.Society of Automotive Engineers.2003(1):3-6
[37]Takeshi Imahashi,Eiji Tomita,Taizo Kimoto.Experimental analysis on the combustion rate due to interf erence of the burned gas in slow speeddiesel engine with a side fuel injection nozzle system.INTERNATIO NAL COUNCILON COMBUSTION ENGINES.(NO 177):1-4
[38]WU Jinjun,HAI Jingtao,SHI Jianzhong.Strategy for diesel rotary engine with common rail injection system.CHINESE JOURNAL OF MECHANICAL ENGINEERING.2006(3):412-414
[39]Tan Wenchun ,Yu Shitao and so on..Application of circuit simulation in hardware design for electronic al control high pressure common-rail fuel system of diesel engine.CHINESE JOURNAL OF MECHANIC AL ENGINEERING,2005(4):613-616