柴油机相继增压与可控进气涡流复合系统研究
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摘要
相继增压可以扩大柴油机功率运行范围、提高低工况经济性以及降低柴油机有害排放，是改善中、高速大功率柴油机低工况性能最为有效的方法，在越来越多的机型上得到应用。本文在原有可控进气涡流系统的TBD620V16柴油机上进行了相继增压系统的改造，形成相继增压与可控进气涡流的复合系统，结果表明，相继增压与可控进气涡流的复合系统可以明显改善柴油机的低工况性能，扩大运行范围，提高经济性。本文主要研究内容如下：
1．可控进气涡流系统、相继增压与可控进气涡流复合系统的三维动态流场研究。根据实际结构建立了进排气道-气门-缸内的三维模型，网格采用非结构化的六面体，网格运动是棱柱层的拉伸，采用瞬态、三维、可压缩、粘性流动假设，湍流模型选用k ε模型，应用SIMPLE算法进行了流场的数值求解。在用稳流试验数据验证了模型的正确性后，对可控进气涡流系统和相继增压与可控进气涡流复合系统的流场进行了分析，着重对直流进气道和螺旋进气道的流场进行计算，对同一进排气门位置的流场变化规律进行了分析，通过分析及整机性能数据的比较，建议取消可控进气涡流系统中的挡板，保留螺旋进气道，组成相继增压与可控进气涡流的复合系统。
2. TBD620V16相继增压与可控进气涡流的复合系统柴油机燃烧过程的研究。对可控进气涡流系统和相继增压与可控进气涡流复合系统的燃烧过程进行比较分析，后者的排放物生成量明显减少。对相继增压与可控进气涡流复合系统柴油机燃油喷射系统参数(喷油提前角、喷雾锥角)进行优化，在额定工况、切换点工况、低工况模拟计算的结果基本一致，喷油提前角延迟，NOx生成物降低，Soot排放量增加，通过分析得出20°BTDC为最佳喷油提前角；喷雾锥角影响燃油在空间的分布，通过分析得出原机155°喷雾锥角最佳。
3．TBD620V16相继增压与可控进气涡流的复合系统柴油机放热率经验公式的研究。在大量试验数据的基础上，对TBD620V16相继增压与可控进气涡流的复合系统柴油机低工况的放热规律进行了分析，利用三韦伯函数对放热率曲线进行数学拟合，采用单纯形法推导出了适用于该柴油机低工况放热率的经验公式，提出了适用于相继增压与可控进气涡流复合系统的低工况放热率特征参数与负荷、转速之间变化规律的数学表达式。
4．TBD620V16柴油机采用相继增压与可控进气涡流复合系统的工作过程研究。基于GT-POWER软件平台，建立了TBD620V16相继增压柴油机工作过程仿真模型，在燃烧模型中选用了适用于相继增压与可控进气涡流复合系统的三韦伯特征参数，改变了燃油喷射系统参数，引入了涡流比对工作过程的影响后，对按标准螺旋桨特性运行的多个工况进行了模拟计算，预测了TBD620V16相继增压与可控进气涡流的复合系统柴油机的切换点。
5. TBD620V16相继增压与可控进气涡流的复合系统柴油机的试验研究。对该柴油机进行了较为全面的试验研究，进行了限制特性试验，得到柴油机的最大运行边界；在低工况进行了负荷特性试验，得到柴油机的万有特性以及柴油机的运行区域；进行了螺旋桨特性试验，得到按标准螺旋桨特性运行时柴油机的各项性能参数，选择了柴油机相继增压的切换点。试验表明，TBD620V16相继增压与可控进气涡流复合系统柴油机在低工况时采用一台增压器工作能够明显改善该机的低工况性能，柴油机的运行区域扩大，经济性得到改善。
Sequential turbocharging technology can expand the power operating range of a dieselengine, improve the economy in low conditions and reduce harmful emissions, which is themost effective way to improve the performance of the medium-speed or high-speedhigh-power diesel engine in low condition and being applied for more and more types ofdiesel engine. Based on the original TBD620V16diesel engine with controllable vortexsystem, modification on the sequential turbocharging system is made in this paper, whichmakes the original engine into a compound system with sequential turbocharging system andcontrollable vortex system, the results show that the diesel engine with this compound systemcan improve the low-condition performance, expand the operating range, increase theeconomy. The main contents of this article as follows:
1. The study of3D dynamic flow field of these three systems, sequential turbochargingsystem, controllable vortex system and the compound system.3D model of the Intake andexhaust ports-valves-cylinder is established based on the actual structure, in whichunstructured hexahedral is used in grid, the grid movement is the stretch of the prismatic layer,a transient-3D-compressible-viscous flow hypothesis is made, and ak εmodel is chosen tobe the turbulence model, this flow field of this model is calculated by SIMPLE algorithm.After the verification of this model by using the data of the steady flow test, analysis on theflow field is made, which is focus on the flow field of the DC inlet port and spiral inlet port,and also a quantitative analysis on variation of the flow field parameters at the same inlet andexhaust valve position is made, by analyzing and comparing the performance data of thewhole engine, the results show that it is advisable to remove the baffle in controllable vortexsystem and retain the spiral inlet port, so the compound system with sequential turbochargingsystem and controllable vortex system is composed.
2. The study of the combustion process of the TBD620V16diesel engine compoundsystem. By comparing the combustion process of the controllable vortex system and thecombustion process of the compound system, it shows that the emissions of the latter systemare significantly reduced. The fuel injection system parameters(injection advance angle, spraycone angle) of the compound system is optimized, the calculation results are in agreement inrated condition, switching point condition and the low condition: the delay of the injection advance angle, lower NOx resultant, more Shoot emissions, so the best injection advanceangle is20。BTDC; the best spray cone angle is155°in original engine, because the spraycone angle impacts the fuel distribution in space.
3. The study of empirical formulas of the heat release rate of the TBD620V16dieselengine compound system. Heat release rate of the TBD620V16diesel engine compoundsystem in low condition is analyzed based on the large number of experiment data,mathematical fitting of the curse of heat release rate is made by3-Viebe function, appropriateempirical expression of the characteristic parameters of heat release rate in low condition isderived by simplex method, and the mathematical expression of the variation amongcharacteristics parameters in low condition, load and speed is presented.
4. The study of the working process of the TBD620V16diesel engine compoundsystem. A simulation model of the TBD620V16sequential turbocharging diesel engine isestablished in GT-POWER software, in which appropriate3-Viebe characteristic parametersare chosen in combustion model, parameters of fuel injecting system is changed, after theimpacts of the swirl ratio on working process is introduced, simulation of multiple operationconditions in accordance with the standard propeller characteristics is carried out, and theswitching point of TBD234V16diesel engine with compound system is predicted.
5. The study of the TBD620V16diesel engine compound system. A morecomprehensive study is carried out, the max running border of the engine is obtained bylimiting characteristic test; the universal characteristic and the operating range of the engineis obtained by load characteristic test in low condition; the performance parameters of theengine in accordance with the standard propeller characteristics is obtained by propellercharacteristic test, and the switching points of the sequential turbocharging is chosen. The testshows that the low-condition performance of TBD234V16diesel engine with compoundsystem can be improved significantly, the operating range is expanded, economy is improveby a single turbocharger when working under low condition.
1．可控进气涡流系统、相继增压与可控进气涡流复合系统的三维动态流场研究。根据实际结构建立了进排气道-气门-缸内的三维模型，网格采用非结构化的六面体，网格运动是棱柱层的拉伸，采用瞬态、三维、可压缩、粘性流动假设，湍流模型选用k ε模型，应用SIMPLE算法进行了流场的数值求解。在用稳流试验数据验证了模型的正确性后，对可控进气涡流系统和相继增压与可控进气涡流复合系统的流场进行了分析，着重对直流进气道和螺旋进气道的流场进行计算，对同一进排气门位置的流场变化规律进行了分析，通过分析及整机性能数据的比较，建议取消可控进气涡流系统中的挡板，保留螺旋进气道，组成相继增压与可控进气涡流的复合系统。
2. TBD620V16相继增压与可控进气涡流的复合系统柴油机燃烧过程的研究。对可控进气涡流系统和相继增压与可控进气涡流复合系统的燃烧过程进行比较分析，后者的排放物生成量明显减少。对相继增压与可控进气涡流复合系统柴油机燃油喷射系统参数(喷油提前角、喷雾锥角)进行优化，在额定工况、切换点工况、低工况模拟计算的结果基本一致，喷油提前角延迟，NOx生成物降低，Soot排放量增加，通过分析得出20°BTDC为最佳喷油提前角；喷雾锥角影响燃油在空间的分布，通过分析得出原机155°喷雾锥角最佳。
3．TBD620V16相继增压与可控进气涡流的复合系统柴油机放热率经验公式的研究。在大量试验数据的基础上，对TBD620V16相继增压与可控进气涡流的复合系统柴油机低工况的放热规律进行了分析，利用三韦伯函数对放热率曲线进行数学拟合，采用单纯形法推导出了适用于该柴油机低工况放热率的经验公式，提出了适用于相继增压与可控进气涡流复合系统的低工况放热率特征参数与负荷、转速之间变化规律的数学表达式。
4．TBD620V16柴油机采用相继增压与可控进气涡流复合系统的工作过程研究。基于GT-POWER软件平台，建立了TBD620V16相继增压柴油机工作过程仿真模型，在燃烧模型中选用了适用于相继增压与可控进气涡流复合系统的三韦伯特征参数，改变了燃油喷射系统参数，引入了涡流比对工作过程的影响后，对按标准螺旋桨特性运行的多个工况进行了模拟计算，预测了TBD620V16相继增压与可控进气涡流的复合系统柴油机的切换点。
5. TBD620V16相继增压与可控进气涡流的复合系统柴油机的试验研究。对该柴油机进行了较为全面的试验研究，进行了限制特性试验，得到柴油机的最大运行边界；在低工况进行了负荷特性试验，得到柴油机的万有特性以及柴油机的运行区域；进行了螺旋桨特性试验，得到按标准螺旋桨特性运行时柴油机的各项性能参数，选择了柴油机相继增压的切换点。试验表明，TBD620V16相继增压与可控进气涡流复合系统柴油机在低工况时采用一台增压器工作能够明显改善该机的低工况性能，柴油机的运行区域扩大，经济性得到改善。
Sequential turbocharging technology can expand the power operating range of a dieselengine, improve the economy in low conditions and reduce harmful emissions, which is themost effective way to improve the performance of the medium-speed or high-speedhigh-power diesel engine in low condition and being applied for more and more types ofdiesel engine. Based on the original TBD620V16diesel engine with controllable vortexsystem, modification on the sequential turbocharging system is made in this paper, whichmakes the original engine into a compound system with sequential turbocharging system andcontrollable vortex system, the results show that the diesel engine with this compound systemcan improve the low-condition performance, expand the operating range, increase theeconomy. The main contents of this article as follows:
1. The study of3D dynamic flow field of these three systems, sequential turbochargingsystem, controllable vortex system and the compound system.3D model of the Intake andexhaust ports-valves-cylinder is established based on the actual structure, in whichunstructured hexahedral is used in grid, the grid movement is the stretch of the prismatic layer,a transient-3D-compressible-viscous flow hypothesis is made, and ak εmodel is chosen tobe the turbulence model, this flow field of this model is calculated by SIMPLE algorithm.After the verification of this model by using the data of the steady flow test, analysis on theflow field is made, which is focus on the flow field of the DC inlet port and spiral inlet port,and also a quantitative analysis on variation of the flow field parameters at the same inlet andexhaust valve position is made, by analyzing and comparing the performance data of thewhole engine, the results show that it is advisable to remove the baffle in controllable vortexsystem and retain the spiral inlet port, so the compound system with sequential turbochargingsystem and controllable vortex system is composed.
2. The study of the combustion process of the TBD620V16diesel engine compoundsystem. By comparing the combustion process of the controllable vortex system and thecombustion process of the compound system, it shows that the emissions of the latter systemare significantly reduced. The fuel injection system parameters(injection advance angle, spraycone angle) of the compound system is optimized, the calculation results are in agreement inrated condition, switching point condition and the low condition: the delay of the injection advance angle, lower NOx resultant, more Shoot emissions, so the best injection advanceangle is20。BTDC; the best spray cone angle is155°in original engine, because the spraycone angle impacts the fuel distribution in space.
3. The study of empirical formulas of the heat release rate of the TBD620V16dieselengine compound system. Heat release rate of the TBD620V16diesel engine compoundsystem in low condition is analyzed based on the large number of experiment data,mathematical fitting of the curse of heat release rate is made by3-Viebe function, appropriateempirical expression of the characteristic parameters of heat release rate in low condition isderived by simplex method, and the mathematical expression of the variation amongcharacteristics parameters in low condition, load and speed is presented.
4. The study of the working process of the TBD620V16diesel engine compoundsystem. A simulation model of the TBD620V16sequential turbocharging diesel engine isestablished in GT-POWER software, in which appropriate3-Viebe characteristic parametersare chosen in combustion model, parameters of fuel injecting system is changed, after theimpacts of the swirl ratio on working process is introduced, simulation of multiple operationconditions in accordance with the standard propeller characteristics is carried out, and theswitching point of TBD234V16diesel engine with compound system is predicted.
5. The study of the TBD620V16diesel engine compound system. A morecomprehensive study is carried out, the max running border of the engine is obtained bylimiting characteristic test; the universal characteristic and the operating range of the engineis obtained by load characteristic test in low condition; the performance parameters of theengine in accordance with the standard propeller characteristics is obtained by propellercharacteristic test, and the switching points of the sequential turbocharging is chosen. The testshows that the low-condition performance of TBD234V16diesel engine with compoundsystem can be improved significantly, the operating range is expanded, economy is improveby a single turbocharger when working under low condition.
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