乳化液泵检测系统的节能关键技术研究
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摘要
随着能源需求的不断增加，煤矿对其生产效率的要求也越来越高。乳化液泵作为煤矿综采工作面的必备设备，其性能与可靠性直接影响到煤矿的生产效率与人员的生命安全，所以乳化液泵在出厂前要按照行业标准MT/T188.2-2000进行严格的检测试验。目前，乳化液泵的检测试验采用的是电动机直接驱动、节流阀或溢流阀加载的方法，该方法结构简单，但装机功率高，能源消耗大，浪费严重，尤其是当检测应用于高产高效煤矿的大功率乳化液泵。因此，开展乳化液泵检测系统的节能关键技术研究对于节约能源，降低检测成本具有重要的现实意义。
本文在江苏省普通高校研究生科研创新计划项目（编号：CXZZ11_0288）的资助下，针对现有检测方法耗能高的弊端，采用理论建模、数值仿真和试验验证相结合的方法，以降低乳化液泵检测时的能源消耗为目标，设计了一套新型的功率回收系统，并深入开展了该系统对乳化液泵运行参数的调节规律和整个系统节能效率方面的研究，为降低乳化液泵检测的能耗与成本提供了理论支撑和技术解决方案。
首先，详细分析了检测标准对于乳化液泵各种检测试验的运行要求和功率消耗情况，设计了一套以“变量泵—变量马达”作为被检测乳化液泵的驱动单元，以“双液压缸—整流阀”作为功率回收单元的新型功率回收系统方案；根据流体连续性和力学平衡推导出了系统驱动乳化液泵转速、压力及回收功率的表达式，分析了其影响因素及调节方法，搭建了乳化液泵检测的功率回收试验系统。
其次，基于功率键合图理论，先分别建立了功率回收系统中各元部件的理论模型和状态方程，再由各元部件的模型组建了整个系统的理论模型，并根据理论模型推导出了整个系统的状态空间方程；基于整个系统的理论模型，在Simulink软件中建立了其仿真模型。
再次，采用仿真和试验相结合的方法，验证了该功率回收系统的可行性；在满载检测工况下，该系统的功率回收系数可达0.76以上，整个系统的节能系数可达0.23以上；分析了系统中各元部件的功率损失比例以及产生的原因。
然后，通过数值仿真得到了变量泵和变量马达的排量组合对于乳化液泵负载压力和转速的影响规律，并对乳化液泵负载压力和转速变化的三维曲面进行了多项式拟合，分别给出了乳化液泵负载压力和转速对变量泵和变量马达排量的拟合公式。
最后，通过仿真和试验研究了乳化液泵的负载压力对于整个系统功率回收系数和节能系数的影响规律，分析了各元部件在不同负载压力下功率损失的变化规律；研究了系统背压力对于乳化液泵运行参数的影响规律及背压力的合理取值。
With the increasing demand of energy, the coal mines should improve theirproduction efficiency as high as possible. The emulsion pump, one of the necessaryequipment on the fully-mechanized face of coal mine, has a great influence on thecoal production efficiency and, more importantly, the life safety of coal mine work-ers due to its dynamic characteristics and reliability. As a result, the emulsion pumpmust be strictly tested before field usage according to the coal industry standard ofChina MT/T188.2-2000. So far, the test system adopted by the coal industry stand-ard employs the electric motor as the direct drive unit and relief valve (or throttlevalve) as the load unit of the test emulsion pump. This system is simple to use. Fromthe view point of energy-saving, however, it is energy-intensive and wastes hugeamount of energy because of its simple working principles. Consequently, the re-search on energy-saving technology for emulsion pump tests would increase the en-ergy efficiency and decease the power consumption and hence the cost of tests.
Financially supported by the program sponsored for scientific innovation re-search of college graduate in Jiangsu province (Grant: CXZZ11_0288), this paperhas designed a novel energy regeneration system (ERS) for emulsion pump tests todecrease the energy consumption of emulsion pump tests. This novel system isdeeply investigated by theoretical modeling, numerical simulation and experimentalvalidation to obtain the variation of running parameters of emulsion pump and theenergy–saving coefficient of the whole system.
Firstly, the requirement of running parameters of emulsion pump by the teststandard is analyzed in detail and then a novel ERS is designed which employs‘variable displacement pump-variable displacement motor’ as the drive unit and‘double cylinders-rectifier valve’ as the power recovery unit. Based on the fluid con-tinuity equation and mechanical equilibrium equation, the analytical expressions ofemulsion pump rotation speed, load pressure and the energy-saving coefficient arederived, respectively. Moreover, the experimental system of ERS is built according-ly.
Secondly, based on the bond graph modeling, the theoretical model of the pro-posed ERS for emulsion pump tests is established by first considering the separatecomponents before assembling them together. So is the status-space equation of theoverall system. Then the simulation model of ERS is built accordingly in the envi- ronment of Simulink software.
Thirdly, the feasibility of this ERS is verified by both simulations and experi-ments. The simulation and experiment results show that in the full load test, for ex-ample, the power recovery coefficient and energy-saving coefficient are0.76and0.23, respectively. The causes of power losses of major components in the ERS areanalyzed and compared as well.
Fourthly, the variation of load pressure and rotation speed of emulsion pump asto the displacement combination of variable displacement pump and motor is ob-tained by the simulation results. The three dimensional surfaces of both load pres-sure and rotation speed of emulsion pump are investigated by polynomial fit andtherefore the polynomial fit expressions of both load pressure and rotation speed ofemulsion pump are given.
Lastly, by both simulations and experiments, the variation of power recoverycoefficient and energy-saving coefficient as to load pressure of emulsion pump areinvestigated. Furthermore, power loss of each component in the ERS is analyzed andcompared in different load pressure conditions. The influence of system back pres-sure on running parameters of emulsion pump is also studied by simulation and ex-periments, and the reasonable value of system back pressure is given.
本文在江苏省普通高校研究生科研创新计划项目（编号：CXZZ11_0288）的资助下，针对现有检测方法耗能高的弊端，采用理论建模、数值仿真和试验验证相结合的方法，以降低乳化液泵检测时的能源消耗为目标，设计了一套新型的功率回收系统，并深入开展了该系统对乳化液泵运行参数的调节规律和整个系统节能效率方面的研究，为降低乳化液泵检测的能耗与成本提供了理论支撑和技术解决方案。
首先，详细分析了检测标准对于乳化液泵各种检测试验的运行要求和功率消耗情况，设计了一套以“变量泵—变量马达”作为被检测乳化液泵的驱动单元，以“双液压缸—整流阀”作为功率回收单元的新型功率回收系统方案；根据流体连续性和力学平衡推导出了系统驱动乳化液泵转速、压力及回收功率的表达式，分析了其影响因素及调节方法，搭建了乳化液泵检测的功率回收试验系统。
其次，基于功率键合图理论，先分别建立了功率回收系统中各元部件的理论模型和状态方程，再由各元部件的模型组建了整个系统的理论模型，并根据理论模型推导出了整个系统的状态空间方程；基于整个系统的理论模型，在Simulink软件中建立了其仿真模型。
再次，采用仿真和试验相结合的方法，验证了该功率回收系统的可行性；在满载检测工况下，该系统的功率回收系数可达0.76以上，整个系统的节能系数可达0.23以上；分析了系统中各元部件的功率损失比例以及产生的原因。
然后，通过数值仿真得到了变量泵和变量马达的排量组合对于乳化液泵负载压力和转速的影响规律，并对乳化液泵负载压力和转速变化的三维曲面进行了多项式拟合，分别给出了乳化液泵负载压力和转速对变量泵和变量马达排量的拟合公式。
最后，通过仿真和试验研究了乳化液泵的负载压力对于整个系统功率回收系数和节能系数的影响规律，分析了各元部件在不同负载压力下功率损失的变化规律；研究了系统背压力对于乳化液泵运行参数的影响规律及背压力的合理取值。
With the increasing demand of energy, the coal mines should improve theirproduction efficiency as high as possible. The emulsion pump, one of the necessaryequipment on the fully-mechanized face of coal mine, has a great influence on thecoal production efficiency and, more importantly, the life safety of coal mine work-ers due to its dynamic characteristics and reliability. As a result, the emulsion pumpmust be strictly tested before field usage according to the coal industry standard ofChina MT/T188.2-2000. So far, the test system adopted by the coal industry stand-ard employs the electric motor as the direct drive unit and relief valve (or throttlevalve) as the load unit of the test emulsion pump. This system is simple to use. Fromthe view point of energy-saving, however, it is energy-intensive and wastes hugeamount of energy because of its simple working principles. Consequently, the re-search on energy-saving technology for emulsion pump tests would increase the en-ergy efficiency and decease the power consumption and hence the cost of tests.
Financially supported by the program sponsored for scientific innovation re-search of college graduate in Jiangsu province (Grant: CXZZ11_0288), this paperhas designed a novel energy regeneration system (ERS) for emulsion pump tests todecrease the energy consumption of emulsion pump tests. This novel system isdeeply investigated by theoretical modeling, numerical simulation and experimentalvalidation to obtain the variation of running parameters of emulsion pump and theenergy–saving coefficient of the whole system.
Firstly, the requirement of running parameters of emulsion pump by the teststandard is analyzed in detail and then a novel ERS is designed which employs‘variable displacement pump-variable displacement motor’ as the drive unit and‘double cylinders-rectifier valve’ as the power recovery unit. Based on the fluid con-tinuity equation and mechanical equilibrium equation, the analytical expressions ofemulsion pump rotation speed, load pressure and the energy-saving coefficient arederived, respectively. Moreover, the experimental system of ERS is built according-ly.
Secondly, based on the bond graph modeling, the theoretical model of the pro-posed ERS for emulsion pump tests is established by first considering the separatecomponents before assembling them together. So is the status-space equation of theoverall system. Then the simulation model of ERS is built accordingly in the envi- ronment of Simulink software.
Thirdly, the feasibility of this ERS is verified by both simulations and experi-ments. The simulation and experiment results show that in the full load test, for ex-ample, the power recovery coefficient and energy-saving coefficient are0.76and0.23, respectively. The causes of power losses of major components in the ERS areanalyzed and compared as well.
Fourthly, the variation of load pressure and rotation speed of emulsion pump asto the displacement combination of variable displacement pump and motor is ob-tained by the simulation results. The three dimensional surfaces of both load pres-sure and rotation speed of emulsion pump are investigated by polynomial fit andtherefore the polynomial fit expressions of both load pressure and rotation speed ofemulsion pump are given.
Lastly, by both simulations and experiments, the variation of power recoverycoefficient and energy-saving coefficient as to load pressure of emulsion pump areinvestigated. Furthermore, power loss of each component in the ERS is analyzed andcompared in different load pressure conditions. The influence of system back pres-sure on running parameters of emulsion pump is also studied by simulation and ex-periments, and the reasonable value of system back pressure is given.
引文
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