基于分功率传动原理的旋转机械调速技术与装置研究
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摘要
我国基础工业能源利用率低的问题亟待解决,其中重要的影响因素是生产过程中普遍使用的大型旋转机械(如泵与风机等)能耗过高。研究表明,合理的变速调节方式是此类设备系统节能运行的关键,但迄今国内仍多采用传统的定速节流调节方式,缺乏高效和可靠的传动技术支持,是变速调节这一节能运行主要技术途径难以实施的主要原因。在此背景下,本文围绕大型旋转机械的节能问题,借鉴国外近年提出的功率分流传动技术概念,开展了相关的先进调速传动原理与技术研究。
通过对分功率调速传动的机理分析和可行技术方案分析,本文系统研究了此类调速传动系统的总体设计原理；结合一种采用高效机械传动与液力调速相结合的混合调速传动技术装置的研制,开展了相关的关键技术和试验研究；基于所研究的分功率调速传动原理和技术装置,探索研究了一种适用于大型风机水泵系统节能的流量调节方法。
本文的主要研究工作和成果包括以下三个方面：
1、研究了一种适用于大型旋转机械调速传动的新技术
通过建立有效的系统传动分析模型,研究了分功率传动系统的总体方案和传动机理,掌握了功率流的分析方法及其与传动过程的关系。解决了传动系统调速特性、功率分流与耦合系统的机构学、功率分配原则及传动效率等关键问题,形成了较完整的系统总体传动设计理论与方法。
2、研制了一种采用机-液复合传动调速(HMVD)的技术装置
根据总体功能的设计要求,研究了调速部件、多自由度差动轮系传动机构和结构的设计依据与设计方法等问题。针对调速部件的设计需求,探索了液粘离合器逆向调速的问题,并研制成功新型调速单元部件；研究并设计了具有功率流切断和锁止功能的多自由度差动轮系调速机构；成功研制了具有自主知识产权的原型样机并开展了相关试验研究。
3、提出了一种针对风机水泵系统流量调节的调速与节流复合调节方法
基于所研究HMVD传动装置的功率流可分特性,针对大型风机、水泵系统的流量调节与节能问题,提出了一种调速与节流协调的流量调节机理。通过对分功率液力调速功耗特性和系统管路节流特性的研究,提出了调速与节流相结合的调节流量方法。以系统能耗最低为目标,建立了调速与节流协调优化模型,可根据系统运行工况确定最佳调速与节流分界点。该方法的应用可进一步降低分功率部分液力调速技术不可避免的功率损耗,为风机水泵的节能技术研究提供了一个新的方法。
In the production process of China's basic industries, fans, water pumps and other rotating machinery are the power equipments which have wide range of applications, have the largest number, and take the largest share of energy consumption. However, for the lack of efficient and reliable transmission technology, the applications of major technology method of large equipments'energy-saving operation--the variable-speed control is severely restricted. Thus, the traditional fixed-speed, throttle adjustment method is still widely used in large fans and water pumps system, resulting in great waste of energy.
In this context, this paper presents a new research thought that is substituting for the traditional full power speed-control by part power speed-control, using the existing mature, reliable, small and medium-power speed-control technology to achieve the purpose of high-power rotating machinery's speed control. It aims to meet the demand of large-scale rotating machinery's energy-saving operation, and refers to the power split transmission technology concepts put forward by foreign countries in recent years.
This paper starts with the analysis of the power split speed-control transmission mechanism and possible technical solutions, carries out the research of a typical transmission system apply theory and technology; by the development of a mixed speed-control transmission device, with high efficient mechanical transmission and hydraulic speed control, it carries out the related design theory and method, key technology, prototype development and experimental research. The research based on power split speed-control transmission technology and equipment, leads to the research of new methods of large fans and water pumps system's flow control, and explores a new method of energy-efficient technologies.
Major research work and achievements of this paper include the following three aspects:
1. Study a new technology which applies to large-scale rotating machinery's speed control transmission. It researches and analyzes the technology solutions and drive mechanism of power split transmission system, establishes an effective system transmission model, masters the analysis method of power split and its relationship with the transmission process. It researches key issues such as the speed characteristics, power split, coupling mechanisms, power distribution mechanism and transmission efficiency, forming a reletively complete system overall transmission design theory and method.
2. Develope a hydro-mechanical variable-speed drive (HMVD) device. According to the functional requirements of the overall design, this paper researches some issues, such as the transmission mechanism's assembly programs of speed control components and multi-degree of freedom differential gear, the design basis and design methods of the mechanism and structural design. It explors the issue of reverse speed control and develops a new type of speed control unit components for the first time, carries out a research about cutting off and locking the power flow in the design of multi-degree of freedom differential gear, and successfully developes a prototype with independent intellectual property rights and carries out a pilot study.
3. Research and present a new complex flow control method of pumps and fans system based on HMVD.This paper researches and presents the coordination adjustment principle of speed control and throttle adjustment for the flow control and energy saving of large fans and water pumps system, based on the characteristics of HMVD transmission device that its power flow can be splitted. It researches the speed and throttle adjustment method, with the combination of system pipeline flow characteristics and part power hydraulic speed-power characteristics. It sets the lowest energy consumption as the goal, establishes a coordination optimization model with speed and throttle, and can determine the best speed and throttle points according to system operating conditions. This method breaks through the traditional energy-saving theory of replacing the throttle adjustment entirely with speed control, can reduce the inevitable power loss of existing full power hydraulic speed control system, and explores a new technology direction for pumps and fans energy saving research.
通过对分功率调速传动的机理分析和可行技术方案分析,本文系统研究了此类调速传动系统的总体设计原理；结合一种采用高效机械传动与液力调速相结合的混合调速传动技术装置的研制,开展了相关的关键技术和试验研究；基于所研究的分功率调速传动原理和技术装置,探索研究了一种适用于大型风机水泵系统节能的流量调节方法。
本文的主要研究工作和成果包括以下三个方面：
1、研究了一种适用于大型旋转机械调速传动的新技术
通过建立有效的系统传动分析模型,研究了分功率传动系统的总体方案和传动机理,掌握了功率流的分析方法及其与传动过程的关系。解决了传动系统调速特性、功率分流与耦合系统的机构学、功率分配原则及传动效率等关键问题,形成了较完整的系统总体传动设计理论与方法。
2、研制了一种采用机-液复合传动调速(HMVD)的技术装置
根据总体功能的设计要求,研究了调速部件、多自由度差动轮系传动机构和结构的设计依据与设计方法等问题。针对调速部件的设计需求,探索了液粘离合器逆向调速的问题,并研制成功新型调速单元部件；研究并设计了具有功率流切断和锁止功能的多自由度差动轮系调速机构；成功研制了具有自主知识产权的原型样机并开展了相关试验研究。
3、提出了一种针对风机水泵系统流量调节的调速与节流复合调节方法
基于所研究HMVD传动装置的功率流可分特性,针对大型风机、水泵系统的流量调节与节能问题,提出了一种调速与节流协调的流量调节机理。通过对分功率液力调速功耗特性和系统管路节流特性的研究,提出了调速与节流相结合的调节流量方法。以系统能耗最低为目标,建立了调速与节流协调优化模型,可根据系统运行工况确定最佳调速与节流分界点。该方法的应用可进一步降低分功率部分液力调速技术不可避免的功率损耗,为风机水泵的节能技术研究提供了一个新的方法。
In the production process of China's basic industries, fans, water pumps and other rotating machinery are the power equipments which have wide range of applications, have the largest number, and take the largest share of energy consumption. However, for the lack of efficient and reliable transmission technology, the applications of major technology method of large equipments'energy-saving operation--the variable-speed control is severely restricted. Thus, the traditional fixed-speed, throttle adjustment method is still widely used in large fans and water pumps system, resulting in great waste of energy.
In this context, this paper presents a new research thought that is substituting for the traditional full power speed-control by part power speed-control, using the existing mature, reliable, small and medium-power speed-control technology to achieve the purpose of high-power rotating machinery's speed control. It aims to meet the demand of large-scale rotating machinery's energy-saving operation, and refers to the power split transmission technology concepts put forward by foreign countries in recent years.
This paper starts with the analysis of the power split speed-control transmission mechanism and possible technical solutions, carries out the research of a typical transmission system apply theory and technology; by the development of a mixed speed-control transmission device, with high efficient mechanical transmission and hydraulic speed control, it carries out the related design theory and method, key technology, prototype development and experimental research. The research based on power split speed-control transmission technology and equipment, leads to the research of new methods of large fans and water pumps system's flow control, and explores a new method of energy-efficient technologies.
Major research work and achievements of this paper include the following three aspects:
1. Study a new technology which applies to large-scale rotating machinery's speed control transmission. It researches and analyzes the technology solutions and drive mechanism of power split transmission system, establishes an effective system transmission model, masters the analysis method of power split and its relationship with the transmission process. It researches key issues such as the speed characteristics, power split, coupling mechanisms, power distribution mechanism and transmission efficiency, forming a reletively complete system overall transmission design theory and method.
2. Develope a hydro-mechanical variable-speed drive (HMVD) device. According to the functional requirements of the overall design, this paper researches some issues, such as the transmission mechanism's assembly programs of speed control components and multi-degree of freedom differential gear, the design basis and design methods of the mechanism and structural design. It explors the issue of reverse speed control and develops a new type of speed control unit components for the first time, carries out a research about cutting off and locking the power flow in the design of multi-degree of freedom differential gear, and successfully developes a prototype with independent intellectual property rights and carries out a pilot study.
3. Research and present a new complex flow control method of pumps and fans system based on HMVD.This paper researches and presents the coordination adjustment principle of speed control and throttle adjustment for the flow control and energy saving of large fans and water pumps system, based on the characteristics of HMVD transmission device that its power flow can be splitted. It researches the speed and throttle adjustment method, with the combination of system pipeline flow characteristics and part power hydraulic speed-power characteristics. It sets the lowest energy consumption as the goal, establishes a coordination optimization model with speed and throttle, and can determine the best speed and throttle points according to system operating conditions. This method breaks through the traditional energy-saving theory of replacing the throttle adjustment entirely with speed control, can reduce the inevitable power loss of existing full power hydraulic speed control system, and explores a new technology direction for pumps and fans energy saving research.
引文
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