新型二甲醚共轨系统的开发与研究
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摘要
二甲醚(DME)具有高十六烷值和无烟燃烧特性,是柴油机的理想替代燃料,但二甲醚低粘度所导致的喷射系统偶件的磨损和泄漏问题,已成为二甲醚车用技术的主要障碍。本文从供油和喷油两个方面,创新性地提出了一种适用于二甲醚燃料喷射的新型共轨式电控喷射系统的解决方案,有效地回避上述两个难题,从而达到彻底解决问题的目的。
本文提出基于碰撞原理二甲醚共轨喷油器设计方案:衔铁在自由升程阶段蓄存电磁能并转化为动能,当衔铁与针阀发生撞击时,电磁力、撞击力联合作用在针阀上,确保针阀可靠快速打开。经过仿真计算和样机实验,喷油器的新型工作原理得到证实。研究表明:基于这种工作原理的共轨式电控喷油器具备如下特点:内部无偶件、无回油口、24V电压直接驱动,能灵活地实现预喷射。进一步的研究表明:存在最佳的自由升程,自由升程过大针阀开启响应滞后,过小则针阀开启困难。
提出了利用压力转换器,将机油压力转换为二甲醚压力的供油系统方案。开发成功了活塞式和膜片蓄能器式两种压力转换器,成功地解决了二甲醚的加压问题,回避了目前技术中二甲醚油泵柱塞泄漏与磨损问题。
针对二甲醚的物理特性和二甲醚喷射系统的特点,自主开发成功了二甲醚喷油规律测试系统,通过不同参数下喷油规律实验,对仿真模型研究的结果进行验证,实验结果表明系统的仿真模型具有较好的可信度。实际喷射系统的开启响应速度可达0.38ms,在PWM驱动下关闭响应速度达到0.68ms;喷射系统可以实现0.4ms间隔的预喷;合理匹配自由和有效升程及优化管路参数可以有效改善系统的喷油特性。
根据二甲醚燃料及新型喷射系统的特点,建立了二甲醚燃料发动机的燃烧过程仿真模型,并预测了关键性控制参数对燃烧过程和发动机性能的影响规律,为下阶段的发动机台架实验作好理论准备。研究结果表明:采用25MPa喷射压力可以在满足经济性、动力性的前提下,获得较好NO排放和较低的压力升高率;合理的预喷射量及主喷提前角,可以有效降低NO排放和燃烧噪声,获得比单次喷射更好的NO-指示效率折衷曲线和压力升高率-指示效率折衷曲线。
上述工作为二甲醚共轨技术的实用化打下了坚实的理论和技术基础。
Being high cetane number and combustion with soot-free emission, Dimethyl ether (DME)is considered an ideal alternative fuel for diesel engines. However, the problems of serious wear abrasion and leakage to the sealing couplings of fuel injection system caused by DME low viscosity become a major obstacle to DME’s application in vehicles. From fuel supply and fuel injection, an innovative solution of a new type of electronic control common-rail injection system suitable for DME injection was put forward in this paper. Because of effective avoidance to the above two difficulties, the program could solve the problems completely.
The DME injector design ideas based on the collision principle was proposed: in the free lift , the armature stored the electromagnetic energy and transformed into kinetic energy, and when the collision between the armature and needle occurred, the needle could open quickly and reliably because of electro-magnetic force and impact force acting on it. By simulation and prototype experiment, the new type injector working principle was confirmed. Studies have shown that: the new type common-rail electric control injector has the characteristics of no internal couplings, no spill port, driven by 24V directly and flexible pre-injection. Further research shows that the injector exists the best free lift, and the overlong free lift causes the needle’s opening response lag and too short free lift results in difficulty to the needle opening.
The fuel supplying idea with converting the machine oil pressure to the DME pressure by pressure converter was proposed. Two kinds of pressure converters with a plunger and diaphragm accumulators were developed, successfully solved the problem of DME pressurization and skirted round the wear abrasion and leakage problem to the plunger of DME pump.
Addressing the DME physical properties and the characteristics of DME injection system, the DME fuel injection law test system was developed. By experiments of fuel injection law under condition of different parameters, the results of simulation model were verified,and proved that the system simulation model has the better credibility. The practical opening response time of the injector is 0.38ms, the corresponding closing response time is 0.68ms under the condition of PWM-driven, and the injection system can achieve pre-injection with 0.4ms dwell. Reasonable matching of free and effective lift and optimization of pipeline parameters can improve the characteristics of fuel injection..
According to the DME properties and new type injection system, the simulation model of DME combustion process in a diesel engine was established, the effects of critical parameters on the combustion process and the engine performance were predicted and the theory guidance for the later engine bench experiments were prepared. The results show that: under the condition of meeting economy and power performance, 25MPa injection pressure can achieve better NO emission and lower ratio of pressure rise. With reasonable fuel amount of pre-injection and main injection advance angle, NO emissions and combustion noise can be reduced effectively and the trade-off curves of pre-injection is better than the single injection in NO-indicated efficiency and ratio of pressure rise-indicated efficiency.
The above work built a stable base of theory and technology for DME common-rail technology practical application
本文提出基于碰撞原理二甲醚共轨喷油器设计方案:衔铁在自由升程阶段蓄存电磁能并转化为动能,当衔铁与针阀发生撞击时,电磁力、撞击力联合作用在针阀上,确保针阀可靠快速打开。经过仿真计算和样机实验,喷油器的新型工作原理得到证实。研究表明:基于这种工作原理的共轨式电控喷油器具备如下特点:内部无偶件、无回油口、24V电压直接驱动,能灵活地实现预喷射。进一步的研究表明:存在最佳的自由升程,自由升程过大针阀开启响应滞后,过小则针阀开启困难。
提出了利用压力转换器,将机油压力转换为二甲醚压力的供油系统方案。开发成功了活塞式和膜片蓄能器式两种压力转换器,成功地解决了二甲醚的加压问题,回避了目前技术中二甲醚油泵柱塞泄漏与磨损问题。
针对二甲醚的物理特性和二甲醚喷射系统的特点,自主开发成功了二甲醚喷油规律测试系统,通过不同参数下喷油规律实验,对仿真模型研究的结果进行验证,实验结果表明系统的仿真模型具有较好的可信度。实际喷射系统的开启响应速度可达0.38ms,在PWM驱动下关闭响应速度达到0.68ms;喷射系统可以实现0.4ms间隔的预喷;合理匹配自由和有效升程及优化管路参数可以有效改善系统的喷油特性。
根据二甲醚燃料及新型喷射系统的特点,建立了二甲醚燃料发动机的燃烧过程仿真模型,并预测了关键性控制参数对燃烧过程和发动机性能的影响规律,为下阶段的发动机台架实验作好理论准备。研究结果表明:采用25MPa喷射压力可以在满足经济性、动力性的前提下,获得较好NO排放和较低的压力升高率;合理的预喷射量及主喷提前角,可以有效降低NO排放和燃烧噪声,获得比单次喷射更好的NO-指示效率折衷曲线和压力升高率-指示效率折衷曲线。
上述工作为二甲醚共轨技术的实用化打下了坚实的理论和技术基础。
Being high cetane number and combustion with soot-free emission, Dimethyl ether (DME)is considered an ideal alternative fuel for diesel engines. However, the problems of serious wear abrasion and leakage to the sealing couplings of fuel injection system caused by DME low viscosity become a major obstacle to DME’s application in vehicles. From fuel supply and fuel injection, an innovative solution of a new type of electronic control common-rail injection system suitable for DME injection was put forward in this paper. Because of effective avoidance to the above two difficulties, the program could solve the problems completely.
The DME injector design ideas based on the collision principle was proposed: in the free lift , the armature stored the electromagnetic energy and transformed into kinetic energy, and when the collision between the armature and needle occurred, the needle could open quickly and reliably because of electro-magnetic force and impact force acting on it. By simulation and prototype experiment, the new type injector working principle was confirmed. Studies have shown that: the new type common-rail electric control injector has the characteristics of no internal couplings, no spill port, driven by 24V directly and flexible pre-injection. Further research shows that the injector exists the best free lift, and the overlong free lift causes the needle’s opening response lag and too short free lift results in difficulty to the needle opening.
The fuel supplying idea with converting the machine oil pressure to the DME pressure by pressure converter was proposed. Two kinds of pressure converters with a plunger and diaphragm accumulators were developed, successfully solved the problem of DME pressurization and skirted round the wear abrasion and leakage problem to the plunger of DME pump.
Addressing the DME physical properties and the characteristics of DME injection system, the DME fuel injection law test system was developed. By experiments of fuel injection law under condition of different parameters, the results of simulation model were verified,and proved that the system simulation model has the better credibility. The practical opening response time of the injector is 0.38ms, the corresponding closing response time is 0.68ms under the condition of PWM-driven, and the injection system can achieve pre-injection with 0.4ms dwell. Reasonable matching of free and effective lift and optimization of pipeline parameters can improve the characteristics of fuel injection..
According to the DME properties and new type injection system, the simulation model of DME combustion process in a diesel engine was established, the effects of critical parameters on the combustion process and the engine performance were predicted and the theory guidance for the later engine bench experiments were prepared. The results show that: under the condition of meeting economy and power performance, 25MPa injection pressure can achieve better NO emission and lower ratio of pressure rise. With reasonable fuel amount of pre-injection and main injection advance angle, NO emissions and combustion noise can be reduced effectively and the trade-off curves of pre-injection is better than the single injection in NO-indicated efficiency and ratio of pressure rise-indicated efficiency.
The above work built a stable base of theory and technology for DME common-rail technology practical application
引文
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