离心风机多目标优化及旋转失速机理研究
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摘要
风机属于通用机械范畴,在国民经济的各部门应用十分广泛。尤其在火力发电厂中,风机是保证电厂安全、经济运行及实现节能减排的重要设备之一,因此对其经济性和安全性两个方面进行研究具有重要意义。本文以G4-73型离心风机为研究对象,采用数值模拟与实验研究相结合的方法,在分析风机内部流动机理及结构参数对性能影响规律的基础上,利用遗传算法对风机性能进行优化,设计高效叶轮及旋涡破碎装置,并深入研究旋转失速现象的产生机理及流体动力学特征。主要研究内容及成果如下：
(1)离心风机流场动力学特征研究及参数化数值计算平台开发。在分析网格划分策略及湍流模型等对计算精度的影响基础上,对离心风机的内部流场特征进行了数值研究及熵产计算,计算结果与实验数据吻合良好,为实现风机性能预测和优化奠定了基础。研究发现,湍流耗散是引起熵产的主要原因,而粘性耗散的影响几乎可以忽略,其中叶轮体内熵产最大。在确定计算模型的基础上采用VB编程语言开发了基于参数化的离心风机数值计算平台,包括参数化建模、FLUENT计算及数据分析三个模块,实现了叶轮结构参数变化时几何建模、高质量网格生成、计算模型设置、后处理及数据库查询等功能的完全自动化与体化,为深入研究叶轮结构参数变化对风机性能的影响奠定了基础。
(2)离心风机性能的多目标优化及实验研究。基于参数化数值计算平台研究了叶轮结构参数包括叶片数、叶片出口安装角和叶轮出口宽度等对风机性能的影响规律。设计正交试验构造训练样本,基于BP神经网络构建了离心风机性能参数预测模型,并利用遗传算法对风机全压和效率进行多目标优化,获得了新型叶轮结构参数组合。为验证优化结果的正确性,对加装新型叶轮的风机分别进行了数值模拟和实验研究。结果表明,加装新型叶轮后风机全压和效率提高,且高效区拓宽,在65%-100%相对流量范围内,风机噪声降低。
(3)风机蜗壳流场动力学特征分析及优化。研究了离心风机蜗壳内部流动规律,发现蜗壳内部存在螺旋向前推进的类S型大型旋涡运动。基于减小流动损失和泄漏损失的思想,设计了一种旋涡破碎装置。对加装漩涡破碎装置前后的风机分别进行了数值模拟及性能和噪声实验。模拟结果表明,加装旋涡破碎装置后,大尺度旋涡得到破碎且强度减弱,蜗壳体内熵产明显降低,泄漏损失减小。实验结果表明,加装旋涡破碎装置后,相对流量大于45%时,风机全压明显增大,且高效区拓宽；风机噪声降低,且在最高效率点处,风机中、低频段噪声明显降低。
(4)离心风机旋转失速动力学特征的机理研究。基于编写的UDF节流阀函数对离心风机旋转失速现象进行了数值模拟,通过在流场中设置监视点获得了失速团的传播速度及失速频率。探讨了旋转失速的发生机理及影响因素,分析了从失速先兆发展到失速团的径向、轴向和周向全三维的非定常迁移过程,及失速特征和失速团个数的变化。深入探讨了失速团的周向传播机理,且揭示了小流量区风机全压波动及其频率的重要原因。研究结果为风机旋转失速故障的预防、监测与诊断奠定了基础。
As one of universal machines, fans have been widely used in lots of departments of the national economy. It is one of major devices for ensuring safe and economic operation for power plants as well as realizing energy saving and emission reduction, thus it's of great significance to study fan's economy and safety. In this paper, G4-73 centrifugal fan is chosen as the study object. Combined with numerical simulation and experimental research, the flow mechanism and influence law of structure parameters on fan performance is analyzed. Then, the impeller structure parameters are optimized by genetic algorithm and vortex-broken device is designed for improving fan performance. Moreover, the mechanism and dynamic characteristics of rotating stall are investigated. Main contents and results of the paper are as follows.
(1) Study on dynamic characteristics of flow field for centrifugal fan and development of parametric numerical calculation platform. After analyzing the influence of mesh division strategy and turbulence models on computational accuracy, the flow field is solved by numerical simulation and entropy generation calculating. Numerical results are in good agreement with the experimental data, setting a basis for the realization of performance prediction and optimization of fan. Results show that turbulent dissipation is the primary cause of entropy generation while viscous dissipation is almost negligible. Entropy generation is largest inside the impeller. After confirming the calculation models, parametric numerical calculation platform for centrifugal fan is developed with VB programming language, including three modules, parametric modeling, FLUENT calculating and data analysis. The platforms can realize full functional automation and integration of geometric modeling, high-quality mesh generation, model setup, post-processing, data-base query and so on when structural parameters of the impeller change, to set a basis for in-depth study on the impacts of structural parameter variation on fan's performances.
(2) Multi-objective optimization and experimental research of centrifugal fan performance. The influence laws of impeller structural parameters including the blade number, outlet installation angle of blade, and width of the impeller outlet on fan performance is studied with parametric numerical calculation platform. After obtained the training samples by orthogonal test, prediction model for centrifugal fan performance parameters is constructed based on BP neural network, and we obtain a new type of impeller structure parameters through multi-objective optimization to full pressure and efficiency of the fan by genetic algorithms. In order to verify the accuracy of optimization results, numerical and experimental studies are conducted to the fan with the new impeller. The results show that full pressure and efficiency of the fan improved after installation of the new impeller, the effective area expanded and the fan noise reduces as relative flowrate ranged from 65%to 100%.
(3) The characteristics analysis and improvement for flow field of fan volute. The internal flow rules of volute are studied and S-like large-scale spiral whirls in volute are push forward. A vortex-broken device is designed for reducing flow loss and leak loss. Numerical simulation, performance and noise experiments are carried out respectively before and after the installation of the device. The simulation results show that large-scale swirl is broken and its intensity becomes weaker, entropy generation inside volute is reduced sharply, as well as the leak loss is decreased with the device. The experimental results illustrate that after the device was added, when relative flowrate more than 45%, full pressure increase significantly and efficiency area to broaden. Fan noise reduction, mid-frequency and low-frequency noise significantly decrease at the maximum efficiency point.
(4) The mechanism investigation on dynamic characteristics of rotating stall for centrifugal fan. Phenomenon of rotating stall is numerical simulated with the throttle valve function compiled with user defined function. The speed of stall cell and stall frequency are obtained by the terms of setting monitoring points in flow field. Production mechanism of rotating stall was discussed. The full three dimensional unsteady transport processes including the radial, axial and circumferential directions is analyzed from the stall inception become to stall cell. Also, the change of stall characteristics and numbers of stall cell is studied. Mechanism of circumference transmission for stall cell, reasons that full pressure fluctuation and its frequency in low flowrate condition are explored. The results will provide a foundation for fault prevention, monitoring and diagnosis of rotating stall.
(1)离心风机流场动力学特征研究及参数化数值计算平台开发。在分析网格划分策略及湍流模型等对计算精度的影响基础上,对离心风机的内部流场特征进行了数值研究及熵产计算,计算结果与实验数据吻合良好,为实现风机性能预测和优化奠定了基础。研究发现,湍流耗散是引起熵产的主要原因,而粘性耗散的影响几乎可以忽略,其中叶轮体内熵产最大。在确定计算模型的基础上采用VB编程语言开发了基于参数化的离心风机数值计算平台,包括参数化建模、FLUENT计算及数据分析三个模块,实现了叶轮结构参数变化时几何建模、高质量网格生成、计算模型设置、后处理及数据库查询等功能的完全自动化与体化,为深入研究叶轮结构参数变化对风机性能的影响奠定了基础。
(2)离心风机性能的多目标优化及实验研究。基于参数化数值计算平台研究了叶轮结构参数包括叶片数、叶片出口安装角和叶轮出口宽度等对风机性能的影响规律。设计正交试验构造训练样本,基于BP神经网络构建了离心风机性能参数预测模型,并利用遗传算法对风机全压和效率进行多目标优化,获得了新型叶轮结构参数组合。为验证优化结果的正确性,对加装新型叶轮的风机分别进行了数值模拟和实验研究。结果表明,加装新型叶轮后风机全压和效率提高,且高效区拓宽,在65%-100%相对流量范围内,风机噪声降低。
(3)风机蜗壳流场动力学特征分析及优化。研究了离心风机蜗壳内部流动规律,发现蜗壳内部存在螺旋向前推进的类S型大型旋涡运动。基于减小流动损失和泄漏损失的思想,设计了一种旋涡破碎装置。对加装漩涡破碎装置前后的风机分别进行了数值模拟及性能和噪声实验。模拟结果表明,加装旋涡破碎装置后,大尺度旋涡得到破碎且强度减弱,蜗壳体内熵产明显降低,泄漏损失减小。实验结果表明,加装旋涡破碎装置后,相对流量大于45%时,风机全压明显增大,且高效区拓宽；风机噪声降低,且在最高效率点处,风机中、低频段噪声明显降低。
(4)离心风机旋转失速动力学特征的机理研究。基于编写的UDF节流阀函数对离心风机旋转失速现象进行了数值模拟,通过在流场中设置监视点获得了失速团的传播速度及失速频率。探讨了旋转失速的发生机理及影响因素,分析了从失速先兆发展到失速团的径向、轴向和周向全三维的非定常迁移过程,及失速特征和失速团个数的变化。深入探讨了失速团的周向传播机理,且揭示了小流量区风机全压波动及其频率的重要原因。研究结果为风机旋转失速故障的预防、监测与诊断奠定了基础。
As one of universal machines, fans have been widely used in lots of departments of the national economy. It is one of major devices for ensuring safe and economic operation for power plants as well as realizing energy saving and emission reduction, thus it's of great significance to study fan's economy and safety. In this paper, G4-73 centrifugal fan is chosen as the study object. Combined with numerical simulation and experimental research, the flow mechanism and influence law of structure parameters on fan performance is analyzed. Then, the impeller structure parameters are optimized by genetic algorithm and vortex-broken device is designed for improving fan performance. Moreover, the mechanism and dynamic characteristics of rotating stall are investigated. Main contents and results of the paper are as follows.
(1) Study on dynamic characteristics of flow field for centrifugal fan and development of parametric numerical calculation platform. After analyzing the influence of mesh division strategy and turbulence models on computational accuracy, the flow field is solved by numerical simulation and entropy generation calculating. Numerical results are in good agreement with the experimental data, setting a basis for the realization of performance prediction and optimization of fan. Results show that turbulent dissipation is the primary cause of entropy generation while viscous dissipation is almost negligible. Entropy generation is largest inside the impeller. After confirming the calculation models, parametric numerical calculation platform for centrifugal fan is developed with VB programming language, including three modules, parametric modeling, FLUENT calculating and data analysis. The platforms can realize full functional automation and integration of geometric modeling, high-quality mesh generation, model setup, post-processing, data-base query and so on when structural parameters of the impeller change, to set a basis for in-depth study on the impacts of structural parameter variation on fan's performances.
(2) Multi-objective optimization and experimental research of centrifugal fan performance. The influence laws of impeller structural parameters including the blade number, outlet installation angle of blade, and width of the impeller outlet on fan performance is studied with parametric numerical calculation platform. After obtained the training samples by orthogonal test, prediction model for centrifugal fan performance parameters is constructed based on BP neural network, and we obtain a new type of impeller structure parameters through multi-objective optimization to full pressure and efficiency of the fan by genetic algorithms. In order to verify the accuracy of optimization results, numerical and experimental studies are conducted to the fan with the new impeller. The results show that full pressure and efficiency of the fan improved after installation of the new impeller, the effective area expanded and the fan noise reduces as relative flowrate ranged from 65%to 100%.
(3) The characteristics analysis and improvement for flow field of fan volute. The internal flow rules of volute are studied and S-like large-scale spiral whirls in volute are push forward. A vortex-broken device is designed for reducing flow loss and leak loss. Numerical simulation, performance and noise experiments are carried out respectively before and after the installation of the device. The simulation results show that large-scale swirl is broken and its intensity becomes weaker, entropy generation inside volute is reduced sharply, as well as the leak loss is decreased with the device. The experimental results illustrate that after the device was added, when relative flowrate more than 45%, full pressure increase significantly and efficiency area to broaden. Fan noise reduction, mid-frequency and low-frequency noise significantly decrease at the maximum efficiency point.
(4) The mechanism investigation on dynamic characteristics of rotating stall for centrifugal fan. Phenomenon of rotating stall is numerical simulated with the throttle valve function compiled with user defined function. The speed of stall cell and stall frequency are obtained by the terms of setting monitoring points in flow field. Production mechanism of rotating stall was discussed. The full three dimensional unsteady transport processes including the radial, axial and circumferential directions is analyzed from the stall inception become to stall cell. Also, the change of stall characteristics and numbers of stall cell is studied. Mechanism of circumference transmission for stall cell, reasons that full pressure fluctuation and its frequency in low flowrate condition are explored. The results will provide a foundation for fault prevention, monitoring and diagnosis of rotating stall.
引文
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