离心压缩机无叶扩压器失速与系统喘振先兆分析研究
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摘要
离心压缩机作为一种提高气体压力的通用机械,在国民经济的许多部门得到了广泛的应用,并占有重要地位,但是同时也是这些部门的耗能大户。近年来,国际国内能源形势的日益严峻也对离心压缩机的设计提出了更高的要求,即要求设计压比更高、效率更高、工作范围更宽的离心压缩机。而这其中对工作范围的要求尤其突出,比如工作范围的增加可明显降低车用涡轮增压器的匹配困难;增加CHP系统热电比调节范围等。除了堵塞之外,失速和喘振是限制离心压缩机稳定工作范围的主要原因,同时也是级间匹配或压缩机与透平匹配机组匹配的关键问题,处理不当,甚至会导致机毁人亡的灾难性事故。然而,迄今为止有关离心压缩机的研究并未有突破性进展,因此这方面的研究是本领域的前沿热点,本文对此进行了若干尝试性的工作,现将主要的工作与结果总结如下:
1.对无叶扩压器旋转失速的起因进行了新解释,研究方法主要包括数值模拟以及数值结果与实验结果对比。本文采用了二维数值模拟方法对无叶扩压器从核心区流动失稳的角度进行了研究,计算中需要在叶轮出口给定射流-尾迹的边界条件。计算结果表明无叶扩压器内的确存在与边界层关系不大的,而与小流量下叶轮出口的射流-尾迹结构密切相关的一种旋转失速形式。从射流-尾迹的结构来说,射流与尾迹在周向所占据范围的比例对失速临界角具有很大的影响,而射流和尾迹的强度比则对失速几乎没有影响。文中同时还研究了其它参数对旋转失速起始和失速特性的影响;
2.首先建立了基于实数编码遗传算法优化初始权值的小波神经网络,然后利用该工具对现有文献中有关无叶扩压器旋转失速研究的数据进行分析,从而发现在b3/D2≈0.05附近,无叶扩压器几何参数对失速特性的影响差异较大,这也就验证了上一章提出的不同宽度扩压器可能存在不同失速机理的假设;另外有关无叶扩压器失速特征的实验研究中在扩压器后均不存在后续部件蜗壳,因此作者认为还需要分析蜗壳的影响,在意大利佛罗伦萨大学学者的帮助下,作者对新比隆公司的某多级压缩级末级的失速数据进行分析,结果发现蜗壳的确对无叶扩压器的失速特性有影响,但这种影响与叶轮的出口宽度有关,当叶轮出口宽度较大时,失速临界角预测可以不考虑下游蜗壳的影响;
3.尽管上述两部分对无叶扩压器的失速机理和影响因素进行了分析,然而可能更需要关注的是如何扩展给定的无叶扩压器的稳定性范围,即推迟失速临界角。作者对日本横滨国立大学所用的径向开槽方法进行了详细的数值模拟,并分析了开槽对扩压器流场的影响,在这些分析的基础上,建立了槽内流动的理论模型,并将其与实验结果进行了对比,随后作者建立了开槽参数的选取准则,从而为实际工业提供指导,最后是法国南特中央理工学院利用该准则进行的实验,实验结果验证了该准则的正确性;
4.前述部分关注的是无叶扩压器的失速问题,而对于离心压缩机中的离心风机,由于叶轮出口的动压较小,同时处于制造成本的考虑,在叶轮和蜗壳之间一般并不采用无叶扩压器,因此此类风机的失速研究,必须要考虑叶轮和蜗壳的相互影响。本部分利用了数值模拟和实验研究手段分析了蜗壳+5种叶轮组合在不同流量下压缩机内部流场和动态速度信号的变化,得到了叶轮和蜗壳对系统稳定性的影响;此外还分析了叶轮内部各个通道的流量以及蜗壳内部流动结构随流量的关系,并提出了蜗舌内循环流量与有效增压的蜗壳出流量之比这一参数作为判断系统逼近失稳的依据;
5.最后一部分从系统角度对课题组研发的转速为52000rpm的二级高速离心压缩机的喘振特性进行了研究,主要是采用复Morlet小波对不同位置采集到的压力信号从时频角度进行了分析,从而探讨了系统的喘振过程和引起失稳的可能部件,由于压力信号采集中采用了引压管,为此还对引压管的频率响应特性进行了理论和实验研究。在喘振信号分析的基础上,作者还提出了基于标准差变换系数的喘振先兆预警方法,并将该方法应用于本文的实验结果以及波兰Lord理工大学的某离心鼓风机实验台,结果表明该方法可用于喘振预警,但方法的有效性很大程度上取决于传感器的位置,故文中还探讨了压力传感器位置选取对喘振先兆的影响。
本文上述五个方面分别从离心压缩机的部件和系统的角度研究了压缩机的旋转失速和喘振,研究方法包括实验和理论建模。尽管其不能彻底解决问题,但也是从某些角度丰富了离心压缩机失速和喘振的发生机理、预测与基于先兆信号的预警分析等诸多内容,并在一定程度上有助于指导带无叶扩压器的离心压缩机的扩稳设计与安全运行。
Centrifugal Compressor is a kind of general purpose machinery for improvinggas pressure, which is widely used in many fields, plays an important role and con-sumes huge amount of energy. In recent years, the energy situation also puts forwardstringent requirements on the design of centrifugal compressors, i.e., higher pressureratio, higher efficiency,and wider working range. In these factors, the last one is themost prominent one, if possible, which can decrease the matching difficulties of au-tomotive turbochargers and increase the heating and electricity ratio of CHP system.Besides choke, stall and surge are the main causes for the limitation of stable oper-ation, hinderance of stage matching of centrifugal compressors. If not properly con-trolled, they even can lead to catastrophic disasters. However, until now, there are stillno theoretical breakthroughs especially for radial compressors. Thus, there are stillneeds to do further research until the final a final solution was found. In the followingpart, the author sums the related works and contributions to this filed which were doneduring his study for pursuing doctor’s degree.
1.Making new explanations about the occurrences of rotating stall. Researchmethods include numerical simulation and comparison between numerical results andexperimental results. Taking the limitations of computational resources and quanti-ties of adjusting parameters, two-dimensional simulation was adopted to investigaterotating stall from the point of core ?ow instability. The results indicate that theredoes exist a kind of stall mechanism which has little relationship with boundary layer.After the confirmation, the authors also studied the inffuences of geometry and ?owparameters on stall inception and mature stall characteristics.
2. Establishing a neural network with genetic optimized initial weights and an-alyzing the experimental data on rotating stall in open literature. It was found thatdiffuser geometric parameters have distinct effects on rotating stall when the parame-ter b3/D2≈0.05. In this section, the in?uences of downstream component was alsoinvestigated with data from Florence University, Italy. It is shown that the in?uencesof volute should be considered with impeller outlet width to outlet diameter ratio lessthan a certain value.
3. Adopting radial grooves on the diffuser walls for passive control of rotatingstall. Firstly, detailed numerical study was adopted to study the in?uences of grooveson the ?ow field in vaneless diffuser; then the groove ?ow was modeled theoretically;lastly, the author made a guideline for choosing groove parameters. Fortunately, theguidelines and the groove method were put into real industry turbocharger for test inEcole Centrale de Nantes. The initial findings agree well with our theoretical results.
4. Analyzing mutual interactions between impeller and volute on the inception ofrotating stall and surge. Research tools include CFD (computational ?uid dynamics),PIV and hot-wire anemometry. Through the research, the author not only answerthe question that why the optimized impeller configuration is the one with narrowestworking range but also the abnormal phenomenon that the efficiency of back-curvedimpeller configuration was even lower than the forward-curved one.
5. Surge characteristics and pathology were analyzed through the pressure sig-nals acquired from different positions on a two-stage centrifugal compressor. Thefrequency response characteristics were also studied experimentally and theoretically.Based on the former research and understanding of the system, the author put forwarda new surge detection variable called coefficient of standard deviation which couldfind surge precursor and advance the time of warning.
The above five sections investigated rotating stall and surge in centrifugal com-pressor. The research tools include experiments and theoretical modeling. Even itcouldn’t solve the problems completely, it does enrich the scenario of rotating stalland surge and is helpful for guiding the design of centrifugal compressor with vane-less diffuser and its production.
1.对无叶扩压器旋转失速的起因进行了新解释,研究方法主要包括数值模拟以及数值结果与实验结果对比。本文采用了二维数值模拟方法对无叶扩压器从核心区流动失稳的角度进行了研究,计算中需要在叶轮出口给定射流-尾迹的边界条件。计算结果表明无叶扩压器内的确存在与边界层关系不大的,而与小流量下叶轮出口的射流-尾迹结构密切相关的一种旋转失速形式。从射流-尾迹的结构来说,射流与尾迹在周向所占据范围的比例对失速临界角具有很大的影响,而射流和尾迹的强度比则对失速几乎没有影响。文中同时还研究了其它参数对旋转失速起始和失速特性的影响;
2.首先建立了基于实数编码遗传算法优化初始权值的小波神经网络,然后利用该工具对现有文献中有关无叶扩压器旋转失速研究的数据进行分析,从而发现在b3/D2≈0.05附近,无叶扩压器几何参数对失速特性的影响差异较大,这也就验证了上一章提出的不同宽度扩压器可能存在不同失速机理的假设;另外有关无叶扩压器失速特征的实验研究中在扩压器后均不存在后续部件蜗壳,因此作者认为还需要分析蜗壳的影响,在意大利佛罗伦萨大学学者的帮助下,作者对新比隆公司的某多级压缩级末级的失速数据进行分析,结果发现蜗壳的确对无叶扩压器的失速特性有影响,但这种影响与叶轮的出口宽度有关,当叶轮出口宽度较大时,失速临界角预测可以不考虑下游蜗壳的影响;
3.尽管上述两部分对无叶扩压器的失速机理和影响因素进行了分析,然而可能更需要关注的是如何扩展给定的无叶扩压器的稳定性范围,即推迟失速临界角。作者对日本横滨国立大学所用的径向开槽方法进行了详细的数值模拟,并分析了开槽对扩压器流场的影响,在这些分析的基础上,建立了槽内流动的理论模型,并将其与实验结果进行了对比,随后作者建立了开槽参数的选取准则,从而为实际工业提供指导,最后是法国南特中央理工学院利用该准则进行的实验,实验结果验证了该准则的正确性;
4.前述部分关注的是无叶扩压器的失速问题,而对于离心压缩机中的离心风机,由于叶轮出口的动压较小,同时处于制造成本的考虑,在叶轮和蜗壳之间一般并不采用无叶扩压器,因此此类风机的失速研究,必须要考虑叶轮和蜗壳的相互影响。本部分利用了数值模拟和实验研究手段分析了蜗壳+5种叶轮组合在不同流量下压缩机内部流场和动态速度信号的变化,得到了叶轮和蜗壳对系统稳定性的影响;此外还分析了叶轮内部各个通道的流量以及蜗壳内部流动结构随流量的关系,并提出了蜗舌内循环流量与有效增压的蜗壳出流量之比这一参数作为判断系统逼近失稳的依据;
5.最后一部分从系统角度对课题组研发的转速为52000rpm的二级高速离心压缩机的喘振特性进行了研究,主要是采用复Morlet小波对不同位置采集到的压力信号从时频角度进行了分析,从而探讨了系统的喘振过程和引起失稳的可能部件,由于压力信号采集中采用了引压管,为此还对引压管的频率响应特性进行了理论和实验研究。在喘振信号分析的基础上,作者还提出了基于标准差变换系数的喘振先兆预警方法,并将该方法应用于本文的实验结果以及波兰Lord理工大学的某离心鼓风机实验台,结果表明该方法可用于喘振预警,但方法的有效性很大程度上取决于传感器的位置,故文中还探讨了压力传感器位置选取对喘振先兆的影响。
本文上述五个方面分别从离心压缩机的部件和系统的角度研究了压缩机的旋转失速和喘振,研究方法包括实验和理论建模。尽管其不能彻底解决问题,但也是从某些角度丰富了离心压缩机失速和喘振的发生机理、预测与基于先兆信号的预警分析等诸多内容,并在一定程度上有助于指导带无叶扩压器的离心压缩机的扩稳设计与安全运行。
Centrifugal Compressor is a kind of general purpose machinery for improvinggas pressure, which is widely used in many fields, plays an important role and con-sumes huge amount of energy. In recent years, the energy situation also puts forwardstringent requirements on the design of centrifugal compressors, i.e., higher pressureratio, higher efficiency,and wider working range. In these factors, the last one is themost prominent one, if possible, which can decrease the matching difficulties of au-tomotive turbochargers and increase the heating and electricity ratio of CHP system.Besides choke, stall and surge are the main causes for the limitation of stable oper-ation, hinderance of stage matching of centrifugal compressors. If not properly con-trolled, they even can lead to catastrophic disasters. However, until now, there are stillno theoretical breakthroughs especially for radial compressors. Thus, there are stillneeds to do further research until the final a final solution was found. In the followingpart, the author sums the related works and contributions to this filed which were doneduring his study for pursuing doctor’s degree.
1.Making new explanations about the occurrences of rotating stall. Researchmethods include numerical simulation and comparison between numerical results andexperimental results. Taking the limitations of computational resources and quanti-ties of adjusting parameters, two-dimensional simulation was adopted to investigaterotating stall from the point of core ?ow instability. The results indicate that theredoes exist a kind of stall mechanism which has little relationship with boundary layer.After the confirmation, the authors also studied the inffuences of geometry and ?owparameters on stall inception and mature stall characteristics.
2. Establishing a neural network with genetic optimized initial weights and an-alyzing the experimental data on rotating stall in open literature. It was found thatdiffuser geometric parameters have distinct effects on rotating stall when the parame-ter b3/D2≈0.05. In this section, the in?uences of downstream component was alsoinvestigated with data from Florence University, Italy. It is shown that the in?uencesof volute should be considered with impeller outlet width to outlet diameter ratio lessthan a certain value.
3. Adopting radial grooves on the diffuser walls for passive control of rotatingstall. Firstly, detailed numerical study was adopted to study the in?uences of grooveson the ?ow field in vaneless diffuser; then the groove ?ow was modeled theoretically;lastly, the author made a guideline for choosing groove parameters. Fortunately, theguidelines and the groove method were put into real industry turbocharger for test inEcole Centrale de Nantes. The initial findings agree well with our theoretical results.
4. Analyzing mutual interactions between impeller and volute on the inception ofrotating stall and surge. Research tools include CFD (computational ?uid dynamics),PIV and hot-wire anemometry. Through the research, the author not only answerthe question that why the optimized impeller configuration is the one with narrowestworking range but also the abnormal phenomenon that the efficiency of back-curvedimpeller configuration was even lower than the forward-curved one.
5. Surge characteristics and pathology were analyzed through the pressure sig-nals acquired from different positions on a two-stage centrifugal compressor. Thefrequency response characteristics were also studied experimentally and theoretically.Based on the former research and understanding of the system, the author put forwarda new surge detection variable called coefficient of standard deviation which couldfind surge precursor and advance the time of warning.
The above five sections investigated rotating stall and surge in centrifugal com-pressor. The research tools include experiments and theoretical modeling. Even itcouldn’t solve the problems completely, it does enrich the scenario of rotating stalland surge and is helpful for guiding the design of centrifugal compressor with vane-less diffuser and its production.
引文
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