一种大功率气体燃料发动机电控喷射装置的研究
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摘要
气体燃料发动机有着有害污染物和二氧化碳排放量相对少的优势,不仅在高效清洁利用能源,而且在有效利用工业可燃废气等方面均可以发挥重要作用,节能减排与环境保护推动着气体燃料发动机的技术进步与广泛应用。
气体燃料电控喷射装置的应用,可实现多点顺序间歇供气方式在发动机各缸进气道前顺序间歇(一般在进气过程中)供入气体燃料,可以有效解决发动机进气道及进气管内回火、扫气阶段气体燃料流失等问题,改善发动机性能,适用于各类气体燃料,所需气体燃料的压力较低,特别适用于需要大流量、低压力的供气场合。为了实现在气体燃料发动机经济性、动力性及排放指标等方面达到国外先进水平,同时对各类不同成份、热值的可燃气体具有良好适应性的目标,必须深入研究作为关键技术的气体燃料电控喷射装置。论文提出了一类应用动圈式电磁直线执行器和菌型阀结构的气体燃料电控喷射装置,并通过理论分析、仿真计算以及与试验研究相结合的方法对其结构设计、流量特性、控制技术等进行了深入系统地研究,为其工程化应用以及大功率气体燃料发动机性能提升打下了良好的基础。
论文的主要工作和研究成果包括以下几个方面：
(1)分析了气体燃料电控喷射装置的国内外研究现状,提出了一类应用动圈式电磁直线执行器和菌型阀结构的气体燃料电控喷射装置,对喷射装置的结构、主要设计参数和控制器设计等进行了深入研究,最终研制出了气体燃料电控喷射装置样件并进行了试验验证。测试结果表明,喷射装置的过渡时间为5ms,最大气门升程可达4mm,工作稳定可靠,满足大功率气体燃料发动机对喷射装置的大流量、高响应等要求。
(2)建立了气体燃料喷射装置的流动数值模拟计算模型,分析了稳态和非稳态工况下的流量特性并进行了试验验证。明确了电控喷射装置的流量特性随着气门升程、气门外径、压差以及气门开启时间等主要设计及控制参数变化的规律,建立了可直接用于气体燃料喷射量调节控制的气体燃料喷射量和气门总开启时间的映射关系,为气体燃料电控喷射装置在发动机上的应用打下了良好的基础。
(3)确定了气体燃料喷射装置在发动机上的布置方案,并讨论了应用喷射装置后发动机性能改进的技术途径。设计了发动机整机控制器,提出了以发动机转速为目标的闭环控制以及模拟信号输入端口和PWM控制信号输出端口多路复用的技术方案。进一步针对应用电控喷射装置的发动机性能改善的技术途径进行了分析,并提出了发动机改进设计方案,分析了控制器综合设计应实现的功能,对发动机空燃比进行闭环控制,并给出了改进的发动机控制器方案。
(4)建立了气体燃料发动机应用电控喷射装置后的非稳态CFD计算模型,并在此基础上研究了喷射装置不同的控制参数和安装参数对气体燃料进气和混合气形成过程的影响。分析比较了不同的喷射装置安装位置下气体燃料进气过程的变化情况,并明确了喷射装置靠近燃烧室后对提高气体燃料进气充分程度的优势。确定了气体燃料电控喷射装置喷射脉宽的调节范围,探讨了通过增加气体燃料和进气空气的压力差值来增加喷射量的方法。
(5)完成了应用气体燃料喷射装置的大功率发动机的实机验证性试验。进行了包括发动机起动、怠速稳定性、各缸均匀性调整以及给定转速下增减不同负荷的试验,自行研制的电控喷射装置具备良好的控制特性、高响应速度和低落座速度等优势,能够将气体燃料定时、定量地喷射到发动机每一气缸靠近进气道的进气歧管内,实现多点顺序间歇的供气方式以及对各缸空燃比的实时、准确、独立的调节,验证了技术的可行性。
Gas engine has advantages of less harmful pollutants and CO2emissions. It can play an important role not only in high efficient and clean energy utilization, but also in effective utilization of combustible gas. Energy saving and environment protection can promote the gas engine technology process and application. The adoption of gas fuel electronically controlled injection device realizes multi-point sequential and intermittent supply mode so that it supplies gas fuel to engine inlets sequentially and intermittently. It can effectively solve the problems of backfire in engine inlets and gas fuel loss during scavenging phase, and as a result improve the engine performance. Gas engine is applicable to many types of gas fuel. The gas fuel pressure required is relatively low, especially suitable for large flow rate and low pressure gas supply. In order to achieve the advanced level of engine economy, power and emission index in international, and adapt all kinds of different ingredients and heat value combustible gas perfectly, further study on gas fuel electronically controlled injection device which is the core technology is necessary. This thesis puts forward a kind of adopting moving-coil electromagnetic linear actuator and bacterium type valve gas fuel electronically controlled injection device. The structural design, control strategy, performance and flow characteristics of this device are systematic and deeply studied through the methods of theoretical analysis, simulation calculation and experiment. This thesis lays a good foundation for the further research and application of the heavy-duty gas fuel engine.
(1) The development of gas fuel injection device is analyzed in this study, and an innovation gas fuel injection device using the moving-coil electromagnetic linear actuator and mushrooms type valve structure is proposed. Then, the structure, main design parameters and controller design are deeply researched. Finally the prototype of the injection device is developed and the performance test is completed. The results show that the transition time of the injection device is controlled in5ms, and the maximum valve lift can be reached4mm. The device works stable and reliably, and the technical solution can meet the requirements of high flow rate and response of the engine.
(2) The numerical simulation models are established in this paper. The static and transient flow characteristics of the gas fuel injection device are calculated, and the experimental validation was also completed. The variation law between injection device and the main design and control parameters such as maximum valve lift, valve diameters, pressure differences, and valve open durations is determined. The mapping relationship of the injection quantity of gas fuel and the total opening time of the valve is established, which lays a good foundation for the gas fuel electronically controlled injection device's engineering application.
(3) The layout scheme of gas fuel injection device is determined, and the technology way to improve engine performance after the application of injection device is discussed. Engine controller is developed and control scheme is designed with engine speed as the control target. Analog signal input port and PWM signal output port multiplexing technology is adopted. Moreover, the entire function of engine controller which should realize during integrated design in advanced research is put forward and close-loop control of air fuel ratio is implemented. In the end, the improved engine controller scheme is presented.
(4) The transient CFD numerical simulation model of a gas engine cylinder based on an electronically controlled gas fuel injection device is built, and influences to gas fuel intake and mixing process caused by control parameters and installation parameters of the gas fuel injection device are investigated. The gas fuel intake process is analyzed when the installation of gas fuel injection device is different, and the advantage of higher gas fuel intake sufficient degree is determined when the installation is close to combustion chamber. The injection pulse width regulation range of the electronically controlled gas fuel injection device is determined, and a method of increasing gas injection through increasing the pressure difference between gas fuel and air is discussed.
(5) The real machine confirmatory test of a heavy-duty engine applied with gas fuel injection device is completed. Experiments including engine starting, idle speed stability, uniformity adjustment of each cylinder and load increasing and decreasing under given speed are conducted. The developed gas fuel injection device has the advantages of good control characteristics, high response speed and low seating speed, and can inject the gas fuel into intake manifold close to inlet port of each cylinder at fixed time with fixed quantity. Also it is capable of multi-point sequential intermittent supply method and regulating air-fuel ratio of each cylinder real-time, accurately and independently, which verifies the feasibility of the technology.
气体燃料电控喷射装置的应用,可实现多点顺序间歇供气方式在发动机各缸进气道前顺序间歇(一般在进气过程中)供入气体燃料,可以有效解决发动机进气道及进气管内回火、扫气阶段气体燃料流失等问题,改善发动机性能,适用于各类气体燃料,所需气体燃料的压力较低,特别适用于需要大流量、低压力的供气场合。为了实现在气体燃料发动机经济性、动力性及排放指标等方面达到国外先进水平,同时对各类不同成份、热值的可燃气体具有良好适应性的目标,必须深入研究作为关键技术的气体燃料电控喷射装置。论文提出了一类应用动圈式电磁直线执行器和菌型阀结构的气体燃料电控喷射装置,并通过理论分析、仿真计算以及与试验研究相结合的方法对其结构设计、流量特性、控制技术等进行了深入系统地研究,为其工程化应用以及大功率气体燃料发动机性能提升打下了良好的基础。
论文的主要工作和研究成果包括以下几个方面：
(1)分析了气体燃料电控喷射装置的国内外研究现状,提出了一类应用动圈式电磁直线执行器和菌型阀结构的气体燃料电控喷射装置,对喷射装置的结构、主要设计参数和控制器设计等进行了深入研究,最终研制出了气体燃料电控喷射装置样件并进行了试验验证。测试结果表明,喷射装置的过渡时间为5ms,最大气门升程可达4mm,工作稳定可靠,满足大功率气体燃料发动机对喷射装置的大流量、高响应等要求。
(2)建立了气体燃料喷射装置的流动数值模拟计算模型,分析了稳态和非稳态工况下的流量特性并进行了试验验证。明确了电控喷射装置的流量特性随着气门升程、气门外径、压差以及气门开启时间等主要设计及控制参数变化的规律,建立了可直接用于气体燃料喷射量调节控制的气体燃料喷射量和气门总开启时间的映射关系,为气体燃料电控喷射装置在发动机上的应用打下了良好的基础。
(3)确定了气体燃料喷射装置在发动机上的布置方案,并讨论了应用喷射装置后发动机性能改进的技术途径。设计了发动机整机控制器,提出了以发动机转速为目标的闭环控制以及模拟信号输入端口和PWM控制信号输出端口多路复用的技术方案。进一步针对应用电控喷射装置的发动机性能改善的技术途径进行了分析,并提出了发动机改进设计方案,分析了控制器综合设计应实现的功能,对发动机空燃比进行闭环控制,并给出了改进的发动机控制器方案。
(4)建立了气体燃料发动机应用电控喷射装置后的非稳态CFD计算模型,并在此基础上研究了喷射装置不同的控制参数和安装参数对气体燃料进气和混合气形成过程的影响。分析比较了不同的喷射装置安装位置下气体燃料进气过程的变化情况,并明确了喷射装置靠近燃烧室后对提高气体燃料进气充分程度的优势。确定了气体燃料电控喷射装置喷射脉宽的调节范围,探讨了通过增加气体燃料和进气空气的压力差值来增加喷射量的方法。
(5)完成了应用气体燃料喷射装置的大功率发动机的实机验证性试验。进行了包括发动机起动、怠速稳定性、各缸均匀性调整以及给定转速下增减不同负荷的试验,自行研制的电控喷射装置具备良好的控制特性、高响应速度和低落座速度等优势,能够将气体燃料定时、定量地喷射到发动机每一气缸靠近进气道的进气歧管内,实现多点顺序间歇的供气方式以及对各缸空燃比的实时、准确、独立的调节,验证了技术的可行性。
Gas engine has advantages of less harmful pollutants and CO2emissions. It can play an important role not only in high efficient and clean energy utilization, but also in effective utilization of combustible gas. Energy saving and environment protection can promote the gas engine technology process and application. The adoption of gas fuel electronically controlled injection device realizes multi-point sequential and intermittent supply mode so that it supplies gas fuel to engine inlets sequentially and intermittently. It can effectively solve the problems of backfire in engine inlets and gas fuel loss during scavenging phase, and as a result improve the engine performance. Gas engine is applicable to many types of gas fuel. The gas fuel pressure required is relatively low, especially suitable for large flow rate and low pressure gas supply. In order to achieve the advanced level of engine economy, power and emission index in international, and adapt all kinds of different ingredients and heat value combustible gas perfectly, further study on gas fuel electronically controlled injection device which is the core technology is necessary. This thesis puts forward a kind of adopting moving-coil electromagnetic linear actuator and bacterium type valve gas fuel electronically controlled injection device. The structural design, control strategy, performance and flow characteristics of this device are systematic and deeply studied through the methods of theoretical analysis, simulation calculation and experiment. This thesis lays a good foundation for the further research and application of the heavy-duty gas fuel engine.
(1) The development of gas fuel injection device is analyzed in this study, and an innovation gas fuel injection device using the moving-coil electromagnetic linear actuator and mushrooms type valve structure is proposed. Then, the structure, main design parameters and controller design are deeply researched. Finally the prototype of the injection device is developed and the performance test is completed. The results show that the transition time of the injection device is controlled in5ms, and the maximum valve lift can be reached4mm. The device works stable and reliably, and the technical solution can meet the requirements of high flow rate and response of the engine.
(2) The numerical simulation models are established in this paper. The static and transient flow characteristics of the gas fuel injection device are calculated, and the experimental validation was also completed. The variation law between injection device and the main design and control parameters such as maximum valve lift, valve diameters, pressure differences, and valve open durations is determined. The mapping relationship of the injection quantity of gas fuel and the total opening time of the valve is established, which lays a good foundation for the gas fuel electronically controlled injection device's engineering application.
(3) The layout scheme of gas fuel injection device is determined, and the technology way to improve engine performance after the application of injection device is discussed. Engine controller is developed and control scheme is designed with engine speed as the control target. Analog signal input port and PWM signal output port multiplexing technology is adopted. Moreover, the entire function of engine controller which should realize during integrated design in advanced research is put forward and close-loop control of air fuel ratio is implemented. In the end, the improved engine controller scheme is presented.
(4) The transient CFD numerical simulation model of a gas engine cylinder based on an electronically controlled gas fuel injection device is built, and influences to gas fuel intake and mixing process caused by control parameters and installation parameters of the gas fuel injection device are investigated. The gas fuel intake process is analyzed when the installation of gas fuel injection device is different, and the advantage of higher gas fuel intake sufficient degree is determined when the installation is close to combustion chamber. The injection pulse width regulation range of the electronically controlled gas fuel injection device is determined, and a method of increasing gas injection through increasing the pressure difference between gas fuel and air is discussed.
(5) The real machine confirmatory test of a heavy-duty engine applied with gas fuel injection device is completed. Experiments including engine starting, idle speed stability, uniformity adjustment of each cylinder and load increasing and decreasing under given speed are conducted. The developed gas fuel injection device has the advantages of good control characteristics, high response speed and low seating speed, and can inject the gas fuel into intake manifold close to inlet port of each cylinder at fixed time with fixed quantity. Also it is capable of multi-point sequential intermittent supply method and regulating air-fuel ratio of each cylinder real-time, accurately and independently, which verifies the feasibility of the technology.
引文
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