车用发动机智能冷却系统基础问题研究
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摘要
车辆及发动机技术的发展、能源与环境问题的涌现和人们使用需求的提升使冷却系统的功能定义不断演变、技术路径不断进化、性能要求不断提升,冷却系统已不再是以冷却为唯一目标的辅助配置,而是在车辆起动、行驶、停机等各个工作阶段,需满足排放法规、经济性需求、动力需求、舒适性需求以及可靠性与耐久性的综合性系统。智能化是兼顾各种问题与需求的关键技术,是车辆及发动机冷却系统的进化与发展趋势。但智能化并非孤立的技术手段,而与其他技术路径相辅相承；智能冷却系统各部件的运行亦非孤立,而是依据车辆行驶路况及发动机运行工况的变化协同工作。正因如此,在车辆及发动机运行的全工况下针对多个目标作系统化协调控制运行成为智能冷却系统技术的关键问题。
本文通过试验研究为主数值仿真为辅的手段,研究了车用发动机智能冷却系统的基础问题,制定了基于电子水泵、电子风扇、电子节温器和电加热器的发动机全工况智能冷却系统控制策略,并予以试验验证,旨在按需调节冷却液温度实现精确冷却,并在起动阶段缩短暖机时间,在停机之后避免热浸现象,从而提高燃油经济性、整机可靠性并减少污染物排放。本文的主要工作内容包括：
1.建立了包含发动机台架试验系统、车载试验系统和风洞试验系统的乘用车智能冷却系统试验研究平台,提出用环境温度、冷却液散热量、冷却风速、发动机的转速与负荷率等参数在三个试验系统之间传递数据的方法,并为提高冷却液散热量的测量计算精度设计了一种基于对联热电偶的小温差测量新方法,并验证了其测量误差可控制在士0.04℃。
2.开展了智能冷却控制系统脉谱图(MAP)研究。基于上述三个试验系统分别开展了发动机热平衡研究、车辆迎风冷却强度研究以及包含冷却模块散热性能、冷却水泵特性和冷却风扇特性在内的机外冷却系统部件工作特性研究,制定了智能冷却控制系统MAP。研究表明：以环境温度、车速、发动机转速和负荷率为输入量,以风扇转速和水泵转速为输出量,可用8个关系式确定地描述其内在联系,并以此为基础以风扇与水泵功率之和最小化为原则,制定了由冷却液散热量MAP、水泵转速MAP和风扇转速MAP组成的智能冷却控制系统MAP。
3.开展了稳态工况下发动机内部冷却状况的数值仿真研究。使用计算流体动力学(CFD, Computational Fluid Dynamics)和数值传热学(NHT, Numerical Heat Transfer))方法对冷却水套内冷却液的流动与传热进行了模拟分析。结果表明：冷却液流量对发动机内部冷却状况影响显著,若以过热区域为评价标准,在发动机工作过程中存在安全流量qcs。本文提出了以冷却液散热量Qc为基准进行工况划分的方法,获得qcs-Qc曲线,并依此对智能冷却控制系统MAP作安全修正。
4.开展了发动机暖机及后冷却控制技术研究。研究对比了采用电加热器进行同步加热、预加热以及联合加热的多个辅助加热方案对暖机过程温升时间和燃油消耗的影响,并开展了采用模糊控制的电子节温器在暖机过程中对冷却液温度实行精确调节的研究,最后研究了基于电子风扇和电子水泵联合调节的热态停机后冷却控制技术。结果表明：采用电加热器的各个辅助加热方案均可显著缩短暖机时间,同时降低燃油消耗,但改善水平各有千秋,暖机时间减幅和净节油率最高可达66.1%和32.7%；采用模糊控制的电子节温器可有效降低节温器初次开启时的温度波动至2.2℃以内,并迅速稳定在目标值附近,波动小于1℃；多个后冷却技术方案中,单独开启水泵以最低转速续流的方式为最优,既可有效避免停机热浸现象发生,又可节约能耗。
5.开展了智能冷却系统集成控制技术研究。将上述结果与结论进行综合研究,形成了基于电子水泵、电子风扇、电子节温器和电加热器的发动机全工况控制策略,并在实验室中建立了控制系统,选取典型工况进行了试验验证。结果表明：相比原机冷却系统而言,以MAP前馈+PID反馈和模糊控制为主要控制策略的智能冷却系统能够明显缩短暖机时间、更精确地控制发动机冷却液温度、有效抑制发动机停机后的热浸现象,并且更加节能。
In order to face the energy and environmental challenges and to meet the demanding customer needs, engine cooling system has been expanding and extending its functional envelop along with the rapid development of vehicle and engine technology. With the rigorous performance requirements, the technical roadmap of cooling system has been evolving, from an auxiliary component only for cooling as before, to a comprehensive thermal management system to help vehicle meet the demands of emission regulations, fuel economy, traction performance, ride comfort, reliability and durability during all operating conditions (e.g. start-up, driving, and stop). Intelligent cooling management is the key technology to take all crucial demands into consideration, and it is the very future technology with the evolution and development of cooling system. Intelligent cooling management is meant to coordinate different cooling components according to the variation of the road and engine conditions. Therefore, it is important to design and develop a systematic and coordinated control system, aiming to satisfy multiple objectives under all operating conditions of engine.
This dissertation studied the fundamental problems of intelligent cooling system through experimental investigation and simulation. The control strategy of cooling system was designed to cover all operating conditions of engine, and then the validation experiments were completed. The target of control strategy is to adjust the temperature of coolant to realize accurate cooling, and to shorten the warm-up time during start-up and to avoid heat soak after engine shutdown. Therefore, the fuel economy and reliability of engine can be improved, and the pollutant emission can be reduced.
The main contents of the thesis are as follows:
1. The experimental platform of intelligent cooling system on passenger vehicles was established, which included the engine test system, vehicle mounted test system and wind-tunnel test system. Then the data fusion method among the three sub-systems was proposed using parameters such as ambient temperature, heat rejection of coolant, velocity of cooling air, engine speed and load. In addition, a new test method of small temperature difference was designed to improve the test accuracy of heat rejection of coolant based on compound thermal couple, it was validated that the measurement error is within the range of±0.04℃.
2. The study of intelligent cooling system MAP was completed. Based on the three systems mentioned above, research have been completed on (1) engine heat balance,(2) vehicle windward cooling and (3) the characteristics of external cooling system (including heat rejection performance of cooling module, cooling pump and fan properties). Then the system MAP was designed and improved. The results show:with ambient temperature, vehicle speed, engine speed and load as the inputs, and cooling fan and pump speed as the outputs, the internal relation between inputs and outputs can be described using8equations. Based on these results, the MAPs of coolant heat rejection, pump and fan speed were made in order to minimize the total power consumption of cooling pump and fan. Then the MAPs were combined to the MAP of the entire cooling system.
3. The cooling control technology of engine warm-up and post-cooling was studied. Using the electric heater as the heating device, different auxiliary heating schemes, including synchro heating, preheating and combined heating, were compared in the respect of the coolant temperature warm-up period and fuel consumption. An electric thermostat based on fuzzy control was designed to realize the accurate adjustment of coolant temperature. Finally, the post-cooling cooling control technology was studied based on combined regulation of electric fan and pump. The results show that the auxiliary heating schemes could apparently shorten the warm-up time and lower the fuel consumption. However, the effects of different schemes were different, with maximum time reduction of66.1%and fuel consumption reduction of32.7%, respectively. The coolant temperature fluctuation can be reduced to2.2℃with the application of electric thermostat, and it can rapidly approach to the steady target state, with the fluctuation less than1℃. The best post-cooling scheme is the running only pump at minimum speed, and it can avoid overheat after engine shutdown, as well as save power consumption.
4. The numerical simulation was carried out to study engine internal cooling under steady conditions. The flow and heat transfer of coolant inside the water jacket was analyzed according to theories of Computational Fluid Dynamics and Numerical Heat Transfer. The results show that the mass flow rate of coolant has obvious and significant effect on the cooling status inside engine. There is a safety mass flow rate qcs during the working process of engine, considering the overheat area minimization as the criterion. A method of engine operating conditions division was proposed with heat rejection of coolant Qc as reference, and then the qcs-Qc curve was acquired and used to modify the cooling system MAP.
5. The integrated control technology of intelligent cooling system was studied. The results and conclusions found above were composed to form the complete control strategy covering all operating conditions of engine. The control system was established and validated with tests under typical conditions. The results show that compared to the original cooling system, the control strategy combining MAP-based forward, PID-based backward and fuzzy control can reduce the warm-up time, adjust coolant temperature more accurately, and effectively avoid heat soak after engine shutdown, as well as lower the power consumption.
本文通过试验研究为主数值仿真为辅的手段,研究了车用发动机智能冷却系统的基础问题,制定了基于电子水泵、电子风扇、电子节温器和电加热器的发动机全工况智能冷却系统控制策略,并予以试验验证,旨在按需调节冷却液温度实现精确冷却,并在起动阶段缩短暖机时间,在停机之后避免热浸现象,从而提高燃油经济性、整机可靠性并减少污染物排放。本文的主要工作内容包括：
1.建立了包含发动机台架试验系统、车载试验系统和风洞试验系统的乘用车智能冷却系统试验研究平台,提出用环境温度、冷却液散热量、冷却风速、发动机的转速与负荷率等参数在三个试验系统之间传递数据的方法,并为提高冷却液散热量的测量计算精度设计了一种基于对联热电偶的小温差测量新方法,并验证了其测量误差可控制在士0.04℃。
2.开展了智能冷却控制系统脉谱图(MAP)研究。基于上述三个试验系统分别开展了发动机热平衡研究、车辆迎风冷却强度研究以及包含冷却模块散热性能、冷却水泵特性和冷却风扇特性在内的机外冷却系统部件工作特性研究,制定了智能冷却控制系统MAP。研究表明：以环境温度、车速、发动机转速和负荷率为输入量,以风扇转速和水泵转速为输出量,可用8个关系式确定地描述其内在联系,并以此为基础以风扇与水泵功率之和最小化为原则,制定了由冷却液散热量MAP、水泵转速MAP和风扇转速MAP组成的智能冷却控制系统MAP。
3.开展了稳态工况下发动机内部冷却状况的数值仿真研究。使用计算流体动力学(CFD, Computational Fluid Dynamics)和数值传热学(NHT, Numerical Heat Transfer))方法对冷却水套内冷却液的流动与传热进行了模拟分析。结果表明：冷却液流量对发动机内部冷却状况影响显著,若以过热区域为评价标准,在发动机工作过程中存在安全流量qcs。本文提出了以冷却液散热量Qc为基准进行工况划分的方法,获得qcs-Qc曲线,并依此对智能冷却控制系统MAP作安全修正。
4.开展了发动机暖机及后冷却控制技术研究。研究对比了采用电加热器进行同步加热、预加热以及联合加热的多个辅助加热方案对暖机过程温升时间和燃油消耗的影响,并开展了采用模糊控制的电子节温器在暖机过程中对冷却液温度实行精确调节的研究,最后研究了基于电子风扇和电子水泵联合调节的热态停机后冷却控制技术。结果表明：采用电加热器的各个辅助加热方案均可显著缩短暖机时间,同时降低燃油消耗,但改善水平各有千秋,暖机时间减幅和净节油率最高可达66.1%和32.7%；采用模糊控制的电子节温器可有效降低节温器初次开启时的温度波动至2.2℃以内,并迅速稳定在目标值附近,波动小于1℃；多个后冷却技术方案中,单独开启水泵以最低转速续流的方式为最优,既可有效避免停机热浸现象发生,又可节约能耗。
5.开展了智能冷却系统集成控制技术研究。将上述结果与结论进行综合研究,形成了基于电子水泵、电子风扇、电子节温器和电加热器的发动机全工况控制策略,并在实验室中建立了控制系统,选取典型工况进行了试验验证。结果表明：相比原机冷却系统而言,以MAP前馈+PID反馈和模糊控制为主要控制策略的智能冷却系统能够明显缩短暖机时间、更精确地控制发动机冷却液温度、有效抑制发动机停机后的热浸现象,并且更加节能。
In order to face the energy and environmental challenges and to meet the demanding customer needs, engine cooling system has been expanding and extending its functional envelop along with the rapid development of vehicle and engine technology. With the rigorous performance requirements, the technical roadmap of cooling system has been evolving, from an auxiliary component only for cooling as before, to a comprehensive thermal management system to help vehicle meet the demands of emission regulations, fuel economy, traction performance, ride comfort, reliability and durability during all operating conditions (e.g. start-up, driving, and stop). Intelligent cooling management is the key technology to take all crucial demands into consideration, and it is the very future technology with the evolution and development of cooling system. Intelligent cooling management is meant to coordinate different cooling components according to the variation of the road and engine conditions. Therefore, it is important to design and develop a systematic and coordinated control system, aiming to satisfy multiple objectives under all operating conditions of engine.
This dissertation studied the fundamental problems of intelligent cooling system through experimental investigation and simulation. The control strategy of cooling system was designed to cover all operating conditions of engine, and then the validation experiments were completed. The target of control strategy is to adjust the temperature of coolant to realize accurate cooling, and to shorten the warm-up time during start-up and to avoid heat soak after engine shutdown. Therefore, the fuel economy and reliability of engine can be improved, and the pollutant emission can be reduced.
The main contents of the thesis are as follows:
1. The experimental platform of intelligent cooling system on passenger vehicles was established, which included the engine test system, vehicle mounted test system and wind-tunnel test system. Then the data fusion method among the three sub-systems was proposed using parameters such as ambient temperature, heat rejection of coolant, velocity of cooling air, engine speed and load. In addition, a new test method of small temperature difference was designed to improve the test accuracy of heat rejection of coolant based on compound thermal couple, it was validated that the measurement error is within the range of±0.04℃.
2. The study of intelligent cooling system MAP was completed. Based on the three systems mentioned above, research have been completed on (1) engine heat balance,(2) vehicle windward cooling and (3) the characteristics of external cooling system (including heat rejection performance of cooling module, cooling pump and fan properties). Then the system MAP was designed and improved. The results show:with ambient temperature, vehicle speed, engine speed and load as the inputs, and cooling fan and pump speed as the outputs, the internal relation between inputs and outputs can be described using8equations. Based on these results, the MAPs of coolant heat rejection, pump and fan speed were made in order to minimize the total power consumption of cooling pump and fan. Then the MAPs were combined to the MAP of the entire cooling system.
3. The cooling control technology of engine warm-up and post-cooling was studied. Using the electric heater as the heating device, different auxiliary heating schemes, including synchro heating, preheating and combined heating, were compared in the respect of the coolant temperature warm-up period and fuel consumption. An electric thermostat based on fuzzy control was designed to realize the accurate adjustment of coolant temperature. Finally, the post-cooling cooling control technology was studied based on combined regulation of electric fan and pump. The results show that the auxiliary heating schemes could apparently shorten the warm-up time and lower the fuel consumption. However, the effects of different schemes were different, with maximum time reduction of66.1%and fuel consumption reduction of32.7%, respectively. The coolant temperature fluctuation can be reduced to2.2℃with the application of electric thermostat, and it can rapidly approach to the steady target state, with the fluctuation less than1℃. The best post-cooling scheme is the running only pump at minimum speed, and it can avoid overheat after engine shutdown, as well as save power consumption.
4. The numerical simulation was carried out to study engine internal cooling under steady conditions. The flow and heat transfer of coolant inside the water jacket was analyzed according to theories of Computational Fluid Dynamics and Numerical Heat Transfer. The results show that the mass flow rate of coolant has obvious and significant effect on the cooling status inside engine. There is a safety mass flow rate qcs during the working process of engine, considering the overheat area minimization as the criterion. A method of engine operating conditions division was proposed with heat rejection of coolant Qc as reference, and then the qcs-Qc curve was acquired and used to modify the cooling system MAP.
5. The integrated control technology of intelligent cooling system was studied. The results and conclusions found above were composed to form the complete control strategy covering all operating conditions of engine. The control system was established and validated with tests under typical conditions. The results show that compared to the original cooling system, the control strategy combining MAP-based forward, PID-based backward and fuzzy control can reduce the warm-up time, adjust coolant temperature more accurately, and effectively avoid heat soak after engine shutdown, as well as lower the power consumption.
引文
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