基于柴油机万有特性分析的进出口独立控制挖掘机节能研究
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摘要
挖掘机采用泵阀复合进出口独立控制液压系统较传统抗流量饱和的负载敏感系统(LUDV)可显著降低阀口工作压差,提高能量利用效率,同时降低柴油机转速及其扭矩输出,改善柴油机的燃油经济性,但在动臂下降、回转制动工况时液压系统功率输出较小,柴油机工作于低负荷工况,尚有较大节油空间。为优化柴油机工作区域,进一步提高泵阀复合进出口独立控制挖掘机的整机经济性,提出基于柴油机万有特性分析的柴油机-液压泵功率匹配方案。通过对比泵阀复合进出口独立控制系统与LUDV系统的动臂工作特性和回转特性,明确动臂单动作、回转单动作时的功率范围,并依据柴油机万有特性曲线,分析2个系统在相应工况时柴油机的工作区域,指出对于泵阀复合进出口独立控制系统,当动臂下降、回转制动时,柴油机输出功率远小于1 800 r·min~(-1)所对应的额定功率。为改善此工况时柴油机的经济性,基于柴油机三缸工作模式和柴油机两缸工作模的万有特性曲线,确定功率匹配的控制策略,当挖掘机动臂举升时,柴油机全部气缸工作,动臂下降时,柴油机采用两缸工作模式;当以最大半径回转启动时,柴油机全部气缸工作;以最小半径回转启动时,柴油机采用三缸工作模式;回转制动阶段,柴油机工作于两缸模式。建立整机动力系统试验平台,进行动力性和经济性比较试验。试验结果表明:在满足的动力性的前提下,采用柴油机多个气缸停缸技术,动臂单动作举升过程中降低燃油消耗20%,在最大半径回转过程中,可降低燃油消耗40%,在最小半径回转过程中,燃油消耗降低20%,节能效果明显。
Compared with the traditional LUDV(load-independent flow distribution system) system, an excavator with a pump and valve combined with a separate meter-in and meter-out circuit can significantly decrease pressure losses through the valve and improve energy efficiency. The speed and output torque of the diesel engine decrease simultaneously, and the fuel economy of the engine is improved. While the power consumption of the hydraulic system is lower during the boom declined and the swing brake, the diesel engine can work under low-load conditions. To optimize the working area of the diesel engine and further improve the economy of the excavator the operating ranges of the diesel engine to further improve the whole machine economy of the excavator with pump and valve combined separate meter-in and meter-out circuit, a diesel-hydraulic pump power matching scheme is proposed based on the analysis of the universal characteristics of a diesel engine. By comparing the working characteristics of the boom and the swing characteristics of the pump and valve combined with a separate meter-in and meter-out circuit and LUDV system, the power range of the boom action and swing action were specified, and the working area of the diesel engine under the corresponding conditions for these two system were analyzed according to the universal characteristic curve. The output power of the diesel engine is much lower than the power rating at 1 800 r·min~(-1). To improve the economy of diesel engine in these conditions, based on the universal characteristics curves of diesel engine In three-cylinder mode(the first cylinder is stopped in which fuel is off), two-cylinder mode(the first and the fourth cylinder are stopped in which fuel is off),the control strategy of power matching was established. The diesel engine worked with all the cylinders during lifting boom and worked in the two-cylinder mode in declining boom. The diesel engine worked with all the cylinders during swing with the maximum turning radius, while it worked in the three-cylinder mode during launch with minimum turning radius and in the two-cylinder mode during swing braking. A power system test platform was established and comparison experiments with corresponding conditions of the dynamic and economic were tested. The test results show that in the premise of satisfying the power performance, the fuel consumption of the diesel engine can be reduced by 20% during the process of single action lifting of the boom, by 40% during the process of swing with maximum radius, and by 20% during the process of swing with minimum radius when the cylinder deactivation of diesel engine was adopted.
Compared with the traditional LUDV(load-independent flow distribution system) system, an excavator with a pump and valve combined with a separate meter-in and meter-out circuit can significantly decrease pressure losses through the valve and improve energy efficiency. The speed and output torque of the diesel engine decrease simultaneously, and the fuel economy of the engine is improved. While the power consumption of the hydraulic system is lower during the boom declined and the swing brake, the diesel engine can work under low-load conditions. To optimize the working area of the diesel engine and further improve the economy of the excavator the operating ranges of the diesel engine to further improve the whole machine economy of the excavator with pump and valve combined separate meter-in and meter-out circuit, a diesel-hydraulic pump power matching scheme is proposed based on the analysis of the universal characteristics of a diesel engine. By comparing the working characteristics of the boom and the swing characteristics of the pump and valve combined with a separate meter-in and meter-out circuit and LUDV system, the power range of the boom action and swing action were specified, and the working area of the diesel engine under the corresponding conditions for these two system were analyzed according to the universal characteristic curve. The output power of the diesel engine is much lower than the power rating at 1 800 r·min~(-1). To improve the economy of diesel engine in these conditions, based on the universal characteristics curves of diesel engine In three-cylinder mode(the first cylinder is stopped in which fuel is off), two-cylinder mode(the first and the fourth cylinder are stopped in which fuel is off),the control strategy of power matching was established. The diesel engine worked with all the cylinders during lifting boom and worked in the two-cylinder mode in declining boom. The diesel engine worked with all the cylinders during swing with the maximum turning radius, while it worked in the three-cylinder mode during launch with minimum turning radius and in the two-cylinder mode during swing braking. A power system test platform was established and comparison experiments with corresponding conditions of the dynamic and economic were tested. The test results show that in the premise of satisfying the power performance, the fuel consumption of the diesel engine can be reduced by 20% during the process of single action lifting of the boom, by 40% during the process of swing with maximum radius, and by 20% during the process of swing with minimum radius when the cylinder deactivation of diesel engine was adopted.
引文
[1] 董致新,黄伟男,葛磊,等.泵阀复合进出口独立液压挖掘机特性研究[J].机械工程学报,2016,52(12):174-180. DONG Zhi-xin, HUANG Wei-nan, GE Lei, et al. Research on the Performance of Hydraulic Excavator with Pump and Valve Combined Separate Meter in and Meter out Circuits [J]. Journal of Mechanical Engineering, 2016, 52 (12): 174-180.
[2] 黄伟男,权龙,黄家海,等.进出口独立控制液压挖掘机回转系统运行特性[J].机械工程学报,2016,52(20):159-167. HUANG Wei-nan, QUAN Long, HUANG Jia-hai, et al. Excavator Swing System Controlled with Separate Meter-in and Meter-out Method [J]. Journal of Mechanical Engineering, 2016, 52 (20): 159-167.
[3] 权龙,廉自生.应用进出油口独立控制原理改善泵控差动缸系统效率[J].机械工程学报,2005,41(3):123-127. QUAN Long, LIAN Zi-sheng. Improving the Efficiency of Pump Controlled Differential Cylinder System with Inlet and Outlet Separately Controlled Principle [J]. Journal of Mechanical Engineering, 2005, 41 (3): 123-127.
[4] 彭天好,杨华勇,傅新.液压挖掘机全局功率匹配与协调控制[J].机械工程学报,2001,37(11):50-53. PENG Tian-hao, YANG Hua-yong, FU Xin. Hydraulic Excavator Overall Power Match Harmony Control [J]. Journal of Mechanical Engineering, 2001, 37 (11): 50-53.
[5] 杨世平,余浩,刘金刚,等.液压挖掘机动力系统功率匹配及其节能控制[J].机械工程学报,2014,50(5):152-160. YANG Shi-ping, YU Hao, LIU Jin-gang, et al. Research on Power Matching and Energy Saving Control of Power System in Hydraulic Excavator [J]. Journal of Mechanical Engineering, 2014, 50 (5): 152-160.
[6] 耿亚杰,杨敬,权龙.基于负载平衡的混合动力挖掘机功率匹配研究[J].液压与气动,2017(2):63-69. GENG Ya-jie, YANG Jing, QUAN Long. Power Matching of Hybrid Excavator Based on Load Balance [J]. Journal of Chinese Hydraulics Pneumatics, 2017 (2): 63-69.
[7] 高宇,冯培恩,彭贝.液压挖掘机分阶段功率匹配控制技术[J].哈尔滨工程大学学报,2017,38(9):1461-1469. GAO Yu, FENG Pei-en, PENG Bei. Stage-based Power Matching Control of Hydraulic Excavator [J]. Journal of Harbin Engineering University, 2017, 38 (9): 1461-1469.
[8] 金立生,赵丁选,黄运华.液压挖掘机节能用油门模糊控制器的开发研究[J].中国公路学报,2004,17(1):119-122. JIN Li-sheng, ZHAO Ding-xuan, HUANG Yun-hua. Study of the Accelerograph Fuzzy Controller of Hydraulic Excavator Saving Energy [J]. China Journal of Highway and Transport , 2004, 17 (1): 119-122.
[9] 肖清,王庆丰.液压挖掘机混合动力系统的参数匹配方法[J].中国公路学报,2008,21(1):121-126. XIAO Qing, WANG Qing-feng. Parameter Matching Method for Hybrid Power System of Hydraulic Excavator [J]. China Journal of Highway and Transport, 2008, 21 (1): 121-126.
[10] 叶敏,易小刚,蒲东亮,等.基于遗传算法的混凝土泵车全局功率匹配[J].吉林大学学报:自然科学版,2015,45(3):820-828. YE Min, YI Xiao-gang, PU Dong-liang, et al. Global Power Matching on Truck-mounted Concrete Pump Based on Genetic Algorithm [J]. Journal of Jilin University: Engineering and Technology Edition, 2015, 45 (3): 820-828.
[11] 陈礼周,周小波,邬斌扬,等.高压共轨柴油机随机停缸控制策略的试验研究[J].内燃机工程,2016,37(5):205-210. CHEN Li-yong, ZHOU Xiao-bo, WU Bin-yang, et al. Experimental Research on Random Cylinder Deactivation Strategy for High Pressure Common Rail Diesel Engine [J]. Chinese Internal Combustion Engine Engineering, 2016, 37 (5): 205-210.
[12] 张登攀,袁银男,杜家益.车用发动机停缸模式下转速波动仿真[J].农业机械学报,2010,41(2):25-28. ZHANG Deng-pan, YUAN Yin-nan, DU Jia-yi, et al. Modeling of Speed Fluctuations for Automotive Engine Under Cylinder Deactivation Mode [J]. Transactions of the Chinese Society for Agricultural Machinery, 2010, 41 (2): 25-28.
[13] ZAMMIT J P, MCGHEE M, SHAYLER P J. The Influence of Cylinder Deactivation on the Emissions and Fuel Economy of a Four-cylinder Direct-injection Diesel Engine [J]. Journal of Automobile Engineering, 2014, 228 (2): 206-217.
[14] 班立权,郜永涛,肖孟英.内燃机车柴油机停缸节油技术设计研究[J].内燃机,2014(1):48-51. BAN Li-quan, GAO Yong-tao, XIAO Meng-ying. Design and Implementation of Cylinder Deactivation Technology for Locomotive Diesel Engine [J]. Internal Combustion Engines, 2014 (1): 48-51.
[15] 王瀚轩,周斌,张浩.4缸柴油机停缸仿真及试验研究[J].车用发动机,2017(5):64-67. WANG Han-xuan, ZHOU Bin, ZHANG Hao. Simulation and Experimental Investigation on Cylinder Deactivation of 4-cylinder Diesel Engine [J]. Vehicle Engine, 2017 (5): 64-67.
[16] 田翀.柴油机停缸技术试验研究[J].内燃机与配件,2017(9):18-21. TIAN Chong. Experimental Study on the Engine Stop Cylinder Technology [J]. Internal Combustion Engine & Parts, 2017 (9): 18-21.
[17] YANG Jing, QUAN Long, YANG Yang. Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation Technology [J]. Chinese Journal of Mechanical Engineering, 2012, 25 (5): 897-904.
[18] 黄俊,周斌,张钊.停缸技术对柴油机燃油经济性和排放的影响[J].内燃机,2016(3):9-12. HUANG Jun, ZHOU Bin, ZHANG Zhao. Influence of Cylinder Deactivation on the Fuel Economy and Emissions of a Diesel Engine [J]. Internal Combustion Engines, 2016 (3): 9-12.
[19] 杨守平,张付军,赵长禄,等.变排量柴油机曲轴系统扭振特性研究[J].兵工学报,2011,32(9):1047-1052. YANG Shou-ping, ZHANG Fu-jun, ZHAO Chang-lu, et al. Study on Torsional Vibration Characteristics of Crankshaft in Variable Displacement Diesel Engine [J]. ACTA Armamentarii, 2011,32 (9): 1047-1052.
[20] 杨守平,张付军,黄英,等.单缸停缸对内燃机运动机构动力学特性的影响[J].农业机械学报,2011,42(9):8-13. YANG Shou-ping, ZHANG Fu-jun, HUANG Ying, et al. Influence of Single Cylinder Deactivation on Dynamic Performances of Internal Combustion Engine Motion Mechanisms [J]. Transactions of the Chinese Society for Agricultural Machinery, 2011, 42 (9): 8-13.
[2] 黄伟男,权龙,黄家海,等.进出口独立控制液压挖掘机回转系统运行特性[J].机械工程学报,2016,52(20):159-167. HUANG Wei-nan, QUAN Long, HUANG Jia-hai, et al. Excavator Swing System Controlled with Separate Meter-in and Meter-out Method [J]. Journal of Mechanical Engineering, 2016, 52 (20): 159-167.
[3] 权龙,廉自生.应用进出油口独立控制原理改善泵控差动缸系统效率[J].机械工程学报,2005,41(3):123-127. QUAN Long, LIAN Zi-sheng. Improving the Efficiency of Pump Controlled Differential Cylinder System with Inlet and Outlet Separately Controlled Principle [J]. Journal of Mechanical Engineering, 2005, 41 (3): 123-127.
[4] 彭天好,杨华勇,傅新.液压挖掘机全局功率匹配与协调控制[J].机械工程学报,2001,37(11):50-53. PENG Tian-hao, YANG Hua-yong, FU Xin. Hydraulic Excavator Overall Power Match Harmony Control [J]. Journal of Mechanical Engineering, 2001, 37 (11): 50-53.
[5] 杨世平,余浩,刘金刚,等.液压挖掘机动力系统功率匹配及其节能控制[J].机械工程学报,2014,50(5):152-160. YANG Shi-ping, YU Hao, LIU Jin-gang, et al. Research on Power Matching and Energy Saving Control of Power System in Hydraulic Excavator [J]. Journal of Mechanical Engineering, 2014, 50 (5): 152-160.
[6] 耿亚杰,杨敬,权龙.基于负载平衡的混合动力挖掘机功率匹配研究[J].液压与气动,2017(2):63-69. GENG Ya-jie, YANG Jing, QUAN Long. Power Matching of Hybrid Excavator Based on Load Balance [J]. Journal of Chinese Hydraulics Pneumatics, 2017 (2): 63-69.
[7] 高宇,冯培恩,彭贝.液压挖掘机分阶段功率匹配控制技术[J].哈尔滨工程大学学报,2017,38(9):1461-1469. GAO Yu, FENG Pei-en, PENG Bei. Stage-based Power Matching Control of Hydraulic Excavator [J]. Journal of Harbin Engineering University, 2017, 38 (9): 1461-1469.
[8] 金立生,赵丁选,黄运华.液压挖掘机节能用油门模糊控制器的开发研究[J].中国公路学报,2004,17(1):119-122. JIN Li-sheng, ZHAO Ding-xuan, HUANG Yun-hua. Study of the Accelerograph Fuzzy Controller of Hydraulic Excavator Saving Energy [J]. China Journal of Highway and Transport , 2004, 17 (1): 119-122.
[9] 肖清,王庆丰.液压挖掘机混合动力系统的参数匹配方法[J].中国公路学报,2008,21(1):121-126. XIAO Qing, WANG Qing-feng. Parameter Matching Method for Hybrid Power System of Hydraulic Excavator [J]. China Journal of Highway and Transport, 2008, 21 (1): 121-126.
[10] 叶敏,易小刚,蒲东亮,等.基于遗传算法的混凝土泵车全局功率匹配[J].吉林大学学报:自然科学版,2015,45(3):820-828. YE Min, YI Xiao-gang, PU Dong-liang, et al. Global Power Matching on Truck-mounted Concrete Pump Based on Genetic Algorithm [J]. Journal of Jilin University: Engineering and Technology Edition, 2015, 45 (3): 820-828.
[11] 陈礼周,周小波,邬斌扬,等.高压共轨柴油机随机停缸控制策略的试验研究[J].内燃机工程,2016,37(5):205-210. CHEN Li-yong, ZHOU Xiao-bo, WU Bin-yang, et al. Experimental Research on Random Cylinder Deactivation Strategy for High Pressure Common Rail Diesel Engine [J]. Chinese Internal Combustion Engine Engineering, 2016, 37 (5): 205-210.
[12] 张登攀,袁银男,杜家益.车用发动机停缸模式下转速波动仿真[J].农业机械学报,2010,41(2):25-28. ZHANG Deng-pan, YUAN Yin-nan, DU Jia-yi, et al. Modeling of Speed Fluctuations for Automotive Engine Under Cylinder Deactivation Mode [J]. Transactions of the Chinese Society for Agricultural Machinery, 2010, 41 (2): 25-28.
[13] ZAMMIT J P, MCGHEE M, SHAYLER P J. The Influence of Cylinder Deactivation on the Emissions and Fuel Economy of a Four-cylinder Direct-injection Diesel Engine [J]. Journal of Automobile Engineering, 2014, 228 (2): 206-217.
[14] 班立权,郜永涛,肖孟英.内燃机车柴油机停缸节油技术设计研究[J].内燃机,2014(1):48-51. BAN Li-quan, GAO Yong-tao, XIAO Meng-ying. Design and Implementation of Cylinder Deactivation Technology for Locomotive Diesel Engine [J]. Internal Combustion Engines, 2014 (1): 48-51.
[15] 王瀚轩,周斌,张浩.4缸柴油机停缸仿真及试验研究[J].车用发动机,2017(5):64-67. WANG Han-xuan, ZHOU Bin, ZHANG Hao. Simulation and Experimental Investigation on Cylinder Deactivation of 4-cylinder Diesel Engine [J]. Vehicle Engine, 2017 (5): 64-67.
[16] 田翀.柴油机停缸技术试验研究[J].内燃机与配件,2017(9):18-21. TIAN Chong. Experimental Study on the Engine Stop Cylinder Technology [J]. Internal Combustion Engine & Parts, 2017 (9): 18-21.
[17] YANG Jing, QUAN Long, YANG Yang. Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation Technology [J]. Chinese Journal of Mechanical Engineering, 2012, 25 (5): 897-904.
[18] 黄俊,周斌,张钊.停缸技术对柴油机燃油经济性和排放的影响[J].内燃机,2016(3):9-12. HUANG Jun, ZHOU Bin, ZHANG Zhao. Influence of Cylinder Deactivation on the Fuel Economy and Emissions of a Diesel Engine [J]. Internal Combustion Engines, 2016 (3): 9-12.
[19] 杨守平,张付军,赵长禄,等.变排量柴油机曲轴系统扭振特性研究[J].兵工学报,2011,32(9):1047-1052. YANG Shou-ping, ZHANG Fu-jun, ZHAO Chang-lu, et al. Study on Torsional Vibration Characteristics of Crankshaft in Variable Displacement Diesel Engine [J]. ACTA Armamentarii, 2011,32 (9): 1047-1052.
[20] 杨守平,张付军,黄英,等.单缸停缸对内燃机运动机构动力学特性的影响[J].农业机械学报,2011,42(9):8-13. YANG Shou-ping, ZHANG Fu-jun, HUANG Ying, et al. Influence of Single Cylinder Deactivation on Dynamic Performances of Internal Combustion Engine Motion Mechanisms [J]. Transactions of the Chinese Society for Agricultural Machinery, 2011, 42 (9): 8-13.