船用低速二冲程柴油机工作过程仿真与故障模拟
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摘要
船用柴油机工作过程的研究对柴油机故障诊断和性能优化具有重要意义。本文以大连船用柴油机厂制造的MAN B&W6S50MC-C二冲程低速柴油机为主要研究对象,建立了柴油机工作过程数学模型和物理模型,实现柴油机工作过程仿真计算。
本文基于一维发动机工作过程循环模拟分析计算软件AVL BOOST,以MAN B&W 6S50MC-C型低速二冲程柴油机为例,分析了柴油机工作过程数学模型,包括：缸内模型、燃烧模型、换气模型、活塞运动模型、传热模型、涡轮增压器模型和空冷器模型等,建立了准确性较高的柴油机性能模拟方法。本文借助于BOOST软件建立了MAN B&W 6S50MC-C型柴油机物理模型,对柴油机的额定负荷和部分负荷进行了计算分析,依据台架试验结果,反复调试后得到精确的柴油机仿真计算模型。
最后,在验证后的模型基础上,本文对船用柴油机常见故障进行了模拟计算,这些故障包括：燃烧持续期延长、单缸停油、喷油器喷孔磨损、增压器效率降低、中冷器脏污及冷却能力下降和排气定时等故障。在故障设置上,依据故障模拟原理,每个故障分别设置为轻微、中等和严重3个等级,反应了故障产生、发展及恶化的过程。通过故障模拟,分析了影响低速二冲程柴油机性能的主要因素,及在故障逐渐加深时,柴油机主要性能参数(有效功率、燃油消耗率、平均指示压力和最大爆发压力等)变化规律。最终,通过柴油机主要性能参数变化,识别柴油机故障的严重程度,为柴油机故障诊断提供依据。
Research on work process simulation for marine diesel engine is significant for fault diagnosis and performance optimization of diesel engine. A Mathematical and Physical model of diesel engine is established and simulation computation of work process is carried out, according to the MAN B&W 6S5050MC-C two-stroke low-speed diesel engine, which was made by DALIAN MARINE DIESEL WORKS.
Based on one-dimensional simulation computation software of engine work process-AVL BOOST and low-speed two-stroke diesel engine-MAN B&W 6S5050MC-C, this paper analyzed the Mathematical model of diesel engine work process and finally the method to accurate simulation was developed. The Mathematical model includes cylinder model, combustion model, scavenging model, piston motion model, heat transfer model, turbine charger model and air cooler model. With the help of the software-BOOST, the Physical model of MAN B&W 6S5050MC-C diesel engine was established. Comparison with test report, the Physical computation model was simulated and according to repeatedly debugging, gains the accurate simulation computation model of diesel engine.
Finally, on the basis of the validated model, many simulation calculations were made about usual faults of marine diesel engine, which includes combustion duration extension, one cylinder misfiring, fuel injector nozzle holes wearing, turbocharger efficiency decreasing, the cooler dirty and cooling capacity worsen and exhaust valve timing fault. According to fault simulation theory, three levels (slight, medium and heavy) were set about every fault, which simulated the cause, development and deterioration. Through fault simulation, main factors which influence the performance of Two-stroke diesel engine were analyzed. And when faults gradually deepen, main performance factors of diesel engine including effective power, fuel consumption rate, IMEP, maximum combustion pressure was also analyzed. At last, through the change of main performance parameter of diesel engine, fault grade was recognized. It also provide criterion for fault diagnosis.
本文基于一维发动机工作过程循环模拟分析计算软件AVL BOOST,以MAN B&W 6S50MC-C型低速二冲程柴油机为例,分析了柴油机工作过程数学模型,包括：缸内模型、燃烧模型、换气模型、活塞运动模型、传热模型、涡轮增压器模型和空冷器模型等,建立了准确性较高的柴油机性能模拟方法。本文借助于BOOST软件建立了MAN B&W 6S50MC-C型柴油机物理模型,对柴油机的额定负荷和部分负荷进行了计算分析,依据台架试验结果,反复调试后得到精确的柴油机仿真计算模型。
最后,在验证后的模型基础上,本文对船用柴油机常见故障进行了模拟计算,这些故障包括：燃烧持续期延长、单缸停油、喷油器喷孔磨损、增压器效率降低、中冷器脏污及冷却能力下降和排气定时等故障。在故障设置上,依据故障模拟原理,每个故障分别设置为轻微、中等和严重3个等级,反应了故障产生、发展及恶化的过程。通过故障模拟,分析了影响低速二冲程柴油机性能的主要因素,及在故障逐渐加深时,柴油机主要性能参数(有效功率、燃油消耗率、平均指示压力和最大爆发压力等)变化规律。最终,通过柴油机主要性能参数变化,识别柴油机故障的严重程度,为柴油机故障诊断提供依据。
Research on work process simulation for marine diesel engine is significant for fault diagnosis and performance optimization of diesel engine. A Mathematical and Physical model of diesel engine is established and simulation computation of work process is carried out, according to the MAN B&W 6S5050MC-C two-stroke low-speed diesel engine, which was made by DALIAN MARINE DIESEL WORKS.
Based on one-dimensional simulation computation software of engine work process-AVL BOOST and low-speed two-stroke diesel engine-MAN B&W 6S5050MC-C, this paper analyzed the Mathematical model of diesel engine work process and finally the method to accurate simulation was developed. The Mathematical model includes cylinder model, combustion model, scavenging model, piston motion model, heat transfer model, turbine charger model and air cooler model. With the help of the software-BOOST, the Physical model of MAN B&W 6S5050MC-C diesel engine was established. Comparison with test report, the Physical computation model was simulated and according to repeatedly debugging, gains the accurate simulation computation model of diesel engine.
Finally, on the basis of the validated model, many simulation calculations were made about usual faults of marine diesel engine, which includes combustion duration extension, one cylinder misfiring, fuel injector nozzle holes wearing, turbocharger efficiency decreasing, the cooler dirty and cooling capacity worsen and exhaust valve timing fault. According to fault simulation theory, three levels (slight, medium and heavy) were set about every fault, which simulated the cause, development and deterioration. Through fault simulation, main factors which influence the performance of Two-stroke diesel engine were analyzed. And when faults gradually deepen, main performance factors of diesel engine including effective power, fuel consumption rate, IMEP, maximum combustion pressure was also analyzed. At last, through the change of main performance parameter of diesel engine, fault grade was recognized. It also provide criterion for fault diagnosis.
引文
[1]杜荣铭.船舶柴油机.大连：大连海事大学,1992.
[2]Rene muller. ABB涡轮增压器——大型柴油机的必备部件.国外内燃机车,1994.
[3]申小明.船舶柴油机涡轮增压器配合及计算机仿真研究：(硕士学位论文).武汉：武汉理工大学,2008.
[4]郭东波,曾勇.船舶柴油机的现状及发展.船舶工程.2003(2).
[5]绉本强.船用柴油机的现状及发展趋势.世界海运.2006(6).
[6]黄少竹.船舶柴油机.大连：大连海事大学出版,2005.
[7]何文山.船舶柴油机.北京：人民交通出版社,1997.
[8]Oyvind Toft, Jens Thomsen. Some common field experience with large bore 2-stroke engines. CIMAC Congress 2007, Vienna.
[9]倪培永,石秀勇,孟昭昕.直喷式柴油机工作过程模拟计算.内燃机.2003(5).
[10]李敬福.SD2100A直喷式柴油机性能改进：(硕士学位论文).济南：山东大学,2007.
[11]王有槐.船用柴油机增压技术发展.2005年中国国际海事会议和展览会展品技术透析.2006(4).
[12]任自中.船用大中型高压比增压器技术的发展趋势.柴油机.2006(5).
[13]Masaki ohtsu, Kazutaka Shimada. Utilization of Excessive Turbocharger Efficiency. CIMAC Congress 2007, Viena.
[14]孙培廷,李斌.船舶柴油机.大连：大连海事大学出版,2002.
[15]Chang-Su, KIM, Dong-Ho, LEE, Young-Sam, CHO. The Comparison about CFD-Simulation &Measurement Result of Large Two-Stroke Diesel Engine. CIMAC Congress 2001, Hamburg.
[16]黄豪中.柴油均质压燃HCCI发动机燃烧过程数值模拟和实验研究：(硕士学位论文).天津：天津大学,2007.
[17]丰琳琳.二冲程低速柴油机工作过程与增压系统的计算研究：(硕士学位论文).上海：上海交通大学,2007.
[18]邵治家.6106柴油机工作过程的数值模拟及优化：(硕士学位论文).大连：大连理工大学,2007.
[19]刘勤安.大型低速二冲程柴油机工作过程数值模拟和优化：(硕士学位论文).大连：大连海事大学,2009.
[20]王海燕,张均东.大型低速柴油机工作过程建模与仿真.大连海事大学学报.2006(2)
[21]解茂昭.内燃机计算燃烧学.大连：大连理工大学出版社,2005.
[22]袁中庄.非直喷式柴油机气态污染物形成历程研究.内燃机学报,1991.
[23]史绍熙.直喷式柴油机燃烧过程现象学模型.工程热物理学报,1991.
[24]陈凯.速直喷式柴油机新的准维多区燃烧模型.工程热物理学报,1993(2).
[25]刘永长.内燃机热力过程模拟.北京：机械工程出版社,2000.
[26]Allan Kirkpartrick, Gi-Heon Kim, Charles Mitchell. CFD Modeling of Combustion in a Large Bore Two-Stroke Engine. CIMAC Congress 2004, Kyoto.
[27]Yusuke lmamori, H.Endo, K.Sakaguchi, J. Yanagi. Development of combustion system in low speed two-stroke diesel engine using CFD. CIMAC Congress 2004, Kyoto.
[28]周俊杰.柴油机工作过程数值计算.大连：大连理工大学出版社,1990.
[29]韩雪峰.船舶柴油机.北京：人民交通出版社,2004.
[30]满一新.船机维修技术.大连：大连海事大学出版社,1999.
[31]M. Hernqvist. Main Engine Damage from an Insurer's Point of View. CIMAC Congress, Copenhagen,1998.
[32]李国伍.船舶四冲程主柴油机增压系统运行规律的研究：(硕士学位论文).厦门：集美大学,2007.
[33]蒋德明.高等内燃机原理.西安：西安交通大学出版社,2002.
[34]巫朝鑫.WD615.50柴油机工作过程模拟计算和参数优化：(硕士学位论文).大连：大连海事大学,2008.
[35]AVL BOOST Version5.0 Users Guide. AVL, Graz,2006.
[36]R. Tatschl, M. Bogensperger, H. Riediger. Modeling Spray Combustion in Diesel Engines. CIMAC Congress 1998, Copenhagen.
[37]G J Micklow, W Gong. Combustion modeling for direct injection diesel engines. Proquest Science Journals,2001.
[38]Rudolf Demmerle, Samuel Barrow. New Insight into the Piston Running Behaviour of Sulzer Large Bore Diesel Engine. CIMAC Congress, Frankfurt,2008.
[39]陆瑞松.内燃机的传热与热负荷.北京：国防工业出版社.1985.
[40]Dent J C, A basis for the comparison of Various Experimental Methods for Studying Spray penetration, SAE Trand,1971.
[41]Matti Kleimola, Turbo charging Efficiencies-Definitions and Guidelines for Measurement and Calculation. CIMAC Congress, Vienna 2007.
[42]刘英.船用增压器涡轮结构与性能数值研究与改进：(硕士学位论文).大连：大连理工大学,2007.
[43]AVL软件功能介绍.李斯特技术中心(上海)有限公司.
[44]顾俊.排气涡轮增压器与船用柴油机的匹配模拟计算分析：(硕士学位论文).上海：上海交通大学,2007.
[45]Project Guide--S50MC-C Two-stroke Engine.3rd Edition,2000.
[46]Tadeusz Borkowski. The effect of cylinder process variation on total nitrogen oxides emission for large bore slow speed marine engines. CIMAC Congress, Vienna 2007.
[47]Project Guide-Exhaust Gas Turbocharger TCA-Series. Version7,2006.
[48]闫小俊.AVL BOOST发动机性能验证模拟时应注意的几个问题.AVLAST.
[49]Oyvind Toft, Jens thomsen. Some common field experience with large bore 2-stroke engines. CIMAC Congress, Vienna 2007.
[50]李岳春郭于光.船用柴油机的可靠性.上海：上海交大出版社,1993.
[51]Stewart, L. Use Oil Pressure to Predict Engine Failure. Construction Equipment, Vol.83, No. 1,pp86-90,1991.
[52]王洪锋,杨建国,余永华.基于热力参数的柴油机故障模拟试验与分析.船舶工程,2007.
[53]Raluca F.Constantinescu, Peter D. Lawrence, Phillip G.Hill. Model-Based Fault Diagnosis of a Two-Stroke Diesel Engine. IEEE,1995.
[54]Brain J.Murphy, Mitchell S.Lebold, Karl Reichard. Diagnostic Fault Detection for Internal Combustion Engine via Norm Base Map Projections.2004 IEEE Aerospace Conference Proceedings.
[55]彭水生.轮机模拟器6S60MC柴油机主机仿真系统与故障模拟：(博士学位论文).大连：大连海事大学,2000.
[56]Laurie Goldsworthy, a Model for Ignition and Combustion Quality of Heavy Fuel Oil. CIMAC Congress, Vienna 2007.
[57]Markus Schrittwieser, Christoh Schneider. Precise real-time fuel consumption measurement. CIMAC Congress, Vienna 2007.
[58]罗玉君.面向对象的方法在船舶柴油机仿真及故障模拟中的应用：(硕士学位论文),武汉：武汉理工大学.
[59]Jeong-Geun Park, Seok-Pan Seo, Kwang-Suk Oh. Self-learning torsional vibration monitoring system for detection of misfiring and malfunction in diesel engine plants. CIMAC Congress, Vienna 2007.
[60]Hiroyuki Nagamatsu, Jun Tajima. Study on scuffing and Piston Deposits-Hardness of Inorganic Compound's Deposits. CIMAC Congress, Kyoto 2004.
[61]Masaki Ohtsu, Utilization of Excessive Turbocharger Efficiency. CIMAC Congress, Vienna 2007.
[62]翁泽民,黄少竹,陶胜,周学智.船舶二冲程主柴油机增压器喘振故障诊断方法探讨.集美航海学院学报,1997.
[63]李可顺.船用柴油机涡轮增压器对环境温度适应性：(硕士学位论文).大连：大连海事大学,2004.
[64]朱建元.船舶柴油机.北京：人民交通出版社,2004.
[2]Rene muller. ABB涡轮增压器——大型柴油机的必备部件.国外内燃机车,1994.
[3]申小明.船舶柴油机涡轮增压器配合及计算机仿真研究：(硕士学位论文).武汉：武汉理工大学,2008.
[4]郭东波,曾勇.船舶柴油机的现状及发展.船舶工程.2003(2).
[5]绉本强.船用柴油机的现状及发展趋势.世界海运.2006(6).
[6]黄少竹.船舶柴油机.大连：大连海事大学出版,2005.
[7]何文山.船舶柴油机.北京：人民交通出版社,1997.
[8]Oyvind Toft, Jens Thomsen. Some common field experience with large bore 2-stroke engines. CIMAC Congress 2007, Vienna.
[9]倪培永,石秀勇,孟昭昕.直喷式柴油机工作过程模拟计算.内燃机.2003(5).
[10]李敬福.SD2100A直喷式柴油机性能改进：(硕士学位论文).济南：山东大学,2007.
[11]王有槐.船用柴油机增压技术发展.2005年中国国际海事会议和展览会展品技术透析.2006(4).
[12]任自中.船用大中型高压比增压器技术的发展趋势.柴油机.2006(5).
[13]Masaki ohtsu, Kazutaka Shimada. Utilization of Excessive Turbocharger Efficiency. CIMAC Congress 2007, Viena.
[14]孙培廷,李斌.船舶柴油机.大连：大连海事大学出版,2002.
[15]Chang-Su, KIM, Dong-Ho, LEE, Young-Sam, CHO. The Comparison about CFD-Simulation &Measurement Result of Large Two-Stroke Diesel Engine. CIMAC Congress 2001, Hamburg.
[16]黄豪中.柴油均质压燃HCCI发动机燃烧过程数值模拟和实验研究：(硕士学位论文).天津：天津大学,2007.
[17]丰琳琳.二冲程低速柴油机工作过程与增压系统的计算研究：(硕士学位论文).上海：上海交通大学,2007.
[18]邵治家.6106柴油机工作过程的数值模拟及优化：(硕士学位论文).大连：大连理工大学,2007.
[19]刘勤安.大型低速二冲程柴油机工作过程数值模拟和优化：(硕士学位论文).大连：大连海事大学,2009.
[20]王海燕,张均东.大型低速柴油机工作过程建模与仿真.大连海事大学学报.2006(2)
[21]解茂昭.内燃机计算燃烧学.大连：大连理工大学出版社,2005.
[22]袁中庄.非直喷式柴油机气态污染物形成历程研究.内燃机学报,1991.
[23]史绍熙.直喷式柴油机燃烧过程现象学模型.工程热物理学报,1991.
[24]陈凯.速直喷式柴油机新的准维多区燃烧模型.工程热物理学报,1993(2).
[25]刘永长.内燃机热力过程模拟.北京：机械工程出版社,2000.
[26]Allan Kirkpartrick, Gi-Heon Kim, Charles Mitchell. CFD Modeling of Combustion in a Large Bore Two-Stroke Engine. CIMAC Congress 2004, Kyoto.
[27]Yusuke lmamori, H.Endo, K.Sakaguchi, J. Yanagi. Development of combustion system in low speed two-stroke diesel engine using CFD. CIMAC Congress 2004, Kyoto.
[28]周俊杰.柴油机工作过程数值计算.大连：大连理工大学出版社,1990.
[29]韩雪峰.船舶柴油机.北京：人民交通出版社,2004.
[30]满一新.船机维修技术.大连：大连海事大学出版社,1999.
[31]M. Hernqvist. Main Engine Damage from an Insurer's Point of View. CIMAC Congress, Copenhagen,1998.
[32]李国伍.船舶四冲程主柴油机增压系统运行规律的研究：(硕士学位论文).厦门：集美大学,2007.
[33]蒋德明.高等内燃机原理.西安：西安交通大学出版社,2002.
[34]巫朝鑫.WD615.50柴油机工作过程模拟计算和参数优化：(硕士学位论文).大连：大连海事大学,2008.
[35]AVL BOOST Version5.0 Users Guide. AVL, Graz,2006.
[36]R. Tatschl, M. Bogensperger, H. Riediger. Modeling Spray Combustion in Diesel Engines. CIMAC Congress 1998, Copenhagen.
[37]G J Micklow, W Gong. Combustion modeling for direct injection diesel engines. Proquest Science Journals,2001.
[38]Rudolf Demmerle, Samuel Barrow. New Insight into the Piston Running Behaviour of Sulzer Large Bore Diesel Engine. CIMAC Congress, Frankfurt,2008.
[39]陆瑞松.内燃机的传热与热负荷.北京：国防工业出版社.1985.
[40]Dent J C, A basis for the comparison of Various Experimental Methods for Studying Spray penetration, SAE Trand,1971.
[41]Matti Kleimola, Turbo charging Efficiencies-Definitions and Guidelines for Measurement and Calculation. CIMAC Congress, Vienna 2007.
[42]刘英.船用增压器涡轮结构与性能数值研究与改进：(硕士学位论文).大连：大连理工大学,2007.
[43]AVL软件功能介绍.李斯特技术中心(上海)有限公司.
[44]顾俊.排气涡轮增压器与船用柴油机的匹配模拟计算分析：(硕士学位论文).上海：上海交通大学,2007.
[45]Project Guide--S50MC-C Two-stroke Engine.3rd Edition,2000.
[46]Tadeusz Borkowski. The effect of cylinder process variation on total nitrogen oxides emission for large bore slow speed marine engines. CIMAC Congress, Vienna 2007.
[47]Project Guide-Exhaust Gas Turbocharger TCA-Series. Version7,2006.
[48]闫小俊.AVL BOOST发动机性能验证模拟时应注意的几个问题.AVLAST.
[49]Oyvind Toft, Jens thomsen. Some common field experience with large bore 2-stroke engines. CIMAC Congress, Vienna 2007.
[50]李岳春郭于光.船用柴油机的可靠性.上海：上海交大出版社,1993.
[51]Stewart, L. Use Oil Pressure to Predict Engine Failure. Construction Equipment, Vol.83, No. 1,pp86-90,1991.
[52]王洪锋,杨建国,余永华.基于热力参数的柴油机故障模拟试验与分析.船舶工程,2007.
[53]Raluca F.Constantinescu, Peter D. Lawrence, Phillip G.Hill. Model-Based Fault Diagnosis of a Two-Stroke Diesel Engine. IEEE,1995.
[54]Brain J.Murphy, Mitchell S.Lebold, Karl Reichard. Diagnostic Fault Detection for Internal Combustion Engine via Norm Base Map Projections.2004 IEEE Aerospace Conference Proceedings.
[55]彭水生.轮机模拟器6S60MC柴油机主机仿真系统与故障模拟：(博士学位论文).大连：大连海事大学,2000.
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