高速大流量电液配流系统设计理论及应用研究
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摘要
电液配流系统由于具有体积小、功率密度大、结构简单灵活、工作稳定可靠等特点,因此广泛应用在化工流体机械、发动机气门、数字配流泵/马达、液压冲击机械等需要流体输送控制的工业领域。流体输送机械作为工业生产流程的“心脏”,其配流系统的性能很大程度上影响着主机和工艺的稳定性和能耗,同时,随着工业自动化水平的提高,对流体机械的工作效率、噪声及工作寿命的要求也越来越高,开展电液配流系统设计研究是十分重要和迫切的,如何设计高性能、高效率的配流系统从而提升主机的性能也成为了行内研究的热点课题。目前,国内的相关研究开展较晚,成熟的电液配流系统大多从国外进口,价格十分昂贵,而基础的零部件及相关机加工技术对我国实行技术封锁,进行二次产品开发较为困难。因此,开展电液配流系统的设计理论研究,研发具有自主知识产权的电液配流产品,将有助于大幅提升我国在相关领域的技术水平,更好地满足国内日益增长的市场需求。
本文的研究对象为高速大流量电液配流系统,通过结构设计、数学计算、建模仿真和试验验证相结合的方法,深入详细研究了电液配流系统的关键技术。通过建立电液执行器数学模型,分析了影响电液执行器动作延迟特性的因素,提出高响应电液执行器的设计原则。基于提高电液执行器驱动流量的基本思路,提出双高速开关阀并联式和先导式的新型执行器结构,并通过参数优化研究,将先导式电液执行器的开启和关闭延迟时间控制在20ms以内。通过对电液配流过程负载运动特性的分析,提出一种双向高速液压缓冲的新型结构,理论计算及试验表明在该液压缓冲作用下的负载冲击速度大大降低,配流系统的工作可靠性得到大幅提高。为实现电液配流系统研究的工业化应用,将新型电液配流系统应用在往复式压缩机气量无级调节装置中,研究了动态气体力作用过程下的电液配流系统动态特性,开发了压缩机电液配流系统样机,现场应用表明电液配流压缩机成功实现了排气量的无级调节,气量调节过程平稳无冲击,压缩机排气压力波动小于0.2bar。
现将各章内容分述如下：
第一章,简单介绍了配流系统的应用领域、工程背景及研究价值；详细阐述了高速大流量电液配流系统在往复式压缩机气量无级调节技术中的应用背景及技术现状,对比总结了常见的电液配流系统技术方案并重点指出了高速开关配流方案的特点；分析了高速电液执行器、高速开关阀、高速液压缓冲等高速大流量电液配流关键技术的研究进展,本章最后总结了课题的研究意义及主要研究内容。
第二章,根据电液配流系统应用工况提出高速电液执行器的性能指标,介绍了电液执行器的常见结构及工作原理,基于高速开关阀控液压缸的物理模型搭建了电液执行器的基本数学模型,仿真分析了主要设计参数对电液执行器动作延迟特性的影响。基于理论分析结果提出两种不同结构的新型高速电液执行器,分别建立双高速开关阀并联式和先导式电液执行器的理论分析模型,对比研究两种不同类型电液执行器的动态特性。最后,基于电液执行器结构参数的分析结果,提出高速电液执行器的优化设计理论。
第三章,分析高速电液配流系统的工作特性,并提出液压缓冲的性能参数要求。根据高速、短行程的负载特性提出高速液压缓冲的结构方案,详细阐述了其工作原理,并通过数学计算确定了高速液压缓冲的主要结构参数。通过建立双向缓冲的数学模型,深入开展了气阀开启和关闭过程中的动态缓冲特性研究。本章最后总结了双向液压缓冲的优化设计方法。
第四章,阐述了高速大流量电液配流系统的工作原理,介绍了高速大流量电液配流系统的结构组成,其次根据系统物理模型,推导考虑动态力作用下的电液配流系统气阀运动规律数学模型,并在AMESim与Matlab平台下搭建了电液配流系统联合仿真模型,基于仿真模型对电液配流系统的参数可控性、阀片运动规律与系统动态特性进行仿真研究,评估关键参数对系统动态性能的影响,从而为电液配流系统的优化设计提供理论依据。最后,搭建动态性能测试系统对电液配流系统性能参数进行测试,验证仿真模型的正确性并为进一步完善电液配流系统设计理论提供实验数据支持。
第五章,介绍了高速大流量电液配流系统在往复式压缩机气量无级调节技术中的应用情况,阐述了往复式压缩机气量无级调节装置的组成,指明了气量调节压缩机的性能参数,结合压缩机气量无级调节的技术要求,设计了一套高速大流量电液配流系统的工业样机,搭建了由上位机、下位机、止点传感器、通讯模块等组成的控制系统。在中国石化天津炼油厂加氢裂化氢气压缩机上开展了工业试验研究,试验结果表明气量调节装置的节能效果十分显著。
第六章,对本文开展的主要研究工作和成果进行总结,并进一步展望今后的研究工作和研究方向。
With characteristics of small volume, high power density, simple structure and high reliability, electro-hydraulic distribution system (EHFS) has been extensively applied in chemical fluid machinery, engine valve, digital distribution pump/motor, hydraulic impact machine, etc. With fluid transmission machinery working as the heart of industrial production process, the performance of flow distribution system, to a great extent, affects the stability and energy consumption of the main engines and the industrial processing. Besides, with the development of industrial automatization, the efficiency, lower noise and longer operating life of fluid machinery are endued with higher and higher requirement. The research on flow distribution system has appeared to be extremely urgent and important. How to pass the design of flow distribution system with high performance and efficiency to improve the capability of main engines has become a new highlight in the industry. So far, relevant domestic study on EHFS has been carried out later and most of the mature products in China are imported with high price. It's difficult to do secondary development for the basic components and technology blockage. So it'll be conductive to the improvement of relevant technical level in China and better meet market demand by carrying out research on the design of EHFS and developing independent intellectual property products.
Based on the structural design, mathematical calculation, digital simulation and experimental study, this paper particularly discusses the flow distribution system with large flow rate and high speed. The influencing factors of action delay are analyzed by establishing the modeling of electro-hydraulic actuator. The design approach of electro-hydraulic actuator with high response is presented. New actuator structures including the dual high speed on/off valves parallel type and the pilot type are adopted based on the principle of flow rate improvement. The pilot electro-hydraulic actuator has a typical on/off time of20ms by parameters optimization research. A new hydraulic buffer with bidirectional, high speed movement is presented by analysis of load characteristics in the flow distribution process. Calculation and field tests show that, the load impact velocity is largely reduced with operation of this hydraulic buffer, so that the reliability of flow distribution system is greatly improved. In order to realize the industrial applications of EHFS, the new system is installed in the stepless capacity control equipment of reciprocating compressor, and the dynamic characteristics of EHFS with operation of dynamic gas forces is discussed. Experimental results show that the capacity control process is stable without impact and the discharge pressure fluctuation is less than0.2bar.
The main content of each chapter is summarized as following:
In chapter1, the application fields, engineering background and research value of flow distribution system are expounded. The special application background and the technology status of EHFS with large flow rate and high speed in stepless capacity control of reciprocating compressors are described in detail. Through the comparison of common flow distribution technology schemes, the technique features of high speed on/off flow distribution are highlighted. Relative technologies such as high speed electro-hydraulic actuator, high speed on/off valve and high speed hydraulic buffer are analyzed. The research significance and main study content are proposed in the final section of this chapter.
In chapter2, the performance indicators of high speed electro-hydraulic actuator are presented based on the application condition of EHFS. The common structure and working principle of electro-hydraulic actuator are introduced. The basic mathematical model is established based on the physical model of high speed on/off valve control hydraulic cylinder. The influences of main design factors on the actuator action delay are illustrated. Two new high speed actuators with different structures are proposed based on the theoretical analysis. Simulation models of electro-hydraulic actuators, dual high speed on/off valve parallel type and pilot type are established to do comparative research on their dynamic characteristics. Finally, optimization design theory of high speed actuators is proposed through analysis of structure factors.
In chapter3, by analyzing performance characteristics of high speed EHFS, the necessity of adopting hydraulic buffer is described and the performance requirements of hydraulic buffer are proposed. Based on the load features with high speed and short stroke, the structure concept of high speed hydraulic buffer is presented. Then its working principle is elaborated. And the main structural characteristics are determined by mathematical calculation. By establishing the simulation model of the bidirectional buffer, research on dynamic buffering characteristics of opening and closing process is deeply developed. The optimization design theory is summarized in the last section of this chapter.
In chapter4, the working principle of EHFS with large flow rate and high speed is expounded. The structure and elements of EHFS are introduced. Based on the physical modeling of EHFS, the mathematical model of valve motion is established with consideration of dynamic gas force. Then co-simulation model is established in AMESim and Matlab. The controllability, valve motion and dynamic characteristics of EHFS are discussed by simulation study. Theory basis for optimization design of EHFS is provided by analyzing the influence of key factors. Finally, a test rig for dynamic characteristics is built to validate simulation model and provide data support for improvement of EHFS design theory.
In chapter5, the application of EHFS with large flow rate and high speed in stepless capacity control of reciprocating compressors is introduced. The structure of stepless capacity control equipment is described, and the performance characteristics of capacity control compressor are listed. A prototype of EHFS with large flow rate and high speed is designed combined with technical requirements of stepless capacity control technology. Control system consisting of upper computer, lower computer, TDC sensor and communication module is built. Experimental research is carried out on the hydrocracking compressor in Sinopec Tianjin refinery and the results show a remarkable energy saving effect.
In chapter6, all achievements of the dissertation are summarized and the further research work is put forward.
本文的研究对象为高速大流量电液配流系统,通过结构设计、数学计算、建模仿真和试验验证相结合的方法,深入详细研究了电液配流系统的关键技术。通过建立电液执行器数学模型,分析了影响电液执行器动作延迟特性的因素,提出高响应电液执行器的设计原则。基于提高电液执行器驱动流量的基本思路,提出双高速开关阀并联式和先导式的新型执行器结构,并通过参数优化研究,将先导式电液执行器的开启和关闭延迟时间控制在20ms以内。通过对电液配流过程负载运动特性的分析,提出一种双向高速液压缓冲的新型结构,理论计算及试验表明在该液压缓冲作用下的负载冲击速度大大降低,配流系统的工作可靠性得到大幅提高。为实现电液配流系统研究的工业化应用,将新型电液配流系统应用在往复式压缩机气量无级调节装置中,研究了动态气体力作用过程下的电液配流系统动态特性,开发了压缩机电液配流系统样机,现场应用表明电液配流压缩机成功实现了排气量的无级调节,气量调节过程平稳无冲击,压缩机排气压力波动小于0.2bar。
现将各章内容分述如下：
第一章,简单介绍了配流系统的应用领域、工程背景及研究价值；详细阐述了高速大流量电液配流系统在往复式压缩机气量无级调节技术中的应用背景及技术现状,对比总结了常见的电液配流系统技术方案并重点指出了高速开关配流方案的特点；分析了高速电液执行器、高速开关阀、高速液压缓冲等高速大流量电液配流关键技术的研究进展,本章最后总结了课题的研究意义及主要研究内容。
第二章,根据电液配流系统应用工况提出高速电液执行器的性能指标,介绍了电液执行器的常见结构及工作原理,基于高速开关阀控液压缸的物理模型搭建了电液执行器的基本数学模型,仿真分析了主要设计参数对电液执行器动作延迟特性的影响。基于理论分析结果提出两种不同结构的新型高速电液执行器,分别建立双高速开关阀并联式和先导式电液执行器的理论分析模型,对比研究两种不同类型电液执行器的动态特性。最后,基于电液执行器结构参数的分析结果,提出高速电液执行器的优化设计理论。
第三章,分析高速电液配流系统的工作特性,并提出液压缓冲的性能参数要求。根据高速、短行程的负载特性提出高速液压缓冲的结构方案,详细阐述了其工作原理,并通过数学计算确定了高速液压缓冲的主要结构参数。通过建立双向缓冲的数学模型,深入开展了气阀开启和关闭过程中的动态缓冲特性研究。本章最后总结了双向液压缓冲的优化设计方法。
第四章,阐述了高速大流量电液配流系统的工作原理,介绍了高速大流量电液配流系统的结构组成,其次根据系统物理模型,推导考虑动态力作用下的电液配流系统气阀运动规律数学模型,并在AMESim与Matlab平台下搭建了电液配流系统联合仿真模型,基于仿真模型对电液配流系统的参数可控性、阀片运动规律与系统动态特性进行仿真研究,评估关键参数对系统动态性能的影响,从而为电液配流系统的优化设计提供理论依据。最后,搭建动态性能测试系统对电液配流系统性能参数进行测试,验证仿真模型的正确性并为进一步完善电液配流系统设计理论提供实验数据支持。
第五章,介绍了高速大流量电液配流系统在往复式压缩机气量无级调节技术中的应用情况,阐述了往复式压缩机气量无级调节装置的组成,指明了气量调节压缩机的性能参数,结合压缩机气量无级调节的技术要求,设计了一套高速大流量电液配流系统的工业样机,搭建了由上位机、下位机、止点传感器、通讯模块等组成的控制系统。在中国石化天津炼油厂加氢裂化氢气压缩机上开展了工业试验研究,试验结果表明气量调节装置的节能效果十分显著。
第六章,对本文开展的主要研究工作和成果进行总结,并进一步展望今后的研究工作和研究方向。
With characteristics of small volume, high power density, simple structure and high reliability, electro-hydraulic distribution system (EHFS) has been extensively applied in chemical fluid machinery, engine valve, digital distribution pump/motor, hydraulic impact machine, etc. With fluid transmission machinery working as the heart of industrial production process, the performance of flow distribution system, to a great extent, affects the stability and energy consumption of the main engines and the industrial processing. Besides, with the development of industrial automatization, the efficiency, lower noise and longer operating life of fluid machinery are endued with higher and higher requirement. The research on flow distribution system has appeared to be extremely urgent and important. How to pass the design of flow distribution system with high performance and efficiency to improve the capability of main engines has become a new highlight in the industry. So far, relevant domestic study on EHFS has been carried out later and most of the mature products in China are imported with high price. It's difficult to do secondary development for the basic components and technology blockage. So it'll be conductive to the improvement of relevant technical level in China and better meet market demand by carrying out research on the design of EHFS and developing independent intellectual property products.
Based on the structural design, mathematical calculation, digital simulation and experimental study, this paper particularly discusses the flow distribution system with large flow rate and high speed. The influencing factors of action delay are analyzed by establishing the modeling of electro-hydraulic actuator. The design approach of electro-hydraulic actuator with high response is presented. New actuator structures including the dual high speed on/off valves parallel type and the pilot type are adopted based on the principle of flow rate improvement. The pilot electro-hydraulic actuator has a typical on/off time of20ms by parameters optimization research. A new hydraulic buffer with bidirectional, high speed movement is presented by analysis of load characteristics in the flow distribution process. Calculation and field tests show that, the load impact velocity is largely reduced with operation of this hydraulic buffer, so that the reliability of flow distribution system is greatly improved. In order to realize the industrial applications of EHFS, the new system is installed in the stepless capacity control equipment of reciprocating compressor, and the dynamic characteristics of EHFS with operation of dynamic gas forces is discussed. Experimental results show that the capacity control process is stable without impact and the discharge pressure fluctuation is less than0.2bar.
The main content of each chapter is summarized as following:
In chapter1, the application fields, engineering background and research value of flow distribution system are expounded. The special application background and the technology status of EHFS with large flow rate and high speed in stepless capacity control of reciprocating compressors are described in detail. Through the comparison of common flow distribution technology schemes, the technique features of high speed on/off flow distribution are highlighted. Relative technologies such as high speed electro-hydraulic actuator, high speed on/off valve and high speed hydraulic buffer are analyzed. The research significance and main study content are proposed in the final section of this chapter.
In chapter2, the performance indicators of high speed electro-hydraulic actuator are presented based on the application condition of EHFS. The common structure and working principle of electro-hydraulic actuator are introduced. The basic mathematical model is established based on the physical model of high speed on/off valve control hydraulic cylinder. The influences of main design factors on the actuator action delay are illustrated. Two new high speed actuators with different structures are proposed based on the theoretical analysis. Simulation models of electro-hydraulic actuators, dual high speed on/off valve parallel type and pilot type are established to do comparative research on their dynamic characteristics. Finally, optimization design theory of high speed actuators is proposed through analysis of structure factors.
In chapter3, by analyzing performance characteristics of high speed EHFS, the necessity of adopting hydraulic buffer is described and the performance requirements of hydraulic buffer are proposed. Based on the load features with high speed and short stroke, the structure concept of high speed hydraulic buffer is presented. Then its working principle is elaborated. And the main structural characteristics are determined by mathematical calculation. By establishing the simulation model of the bidirectional buffer, research on dynamic buffering characteristics of opening and closing process is deeply developed. The optimization design theory is summarized in the last section of this chapter.
In chapter4, the working principle of EHFS with large flow rate and high speed is expounded. The structure and elements of EHFS are introduced. Based on the physical modeling of EHFS, the mathematical model of valve motion is established with consideration of dynamic gas force. Then co-simulation model is established in AMESim and Matlab. The controllability, valve motion and dynamic characteristics of EHFS are discussed by simulation study. Theory basis for optimization design of EHFS is provided by analyzing the influence of key factors. Finally, a test rig for dynamic characteristics is built to validate simulation model and provide data support for improvement of EHFS design theory.
In chapter5, the application of EHFS with large flow rate and high speed in stepless capacity control of reciprocating compressors is introduced. The structure of stepless capacity control equipment is described, and the performance characteristics of capacity control compressor are listed. A prototype of EHFS with large flow rate and high speed is designed combined with technical requirements of stepless capacity control technology. Control system consisting of upper computer, lower computer, TDC sensor and communication module is built. Experimental research is carried out on the hydrocracking compressor in Sinopec Tianjin refinery and the results show a remarkable energy saving effect.
In chapter6, all achievements of the dissertation are summarized and the further research work is put forward.
引文
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