8AYT10缸内直喷发动机开发及关键技术研究
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摘要
随着油价的不断上涨及排放法规的日趋严格，高效、节能、环保已成为开发发动机新产品的必备条件，具有升功率高、燃油经济性好、排放低、响应速度快的缸内直喷汽油机将成为未来发动机中的主流产品。
本文在8AYN10气道喷射（PFI）汽油机基础上，完成了8AYT10缸内直喷（GDI）汽油机的全新开发，设计了高滚流比气道和特殊顶面凹坑的活塞，优化了活塞环结构、进气管参数和凸轮轴型线，进行了直喷系统的设计及增压器的匹配研究，评价了增压器的高原能力和瞬态响应性能。整机试验结果表明，8AYT10发动机的动力性、经济性和排放指标均满足设计要求，且达到了国际领先水平。
采用CFD模拟技术研究了缸内直喷汽油机的喷雾过程、速度场、湍流动能、空燃比分布及温度场分布，揭示了缸内滚流从孕育、发展到被压缩及破碎的过程规律。同时发现在点火时刻火花塞电极处形成了稳定的流场，并且缸内流场流速和湍流动能以火花塞电极为中心向燃烧室周围呈现从小到大的梯度分布，这种分布有利于稳定燃烧和火焰传播，表明了本文燃烧系统设计的合理性。同时分析了不同喷油器方案对缸内混合气均匀度、燃油浓度及燃油撞壁量的影响，结果表明燃油撞壁量受喷油器方案的影响较大，方案1喷油器相比另两个方案总撞壁量少，且不存在撞击气门现象，说明方案1较为合理。通过研究二次喷射对缸内混合气形成的影响，提出了采用二次喷射策略降低油束贯穿距、减少燃油撞壁量的具体方案，并在冷起动工况中得到了验证。
本文设计开发了研究用缸内直喷光学单缸机，建立了先进的光学测试系统，实现了缸内喷雾过程的可视化研究。利用光学单缸机开展了不同工况下喷雾形状、气流运动及燃烧室结构之间相互作用规律的研究，并与CFD模拟计算结果进行对比分析，证明了模拟计算结果的正确性。分析了不同工况下缸内燃烧时火焰传播及碳烟生成情况，发现在转速1650r/min、全负荷工况下采用二次喷射策略，减小了油束贯穿距，可有效地降低碳烟生成。最后综合光学单缸机试验结果和CFD模拟计算结果确定了方案1喷油器作为最终方案，并推荐冷起动工况下第二次喷油的最佳时刻设置在-100°CAATDC。国内首次采用光学单缸机与CFD模拟技术相结合的研究方法，在试验中验证模拟计算，并通过模拟计算进一步指导试验，使得开发方案的选择更加准确，有效地提高了开发效率，降低了开发风险。
通过建立的GDI发动机试验台架，研究了喷油定时对发动机燃烧特性的影响。结果表明，喷油时刻过早，易出现油束撞击活塞而造成湿壁现象，使得燃烧室壁面温度低，油气混合速度变慢，燃烧热效率下降；而喷油时刻过晚，油气没有充分的时间混合，在点火时刻均匀性较差，火焰传播速度较慢，热效率降低，并影响燃烧稳定性。喷油定时存在最佳时刻，且在最佳喷油时刻，发动机的累积放热率、燃烧持续期均较短，循环变动率较低，输出转矩大，燃油消耗率低，但因最佳喷油时刻燃烧充分，最高燃烧温度高，NOx排放也相对较高。不同喷油压力工况的试验表明，喷油压力越大，喷射出的燃油雾化质量越好，油气混合的更加充分，发动机发出的转矩越大，平均有效燃油消耗率越低。喷油压力的提高对降低HC排放最为明显，而对CO和NOx排放的影响则相对较小。对不同进、排气VVT开度的试验表明，发动机燃油消耗率随着排气VVT开度的增加逐渐降低，而对于燃烧循环变动率而言，排气VVT开度对循环变动率的影响大于进气VVT开度对循环变动率的影响，但总体来说循环变动率控制在3%以内。
建立了光纤测试系统，实现了缸内不规则燃烧现象的可视化研究，分析了发动机负荷和喷油定时对常规爆震的影响机理，得出了有效控制爆震的方法，在低速、大负荷工况的测试结果表明8AYT10发动机火焰传播的不规则度小于40%，说明该发动机具有较好的抗爆震性能。开展了早燃及超级爆震现象的试验研究，总结了缸内早燃发生的时刻及位置分布规律，提出了通过二次喷射策略抑制早燃的思路及具体方法。试验结果表明，在转速1500r/min、全负荷工况下采用优化后的二次喷射策略，发动机在试验工况内累计运行3h，未出现早燃现象，证明了抑制早燃方法的有效性。
通过对GDI发动机振动噪声产生机理的分析，提出了通过减小配缸间隙、偏置活塞销、增大高压油泵柱塞直径、减小喷油速率及优化增压器等方法降低发动机的机械噪声，通过优化点火提前角、改变系统燃烧模式及控制燃油质量等方法降低发动机的燃烧噪声，具有重要的指导意义。
With fuel prices rising and increasingly strict emissions regulations, high efficiency,energy saving and environmental protection has become the essential conditions of a newengine product development. Gasoline Direct Injection (GDI) engine has high power, goodfuel economy, low emissions and rapid response, so it’s main product in the future.
Based on the8AYN10PFI engine,8AYT10GDI engine was designed. High tumbleratio port and piston with special designed top surface have been developed, the piston ringstructure, intake pipe parameter and cam lobe have been optimized, GDI system wasdesigned and turbocharger matching has been studied, and plateau performance, transientresponse character have been estimated. The bench test datas show that the power, fueleconomy and emissions meet expectation, and reached the international leading level.
CFD simulation technology was used to study spray process, speed field, turbulentkinetic energy, air-fuel ratio distribution and temperature distribution of GDI engine.Revealed tumble feature from birth, development to be compressed and broken process incylinder. and find that stable flow field was formed in spark plug electrodes at ignitiontiming, flow velocity and turbulent kinetic energy were gradient distribution from spark plugelectrode to the wall of combustion chamber, and these distribution are conducive to stablecombustion and flame propagation, proved combustion system design of8AYT10isreasonable. The effects of different injectors to mixture uniformity, fuel concentration andfuel impingement wall were analyzed, the results show that the fuel impingement wall iseffected by injector scheme greatly. Scheme1injector assembly was reasonable for littlefuel impingement wall quantity. The effects of secondary injection to mixture formationprocess were studied in cylinder, and proposed the scheme that using secondary injectionstrategies to reduce spray penetration, decrease fuel impingement wall in GDI engine, andthis scheme was verified in cold start condition.
GDI optical single-cylinder engine was designed for researching, and optical testingsystem was established, and it realized visualization of spray process in cylinder. Sprayshape, air motion and combustion chamber structure interaction rules were researched byusing optical single cylinder engine, and the results were compared with CFD calculation,the conclusion was that simulation results were right. Combustion flame propagation underdifferent conditions and soot formation were analysed, and found that through two times injection, the spray penetration can be decreased, and reducing soot formation at1650r/min,full load. Finally, integrated optical single cylinder engine results and CFD simulationresults, the scheme1injector was confirmed and set-100°CA ATDC as second injectiontimming at cold start condition. Optical single cylinder engine testing and CFD simulationtechnology were used in researching at the same time, and this was the first time. Thesimulation results were validated in experiment, and the CFD simulation can guide theexperiment further. Development schemes were more accurately by using this method, andimproved development efficiency, reduced development risks.
Through GDI engine test bench, the effects of injection timing on combustioncharacteristics of GDI engine was studied. The results show that if injection timing was tooearly, fuel beam can impinge on piston and cause wet wall phenomenon, reducedtemperature of chamber wall, decreased mixture speed of air and fuel, and heat efficiencywas low. While if injection timing was too late, there was no enough time for air and fuelmixture, and uniformity was poor at ignition time, flame propagation speed was slow,thermal efficiency was decreased, and combustion stability was poor. Injection timing hasthe best time, and in the best injection timing, cumulative heat release rate and combustionduration of engine were short, and cyclic variation was low, torque was bigger, fuelconsumption was low, but the maximum combustion temperature was high, and NOxemission was high. Experiment of different injection pressure condition shows that ifinjection pressure was high, air and fuel mixture were fully and torque was high, fuelconsumption rate was low. High injection pressure reduced HC emission, but the effects6onCO and NOx emissions were smaller. VVT opening test show that, fuel consumption of theengine was reduced with increasing exhaust VVT opening, while for cyclic variation rate,the effect of exhaust VVT opening to cyclic variation was greater than intake VVT opening,but the cyclic variation rate can be controlled within3%.
A fiber test system was built, and realizing visualization research of irregularcombustion in cylinder, The influence mechanism of conventional knock with engine loadand fuel injection timing were studied, and obtained the effective methods to control knock.Test results at low speed, high load showed that the flame propagation irregular less than40%of8AYT10engine, indicating that the engine has high anti-konck performance. Thepre-ignition and super knock were studied in GDI engine, researched distribution of timeand location when pre-ignition was occur, and proposed the strategy and detail methods forrestraining pre-ignition by secondary injection. The results at1500r/min, full load showthat there was no pre-ignition phenomenon in GDI engine after running3hours by using optimized secondary injection strategy, proved the methods were effective.
Generation mechanism of NVH was analyzed in GDI engine, and the methods forreduce engine’s mechanical noise were proposed, such as decreasing gap between cylinderand piston, using bias piston pin, increasing diameter of the high pressure fuel pumpplunger, reducing injection rate and optimizing turbocharger etc. The methods to reduceengine’s combustion noise were proposed too, such as optimizing ignition advance angle,changing combustion mode and controlling fuel quality. All of these methods haveimportant guiding significance to improve NVH performance of GDI engine.
本文在8AYN10气道喷射（PFI）汽油机基础上，完成了8AYT10缸内直喷（GDI）汽油机的全新开发，设计了高滚流比气道和特殊顶面凹坑的活塞，优化了活塞环结构、进气管参数和凸轮轴型线，进行了直喷系统的设计及增压器的匹配研究，评价了增压器的高原能力和瞬态响应性能。整机试验结果表明，8AYT10发动机的动力性、经济性和排放指标均满足设计要求，且达到了国际领先水平。
采用CFD模拟技术研究了缸内直喷汽油机的喷雾过程、速度场、湍流动能、空燃比分布及温度场分布，揭示了缸内滚流从孕育、发展到被压缩及破碎的过程规律。同时发现在点火时刻火花塞电极处形成了稳定的流场，并且缸内流场流速和湍流动能以火花塞电极为中心向燃烧室周围呈现从小到大的梯度分布，这种分布有利于稳定燃烧和火焰传播，表明了本文燃烧系统设计的合理性。同时分析了不同喷油器方案对缸内混合气均匀度、燃油浓度及燃油撞壁量的影响，结果表明燃油撞壁量受喷油器方案的影响较大，方案1喷油器相比另两个方案总撞壁量少，且不存在撞击气门现象，说明方案1较为合理。通过研究二次喷射对缸内混合气形成的影响，提出了采用二次喷射策略降低油束贯穿距、减少燃油撞壁量的具体方案，并在冷起动工况中得到了验证。
本文设计开发了研究用缸内直喷光学单缸机，建立了先进的光学测试系统，实现了缸内喷雾过程的可视化研究。利用光学单缸机开展了不同工况下喷雾形状、气流运动及燃烧室结构之间相互作用规律的研究，并与CFD模拟计算结果进行对比分析，证明了模拟计算结果的正确性。分析了不同工况下缸内燃烧时火焰传播及碳烟生成情况，发现在转速1650r/min、全负荷工况下采用二次喷射策略，减小了油束贯穿距，可有效地降低碳烟生成。最后综合光学单缸机试验结果和CFD模拟计算结果确定了方案1喷油器作为最终方案，并推荐冷起动工况下第二次喷油的最佳时刻设置在-100°CAATDC。国内首次采用光学单缸机与CFD模拟技术相结合的研究方法，在试验中验证模拟计算，并通过模拟计算进一步指导试验，使得开发方案的选择更加准确，有效地提高了开发效率，降低了开发风险。
通过建立的GDI发动机试验台架，研究了喷油定时对发动机燃烧特性的影响。结果表明，喷油时刻过早，易出现油束撞击活塞而造成湿壁现象，使得燃烧室壁面温度低，油气混合速度变慢，燃烧热效率下降；而喷油时刻过晚，油气没有充分的时间混合，在点火时刻均匀性较差，火焰传播速度较慢，热效率降低，并影响燃烧稳定性。喷油定时存在最佳时刻，且在最佳喷油时刻，发动机的累积放热率、燃烧持续期均较短，循环变动率较低，输出转矩大，燃油消耗率低，但因最佳喷油时刻燃烧充分，最高燃烧温度高，NOx排放也相对较高。不同喷油压力工况的试验表明，喷油压力越大，喷射出的燃油雾化质量越好，油气混合的更加充分，发动机发出的转矩越大，平均有效燃油消耗率越低。喷油压力的提高对降低HC排放最为明显，而对CO和NOx排放的影响则相对较小。对不同进、排气VVT开度的试验表明，发动机燃油消耗率随着排气VVT开度的增加逐渐降低，而对于燃烧循环变动率而言，排气VVT开度对循环变动率的影响大于进气VVT开度对循环变动率的影响，但总体来说循环变动率控制在3%以内。
建立了光纤测试系统，实现了缸内不规则燃烧现象的可视化研究，分析了发动机负荷和喷油定时对常规爆震的影响机理，得出了有效控制爆震的方法，在低速、大负荷工况的测试结果表明8AYT10发动机火焰传播的不规则度小于40%，说明该发动机具有较好的抗爆震性能。开展了早燃及超级爆震现象的试验研究，总结了缸内早燃发生的时刻及位置分布规律，提出了通过二次喷射策略抑制早燃的思路及具体方法。试验结果表明，在转速1500r/min、全负荷工况下采用优化后的二次喷射策略，发动机在试验工况内累计运行3h，未出现早燃现象，证明了抑制早燃方法的有效性。
通过对GDI发动机振动噪声产生机理的分析，提出了通过减小配缸间隙、偏置活塞销、增大高压油泵柱塞直径、减小喷油速率及优化增压器等方法降低发动机的机械噪声，通过优化点火提前角、改变系统燃烧模式及控制燃油质量等方法降低发动机的燃烧噪声，具有重要的指导意义。
With fuel prices rising and increasingly strict emissions regulations, high efficiency,energy saving and environmental protection has become the essential conditions of a newengine product development. Gasoline Direct Injection (GDI) engine has high power, goodfuel economy, low emissions and rapid response, so it’s main product in the future.
Based on the8AYN10PFI engine,8AYT10GDI engine was designed. High tumbleratio port and piston with special designed top surface have been developed, the piston ringstructure, intake pipe parameter and cam lobe have been optimized, GDI system wasdesigned and turbocharger matching has been studied, and plateau performance, transientresponse character have been estimated. The bench test datas show that the power, fueleconomy and emissions meet expectation, and reached the international leading level.
CFD simulation technology was used to study spray process, speed field, turbulentkinetic energy, air-fuel ratio distribution and temperature distribution of GDI engine.Revealed tumble feature from birth, development to be compressed and broken process incylinder. and find that stable flow field was formed in spark plug electrodes at ignitiontiming, flow velocity and turbulent kinetic energy were gradient distribution from spark plugelectrode to the wall of combustion chamber, and these distribution are conducive to stablecombustion and flame propagation, proved combustion system design of8AYT10isreasonable. The effects of different injectors to mixture uniformity, fuel concentration andfuel impingement wall were analyzed, the results show that the fuel impingement wall iseffected by injector scheme greatly. Scheme1injector assembly was reasonable for littlefuel impingement wall quantity. The effects of secondary injection to mixture formationprocess were studied in cylinder, and proposed the scheme that using secondary injectionstrategies to reduce spray penetration, decrease fuel impingement wall in GDI engine, andthis scheme was verified in cold start condition.
GDI optical single-cylinder engine was designed for researching, and optical testingsystem was established, and it realized visualization of spray process in cylinder. Sprayshape, air motion and combustion chamber structure interaction rules were researched byusing optical single cylinder engine, and the results were compared with CFD calculation,the conclusion was that simulation results were right. Combustion flame propagation underdifferent conditions and soot formation were analysed, and found that through two times injection, the spray penetration can be decreased, and reducing soot formation at1650r/min,full load. Finally, integrated optical single cylinder engine results and CFD simulationresults, the scheme1injector was confirmed and set-100°CA ATDC as second injectiontimming at cold start condition. Optical single cylinder engine testing and CFD simulationtechnology were used in researching at the same time, and this was the first time. Thesimulation results were validated in experiment, and the CFD simulation can guide theexperiment further. Development schemes were more accurately by using this method, andimproved development efficiency, reduced development risks.
Through GDI engine test bench, the effects of injection timing on combustioncharacteristics of GDI engine was studied. The results show that if injection timing was tooearly, fuel beam can impinge on piston and cause wet wall phenomenon, reducedtemperature of chamber wall, decreased mixture speed of air and fuel, and heat efficiencywas low. While if injection timing was too late, there was no enough time for air and fuelmixture, and uniformity was poor at ignition time, flame propagation speed was slow,thermal efficiency was decreased, and combustion stability was poor. Injection timing hasthe best time, and in the best injection timing, cumulative heat release rate and combustionduration of engine were short, and cyclic variation was low, torque was bigger, fuelconsumption was low, but the maximum combustion temperature was high, and NOxemission was high. Experiment of different injection pressure condition shows that ifinjection pressure was high, air and fuel mixture were fully and torque was high, fuelconsumption rate was low. High injection pressure reduced HC emission, but the effects6onCO and NOx emissions were smaller. VVT opening test show that, fuel consumption of theengine was reduced with increasing exhaust VVT opening, while for cyclic variation rate,the effect of exhaust VVT opening to cyclic variation was greater than intake VVT opening,but the cyclic variation rate can be controlled within3%.
A fiber test system was built, and realizing visualization research of irregularcombustion in cylinder, The influence mechanism of conventional knock with engine loadand fuel injection timing were studied, and obtained the effective methods to control knock.Test results at low speed, high load showed that the flame propagation irregular less than40%of8AYT10engine, indicating that the engine has high anti-konck performance. Thepre-ignition and super knock were studied in GDI engine, researched distribution of timeand location when pre-ignition was occur, and proposed the strategy and detail methods forrestraining pre-ignition by secondary injection. The results at1500r/min, full load showthat there was no pre-ignition phenomenon in GDI engine after running3hours by using optimized secondary injection strategy, proved the methods were effective.
Generation mechanism of NVH was analyzed in GDI engine, and the methods forreduce engine’s mechanical noise were proposed, such as decreasing gap between cylinderand piston, using bias piston pin, increasing diameter of the high pressure fuel pumpplunger, reducing injection rate and optimizing turbocharger etc. The methods to reduceengine’s combustion noise were proposed too, such as optimizing ignition advance angle,changing combustion mode and controlling fuel quality. All of these methods haveimportant guiding significance to improve NVH performance of GDI engine.
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