涡轮增压和废气再循环耦合的HSDI柴油机清洁燃烧机理研究
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摘要
现代高速直喷(High Speed Direct Injection,简称HSDI)柴油机是乘用车节能减排最有效的技术之一。HSDI柴油发动机兼备传统柴油机和汽油机的卓越性能：油耗低、低转速高扭矩和升功率大等优点。随着节能和减排问题的日益突出,国内多数汽车企业已经把节能减排的“重担”落在HSDI柴油机上。然而,柴油机传统燃烧方式的燃烧路径经过了T-φ图中的碳烟和NOx易生成区,造成碳烟和NOx缸内源排放较高,达到欧Ⅳ和欧V排放标准需要采用复杂的后处理系统。因此,探索可行的清洁高效的燃烧系统,减轻后处理系统的负担和降低后处理系统成本已成为世界柴油动力汽车发展的当务之急。
为了实现HSDI柴油机清洁燃烧,使缸内NOx源排放量达到欧V标准,同时尽可能地降低碳烟的排放量,本文通过仿真与试验相结合的方法,探索了HSDI柴油机通过增压后缸内引入大量冷却EGR实现稀释低温清洁燃烧相关技术路线和优化方法,包括增压技术和EGR控制技术。重点分析了EGR率和喷油规律等参数对缸内喷雾燃烧过程的机理和品质特性。论文研究的主要内容及创新性有以下几方面：
1)分析HSDI柴油机原机(采用单级VGT增压方式)的源排放特性,然后利用整车动力学仿真平台(GT-drive)将原机搭载于某轿车上进行NEDC和FTP75道路循环仿真分析,了解该发动机在这两个典型道路循环行驶工况下的工作区域以及对应工作区域的排放特性。分析结果得知HSDI柴油机应重点改善中低转速中低负荷的排放特性,同时为后期研究稀释低温清洁燃烧发动机工况点的选取提供重要依据。
2)通过反求方法建立了EGR率对增压压力的变化关系式和HSDI柴油机性能仿真模型,得到了多工况点最优VGT开度以及相应的EGR率。研究结果表明,对单级增压而言,增压压力随EGR率增加而增大,当EGR率增加到50%时,增压压力应达0.4MPa以上；对于两级增压而言,两级增压器分担的增压比相等,将造成大部分工作点处于压气机的低效区,不利于提高发动机的燃油经济性；增压压力压比分配应一级大一级小,有利于提高增压系统的效率和整机的燃油经济性。
3)针对内燃机各缸新鲜空气进入量和EGR量不均匀性带来的各种问题,建立了发动机稳态和瞬态进气过程1D&3D耦合仿真平台。利用该平台,研究分析了发动机稳定工况和多种变工况下新鲜空气和EGR的各缸均匀性,包括变工况过程中不同气缸同类气道的进气流量均匀性,以及各缸进气量大小的变化规律。此外,还研究了变工况过程中喷油量变化结束后,进气总量、新鲜空气、EGR、空燃比和BMEP的变化规律,以及趋于稳定的响应时间和响应特性。提出了一种EGR和新鲜空气各缸平衡快速响应的控制方法,该方法获得一项国家发明专利。通过建立该分析手段可以更好地分析和优化各缸的进气均匀性和响应特性,为了解发动机瞬态行为提供了重要的监测和分析手段,也为保证每一缸每一循环实现高效清洁燃烧提供重要的技术保障。
4)建立了稀释低温清洁燃烧仿真研究Kiva-3V平台,包括复杂几何结构拓扑方法,六面体结构网格生成技术。基于Kiva-3V仿真优化平台研究了常规燃烧方式(EGR率为0时)燃油喷射系统对喷雾和燃烧过程的影响,确定了喷嘴的最优几何参数。研究结果表明,过多的喷孔数不利于喷雾和燃烧的改善；油束夹角较小,NOx和碳烟排放升高；喷嘴凸出高度应与燃烧室深度及喷射夹角匹配合理。为了便于数据的快速处理和分析,评价分析发动机各项性能参数,课题开展过程中开发了一套“发动机性能评价数据库及数据自动化处理软件”,并获得了软件著作权。
5)针对HSDI柴油机中等转速中等负荷工况点(RPM=2500r/min BMEP=0.9MPa),利用仿真分析手段和实验验证相结合的方法研究了喷油规律、EGR率、过量空气系数、喷油定时、进气温度和涡流比等参数对高EGR率下喷雾燃烧过程的影响,并揭示NOx、碳烟和CO生成的环境和机理,分析各参数的变化对滞燃期、放热率峰值和排放污染物的变化趋势。通过多参数的耦合优化,得到改善燃烧过程,降低有害排放的参数技术路线,为后期标定该发动机实现欧V排放标准起到指导作用。
最后,通过实验验证了Kiva-3V仿真平台的可靠性,认为该仿真平台能很好的预测缸内喷雾燃烧过程以及排放污染物的生成量。该仿真研究平台不仅可作为发动机燃烧系统的有利开发工具,还可为制定EGR率和增压压力控制策略提供重要的分析手段,获得更多重要信息,为开发清洁低温燃烧系统提出优化方法和提出技术路线。
Modern high speed direct injection (HSDI) diesel engine for passenger car is one of the most effective technologies for energy saving and emission reduction. HSDI diesel engine combines the remarkable performances of both traditional diesel engine and gasoline engine, such as low fuel consumption, high torque at low speed, low noise and high power per liter, etc. As the issues of energy-saving and emission reducing have been becoming more prominent today, in China, most auto companies aim to develop HSDI diesel engine to cope with these problems. However, combustion path of traditional diesel engine passes through the regions which are easy to generate soot and NOx in T-φ plot, and it causes higher sources emission of soot and NOx in cylinder and can't meet the requirements of Euro IV and Euro V emission standard unless adopt complex post-processing system. Therefore, seeking for feasible clean efficient combustion system, lightening post-processing system's burden and reducing post-processing system cost become the most urgent tasks for diesel automobile industry development in the world.
The research aim of this paper is to make the in-cylinder NOx emissions of HSDI diesel engine reach the Euro V standard and reduce soot emissions as much as possible. By the means of combining simulation and experiment, the paper explores optimization methods and technical route of diluted low-temperature clean-combustion technologies on HSDI diesel engine with cooled EGR after turbocharging, including turbocharging and EGR control technology. The paper focuses on how the parameters, including EGR rate and injection law, etc, affect the mechanism and characteristics of quality for cylinder spray and combustion process. The main research contents and innovations are summarized as follows:
(1) Firstly, the emission characteristics of the original HSDI diesel engine (a single-stage turbocharging VGT mode) were analyzed. Then, by using the vehicle dynamics simulation platform (GT-drive), the HSDI diesel engine was added to a car which ran under the New European Driving Cycle (NEDC) and FTP75, and the operation areas and corresponding emission characteristics of this engine under the two road circular running conditions were studied. Results show that it should focus on improving emission characteristics of the HSDI diesel engine under the conditions of low speed and low load, which provide significant evidences for selecting operation point for the latter study.
(2) Secondly, the relationship among EGR rate and boosting pressure as well as the HSDI diesel engine performance simulation model were established through the reverse method. The optimal VGT opening and corresponding EGR rate were obtained. The results show that when the EGR rate increases to50%, boosting pressure should be greater than0.4MPa. For the two levels of supercharger, equivalent intensification causes most working points locate in low efficiency area of compressor, and that is bad for the engine's fuel economy. Unequal boosting pressure distribution can improve both the efficiency of pressurization system and the fuel economy of engine.
(3) Thirdly, to solve the problems caused by the uniformity between fresh air and EGR quantities in each cylinder of IC engine, its steady state and transient state simulation platform based on1D&3D coupling was established. Fresh air and EGR uniformity of each cylinder were analyzed under steady and a variety of non-steady operation conditions, including uniformity of intake flow mass for similar ports but different cylinders and intake mass variation laws of each cylinder. Additionally, the variation laws and response time and response characteristics of total intake mass, fresh air, EGR, BMEP and air-fuel ratio after fuel injection variation ends under non-steady operation condition were also studied. On that basis, a new control method for the balance of EGR and fresh air in each cylinder was proposed, and it was authorized national invention patent. The research method established in this paper is very helpful for analyzing and optimizing intake uniformity and response characteristics of each cylinder. In addition, this method not only gives a important monitoring and analysis means to study engine transient behavior, but also provides a important technical support to realize high efficient clean-combustion in each cylinder at each cycle.
(4) Next, a simulation platform of Kiva-3V for diluted low-temperature clean-combustion, including complex geometric structure topological method and hexahedral structure grid generation technology, was established. On this basis, the influences of fuel injection system on spray and combustion process under conventional combustion method (EGR rate is0) were studied, and finally the optimal geometrical parameters of nozzle were determined. Results show that too many holes is bad for spray and combustion improvement; the smaller fuel beam angle is, the more NOx and soot emissions would be; the nozzle bulge height, combustion chamber depth and jet angle should match reasonably. In order to facilitate data processing and analysis and evaluate performance parameters of the engine, an engine performance evaluation database and automatic data processing software was developed and granted software copyright.
(5) Based on the HSDI diesel engine under operation condition of RPM=2500r/min BMEP=0.9MPa, the effects of fuel injection pattern, EGR rate, excess air coefficient, injection timing, inlet temperature and swirl ratio on the processes of spray and combustion with a high EGR rate were studied by simulation analysis and experiment. Furthermore, the formation environment and mechanism of NOx, soot and CO, the effects of parameters variations on ignition delay, heat release rate and emission pollutants were analyzed. Through the coupling optimization of multiple parameters, an optimized route was determined for improving combustion process and reducing emission pollutants, and it would be helpful guideline in the next stage for engine calibration to meet Euro V emission standard.
Finally, the simulation platform of Kiva-3V was verified by experiment, and it was proved to be reliable and can predict in-cylinder spray combustion process and emission pollutants very well. The simulation platform is not only a favorable tool for engine combustion system development, but also provides important analysis method to determine EGR rate and supercharged pressure control strategy, at the same time gets more important information to propose optimization method and technical route for the development of clean low-temperature combustion system.
为了实现HSDI柴油机清洁燃烧,使缸内NOx源排放量达到欧V标准,同时尽可能地降低碳烟的排放量,本文通过仿真与试验相结合的方法,探索了HSDI柴油机通过增压后缸内引入大量冷却EGR实现稀释低温清洁燃烧相关技术路线和优化方法,包括增压技术和EGR控制技术。重点分析了EGR率和喷油规律等参数对缸内喷雾燃烧过程的机理和品质特性。论文研究的主要内容及创新性有以下几方面：
1)分析HSDI柴油机原机(采用单级VGT增压方式)的源排放特性,然后利用整车动力学仿真平台(GT-drive)将原机搭载于某轿车上进行NEDC和FTP75道路循环仿真分析,了解该发动机在这两个典型道路循环行驶工况下的工作区域以及对应工作区域的排放特性。分析结果得知HSDI柴油机应重点改善中低转速中低负荷的排放特性,同时为后期研究稀释低温清洁燃烧发动机工况点的选取提供重要依据。
2)通过反求方法建立了EGR率对增压压力的变化关系式和HSDI柴油机性能仿真模型,得到了多工况点最优VGT开度以及相应的EGR率。研究结果表明,对单级增压而言,增压压力随EGR率增加而增大,当EGR率增加到50%时,增压压力应达0.4MPa以上；对于两级增压而言,两级增压器分担的增压比相等,将造成大部分工作点处于压气机的低效区,不利于提高发动机的燃油经济性；增压压力压比分配应一级大一级小,有利于提高增压系统的效率和整机的燃油经济性。
3)针对内燃机各缸新鲜空气进入量和EGR量不均匀性带来的各种问题,建立了发动机稳态和瞬态进气过程1D&3D耦合仿真平台。利用该平台,研究分析了发动机稳定工况和多种变工况下新鲜空气和EGR的各缸均匀性,包括变工况过程中不同气缸同类气道的进气流量均匀性,以及各缸进气量大小的变化规律。此外,还研究了变工况过程中喷油量变化结束后,进气总量、新鲜空气、EGR、空燃比和BMEP的变化规律,以及趋于稳定的响应时间和响应特性。提出了一种EGR和新鲜空气各缸平衡快速响应的控制方法,该方法获得一项国家发明专利。通过建立该分析手段可以更好地分析和优化各缸的进气均匀性和响应特性,为了解发动机瞬态行为提供了重要的监测和分析手段,也为保证每一缸每一循环实现高效清洁燃烧提供重要的技术保障。
4)建立了稀释低温清洁燃烧仿真研究Kiva-3V平台,包括复杂几何结构拓扑方法,六面体结构网格生成技术。基于Kiva-3V仿真优化平台研究了常规燃烧方式(EGR率为0时)燃油喷射系统对喷雾和燃烧过程的影响,确定了喷嘴的最优几何参数。研究结果表明,过多的喷孔数不利于喷雾和燃烧的改善；油束夹角较小,NOx和碳烟排放升高；喷嘴凸出高度应与燃烧室深度及喷射夹角匹配合理。为了便于数据的快速处理和分析,评价分析发动机各项性能参数,课题开展过程中开发了一套“发动机性能评价数据库及数据自动化处理软件”,并获得了软件著作权。
5)针对HSDI柴油机中等转速中等负荷工况点(RPM=2500r/min BMEP=0.9MPa),利用仿真分析手段和实验验证相结合的方法研究了喷油规律、EGR率、过量空气系数、喷油定时、进气温度和涡流比等参数对高EGR率下喷雾燃烧过程的影响,并揭示NOx、碳烟和CO生成的环境和机理,分析各参数的变化对滞燃期、放热率峰值和排放污染物的变化趋势。通过多参数的耦合优化,得到改善燃烧过程,降低有害排放的参数技术路线,为后期标定该发动机实现欧V排放标准起到指导作用。
最后,通过实验验证了Kiva-3V仿真平台的可靠性,认为该仿真平台能很好的预测缸内喷雾燃烧过程以及排放污染物的生成量。该仿真研究平台不仅可作为发动机燃烧系统的有利开发工具,还可为制定EGR率和增压压力控制策略提供重要的分析手段,获得更多重要信息,为开发清洁低温燃烧系统提出优化方法和提出技术路线。
Modern high speed direct injection (HSDI) diesel engine for passenger car is one of the most effective technologies for energy saving and emission reduction. HSDI diesel engine combines the remarkable performances of both traditional diesel engine and gasoline engine, such as low fuel consumption, high torque at low speed, low noise and high power per liter, etc. As the issues of energy-saving and emission reducing have been becoming more prominent today, in China, most auto companies aim to develop HSDI diesel engine to cope with these problems. However, combustion path of traditional diesel engine passes through the regions which are easy to generate soot and NOx in T-φ plot, and it causes higher sources emission of soot and NOx in cylinder and can't meet the requirements of Euro IV and Euro V emission standard unless adopt complex post-processing system. Therefore, seeking for feasible clean efficient combustion system, lightening post-processing system's burden and reducing post-processing system cost become the most urgent tasks for diesel automobile industry development in the world.
The research aim of this paper is to make the in-cylinder NOx emissions of HSDI diesel engine reach the Euro V standard and reduce soot emissions as much as possible. By the means of combining simulation and experiment, the paper explores optimization methods and technical route of diluted low-temperature clean-combustion technologies on HSDI diesel engine with cooled EGR after turbocharging, including turbocharging and EGR control technology. The paper focuses on how the parameters, including EGR rate and injection law, etc, affect the mechanism and characteristics of quality for cylinder spray and combustion process. The main research contents and innovations are summarized as follows:
(1) Firstly, the emission characteristics of the original HSDI diesel engine (a single-stage turbocharging VGT mode) were analyzed. Then, by using the vehicle dynamics simulation platform (GT-drive), the HSDI diesel engine was added to a car which ran under the New European Driving Cycle (NEDC) and FTP75, and the operation areas and corresponding emission characteristics of this engine under the two road circular running conditions were studied. Results show that it should focus on improving emission characteristics of the HSDI diesel engine under the conditions of low speed and low load, which provide significant evidences for selecting operation point for the latter study.
(2) Secondly, the relationship among EGR rate and boosting pressure as well as the HSDI diesel engine performance simulation model were established through the reverse method. The optimal VGT opening and corresponding EGR rate were obtained. The results show that when the EGR rate increases to50%, boosting pressure should be greater than0.4MPa. For the two levels of supercharger, equivalent intensification causes most working points locate in low efficiency area of compressor, and that is bad for the engine's fuel economy. Unequal boosting pressure distribution can improve both the efficiency of pressurization system and the fuel economy of engine.
(3) Thirdly, to solve the problems caused by the uniformity between fresh air and EGR quantities in each cylinder of IC engine, its steady state and transient state simulation platform based on1D&3D coupling was established. Fresh air and EGR uniformity of each cylinder were analyzed under steady and a variety of non-steady operation conditions, including uniformity of intake flow mass for similar ports but different cylinders and intake mass variation laws of each cylinder. Additionally, the variation laws and response time and response characteristics of total intake mass, fresh air, EGR, BMEP and air-fuel ratio after fuel injection variation ends under non-steady operation condition were also studied. On that basis, a new control method for the balance of EGR and fresh air in each cylinder was proposed, and it was authorized national invention patent. The research method established in this paper is very helpful for analyzing and optimizing intake uniformity and response characteristics of each cylinder. In addition, this method not only gives a important monitoring and analysis means to study engine transient behavior, but also provides a important technical support to realize high efficient clean-combustion in each cylinder at each cycle.
(4) Next, a simulation platform of Kiva-3V for diluted low-temperature clean-combustion, including complex geometric structure topological method and hexahedral structure grid generation technology, was established. On this basis, the influences of fuel injection system on spray and combustion process under conventional combustion method (EGR rate is0) were studied, and finally the optimal geometrical parameters of nozzle were determined. Results show that too many holes is bad for spray and combustion improvement; the smaller fuel beam angle is, the more NOx and soot emissions would be; the nozzle bulge height, combustion chamber depth and jet angle should match reasonably. In order to facilitate data processing and analysis and evaluate performance parameters of the engine, an engine performance evaluation database and automatic data processing software was developed and granted software copyright.
(5) Based on the HSDI diesel engine under operation condition of RPM=2500r/min BMEP=0.9MPa, the effects of fuel injection pattern, EGR rate, excess air coefficient, injection timing, inlet temperature and swirl ratio on the processes of spray and combustion with a high EGR rate were studied by simulation analysis and experiment. Furthermore, the formation environment and mechanism of NOx, soot and CO, the effects of parameters variations on ignition delay, heat release rate and emission pollutants were analyzed. Through the coupling optimization of multiple parameters, an optimized route was determined for improving combustion process and reducing emission pollutants, and it would be helpful guideline in the next stage for engine calibration to meet Euro V emission standard.
Finally, the simulation platform of Kiva-3V was verified by experiment, and it was proved to be reliable and can predict in-cylinder spray combustion process and emission pollutants very well. The simulation platform is not only a favorable tool for engine combustion system development, but also provides important analysis method to determine EGR rate and supercharged pressure control strategy, at the same time gets more important information to propose optimization method and technical route for the development of clean low-temperature combustion system.
引文
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