内燃机车用增压器性能研究
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摘要
本课题是以目前运营中的引进增压器VTC254为基础，针对我国铁路内燃机车的特点，为解决西部高原内燃机增压的需要和我国铁路机车不断提速的需要，对我国目前的主营机型16V280柴油机匹配的增压器，特别是对压气机进行研究。主要内容包括：提出一种全新的压气机叶轮技术和概念，这种技术将传统的导风轮和压气机分开设计、单独加工改为整体设计、整体加工的单体叶轮；从增压器与柴油机配机计算所得出的基本参数出发，通过对压气机进行热力计算，确定压气机的基本结构参数；再对叶型以及叶轮轮廓与叶轮罩壳的配合间隙进行优化，对新设计的压气机进行喘振和堵塞分析；通过增压器平台性能试验，验证了新设计的压气机的性能水平得到了较大的提高，达到了提高增压器的整体性能水平的目的；通过增压器与柴油机配机试验、以及增压器用于高原条件下的牵引试验，验证了新设计的压气机不但具有高效率，还改善了高效率区的流量分布，使牵引特性线贯穿高效率区。
从分体叶轮到整体叶轮，在工艺水平上已具有较好的基础，前倾后弯叶轮设计中的较大前倾角通过五轴联动铣床实现。新型号的叶轮能有效减少分流损失、潜流损失、摩擦损失、鼓风环流等损失，能有效提高压气机的效率、柴油机的性能水平，改善经济运营指标。该产品自研制成功到目前，已有300多台投入运行。特别是在高原地带，装用这种增压器后，能使柴油机功率少修正或不修正，较好地满足了铁路内燃机车在西部高原条件下的增压需要。
Based on the imported turbocharger VTC254 which is in operation, considering the high altitude in the west as well as continuously speed-raising need and the characteristic of our railway diesel locomotive, in this paper 16V280 diesel engine turbocharger, especially the compressor is discussed. For example, through calculation on the match of turbocharger and diesel engine, a brand-new technology for compressor wheel is introduced. This new technology changes from the traditional method by which the induced and compressor wheel separately are designed and produced to a new one by which the one-piece compressor is designed. On the basis of this new technology and the optimum blade profile, the performance of both the compressor and the turbocharger is largely improved. Through the heating power calculation of the compressor, the analysis of the surge and the block of the compressor, the test-bed performance test of the turbocharger, the matching test of turbocharger and diesel engine, the propulsion test of the turbocharger on plateau condition, it is proved that the newly-designed compressor not only has high efficiency, but also improves the flow distribution in the high efficiency area so that the propulsion line can run through the high efficiency area.
Impeller changed from two-piece to one-piece because of the good base of the technology level. A five-axis milling machine is used to manufacture the blades, which are swept back at the impeller outlet and have a trailing edge which is inclined slightly in the axial direction. The one-piece impeller can effectively reduce the by-pass loss, friction loss, etc. and improve the efficiency of the compressor as well as the performance of the diesel engine. Since the successful development of this product, there have been more than 300 sets of the similar turbocharger put into operation. With this turbocharger on high altitude area, the power of diesel engine need not be modified or less modified, which meets the charging need of the diesel locomotive in the west plateau condition in China.
从分体叶轮到整体叶轮，在工艺水平上已具有较好的基础，前倾后弯叶轮设计中的较大前倾角通过五轴联动铣床实现。新型号的叶轮能有效减少分流损失、潜流损失、摩擦损失、鼓风环流等损失，能有效提高压气机的效率、柴油机的性能水平，改善经济运营指标。该产品自研制成功到目前，已有300多台投入运行。特别是在高原地带，装用这种增压器后，能使柴油机功率少修正或不修正，较好地满足了铁路内燃机车在西部高原条件下的增压需要。
Based on the imported turbocharger VTC254 which is in operation, considering the high altitude in the west as well as continuously speed-raising need and the characteristic of our railway diesel locomotive, in this paper 16V280 diesel engine turbocharger, especially the compressor is discussed. For example, through calculation on the match of turbocharger and diesel engine, a brand-new technology for compressor wheel is introduced. This new technology changes from the traditional method by which the induced and compressor wheel separately are designed and produced to a new one by which the one-piece compressor is designed. On the basis of this new technology and the optimum blade profile, the performance of both the compressor and the turbocharger is largely improved. Through the heating power calculation of the compressor, the analysis of the surge and the block of the compressor, the test-bed performance test of the turbocharger, the matching test of turbocharger and diesel engine, the propulsion test of the turbocharger on plateau condition, it is proved that the newly-designed compressor not only has high efficiency, but also improves the flow distribution in the high efficiency area so that the propulsion line can run through the high efficiency area.
Impeller changed from two-piece to one-piece because of the good base of the technology level. A five-axis milling machine is used to manufacture the blades, which are swept back at the impeller outlet and have a trailing edge which is inclined slightly in the axial direction. The one-piece impeller can effectively reduce the by-pass loss, friction loss, etc. and improve the efficiency of the compressor as well as the performance of the diesel engine. Since the successful development of this product, there have been more than 300 sets of the similar turbocharger put into operation. With this turbocharger on high altitude area, the power of diesel engine need not be modified or less modified, which meets the charging need of the diesel locomotive in the west plateau condition in China.
引文
[1] N.Watson, Turbochargers for the 1980s-Current Trends and Future Prospects, SAE 790063, pp.23-56
[2] 朱梅林，《涡轮增压器原理》，国防工业出版社，1982, pp185-324
[3] 曹孝瑾，《涡轮增压器与柴油机的匹配》，国防工业出版社，1984，pp12-24
[4] 顾宏中，《内燃机中的气体流动用其数值分析》，国防工业出版社，1985，pp200-234
[5] J.L.Leroy etc, New Development of Turbocompound Diesel Engines, Turbocharging and Turbochargers, I Mech E 1986，pp5-32
[6] D.V.Roberts etc, Experimental Investigation of the Fluid Dynamics of Altermative Turbocharger Compressor Volutes,I Mech E,1986， pp145-147
[7] H.Macinnes etc, Comparison of Power loss between Full Floating and Semi-Floating Turbocharger Bearings, c46/82, I Mech E 1982，pp23-25
[8] Akio Wagamatsu etc, Vibration of Impeller, Bulletin of JSME,1977，pp345-356
[9]《叶轮机械气动热力计算、设计与试验经验交流会文集》，1976 ，pp1234-1245
[10] 唐开元，《柴油机增压原理》，国防工业出版社，1985，pp34-256
[11] 陆瑞松，林发森，张瑞，《内燃机的传热与热负荷》，国防工业出版社，1985，pp12-24
[12] 顾宏中，《涡轮增压柴油机热力过程模拟计算》，上海交通大学出版社，1985，pp453-480
[13] 曾丹苓等，《工程热力学》，高等教育出版社，1980，pp534-560
[14] 蒋德明，《内燃机的涡轮增压》，机械工业出版社，1986，pp34-245
[15] 王补宣，《工程传热传质学》，科学出版社，1986，pp432-450
[16] [英]R.S.本森，《内燃机的热力学和空气动力学》，机械工业出版社，1986，pp134-145
[17] Appel M,Die Weiterentwichelte MAN-B&W-Turboladerbaureihe NR/R mit Radailturbine, MTZ 1985，pp1-12
[18] Hugh Maclnnes, Turbochargers, H.P.Books, 1976，pp78-110
[19] R.Keiper, N.Zloch, Contributions to the operating Strength of Centrifugal Compressor wheels for Turbochargers, I Mech E, 1986，pp34-45
[20] 李燕生，陆桂林，《向心透平与离心压气机》，机械工业出版社，1987，pp215-245
[21] Takashi Mikogrami etc, Recent Aerodynamic Advancements in Turbocharger Compressor Stages, SAE 880794，pp1-5
[22] N.Watson, Turbocharged Engines (Internal Combustion Engines, Chapter Four) Academic Press Limited, 1988，pp34-45
[23] H.G.Bozury etc, The MAN B&W Medium Speed Engine Series-The Engine Concept for the 90s, 18th CIMAC, 1989，pp4-245
[24] Zhao Xiaolu etc, An Approximate Three-Dimensional Aerodynamic Design Method for Centrifugal Impeller Blades, Trans of the ASME, January 1990，pp56-245
[25] Project planning manual Turbocharger, NA series, MAN B&W, 1995，pp34-165
[26] A.Whitfield N.C.Baines, Design of Radial Turbomachines, Longman Singapore Publishers, 1990，pp74-85
[27] R.C.Pampreen, Automotive Research Compressor Experience, Journal of Turbomachinery, January, 1990，pp654-1245
[28] 朱大鑫，《涡轮增压与涡轮增压器》，兵器工业第七0研究所，1997，pp12-45
[29] 顾宏中，《涡轮增压柴油机性能研究》，上海交通大学出版社，1998，pp62-165
[30] 万德玉，《柴油机试验测试》，学苑出版社，2000，pp78-89
[31]《第十二届全国大功率柴油机学术年会论文集》，2001，pp75-234
[2] 朱梅林，《涡轮增压器原理》，国防工业出版社，1982, pp185-324
[3] 曹孝瑾，《涡轮增压器与柴油机的匹配》，国防工业出版社，1984，pp12-24
[4] 顾宏中，《内燃机中的气体流动用其数值分析》，国防工业出版社，1985，pp200-234
[5] J.L.Leroy etc, New Development of Turbocompound Diesel Engines, Turbocharging and Turbochargers, I Mech E 1986，pp5-32
[6] D.V.Roberts etc, Experimental Investigation of the Fluid Dynamics of Altermative Turbocharger Compressor Volutes,I Mech E,1986， pp145-147
[7] H.Macinnes etc, Comparison of Power loss between Full Floating and Semi-Floating Turbocharger Bearings, c46/82, I Mech E 1982，pp23-25
[8] Akio Wagamatsu etc, Vibration of Impeller, Bulletin of JSME,1977，pp345-356
[9]《叶轮机械气动热力计算、设计与试验经验交流会文集》，1976 ，pp1234-1245
[10] 唐开元，《柴油机增压原理》，国防工业出版社，1985，pp34-256
[11] 陆瑞松，林发森，张瑞，《内燃机的传热与热负荷》，国防工业出版社，1985，pp12-24
[12] 顾宏中，《涡轮增压柴油机热力过程模拟计算》，上海交通大学出版社，1985，pp453-480
[13] 曾丹苓等，《工程热力学》，高等教育出版社，1980，pp534-560
[14] 蒋德明，《内燃机的涡轮增压》，机械工业出版社，1986，pp34-245
[15] 王补宣，《工程传热传质学》，科学出版社，1986，pp432-450
[16] [英]R.S.本森，《内燃机的热力学和空气动力学》，机械工业出版社，1986，pp134-145
[17] Appel M,Die Weiterentwichelte MAN-B&W-Turboladerbaureihe NR/R mit Radailturbine, MTZ 1985，pp1-12
[18] Hugh Maclnnes, Turbochargers, H.P.Books, 1976，pp78-110
[19] R.Keiper, N.Zloch, Contributions to the operating Strength of Centrifugal Compressor wheels for Turbochargers, I Mech E, 1986，pp34-45
[20] 李燕生，陆桂林，《向心透平与离心压气机》，机械工业出版社，1987，pp215-245
[21] Takashi Mikogrami etc, Recent Aerodynamic Advancements in Turbocharger Compressor Stages, SAE 880794，pp1-5
[22] N.Watson, Turbocharged Engines (Internal Combustion Engines, Chapter Four) Academic Press Limited, 1988，pp34-45
[23] H.G.Bozury etc, The MAN B&W Medium Speed Engine Series-The Engine Concept for the 90s, 18th CIMAC, 1989，pp4-245
[24] Zhao Xiaolu etc, An Approximate Three-Dimensional Aerodynamic Design Method for Centrifugal Impeller Blades, Trans of the ASME, January 1990，pp56-245
[25] Project planning manual Turbocharger, NA series, MAN B&W, 1995，pp34-165
[26] A.Whitfield N.C.Baines, Design of Radial Turbomachines, Longman Singapore Publishers, 1990，pp74-85
[27] R.C.Pampreen, Automotive Research Compressor Experience, Journal of Turbomachinery, January, 1990，pp654-1245
[28] 朱大鑫，《涡轮增压与涡轮增压器》，兵器工业第七0研究所，1997，pp12-45
[29] 顾宏中，《涡轮增压柴油机性能研究》，上海交通大学出版社，1998，pp62-165
[30] 万德玉，《柴油机试验测试》，学苑出版社，2000，pp78-89
[31]《第十二届全国大功率柴油机学术年会论文集》，2001，pp75-234