基于整车性能要求的CA4DD系列柴油机性能设计及开发
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摘要
越来越严苛的排放法规和整车节能要求不断推进发动机技术提升，针对发动机燃烧技术的创新由于受到种种限制，能够应用到生产环节还不多，基于整车应用特点的发动机性能设计及开发成为发动机节能减排的一个研究热点。整车开发的传统流程中，整车与发动机是由两个部门单独开发的，并且整车的性能验证在发动机开发完成之后，在整车验证过程中，经常会出现发动机不能够满足整车要求而反复改进验证的情况，导致开发周期和开发成本的增加。本文提出了整车开发的“V”字形流程，并建立了整车与发动机联合仿真平台，在发动机性能设计过程中应用仿真平台进行整车目标分解，在性能开发过程中对整车性能进行评价和分析，做到从整车到发动机的正向性能开发。在发动机的性能设计和开发过程中，借助于CAE分析手段，完成由发动机到各个子系统的性能指标分解，并在子系统开发过程中对整机性能进行评价分析，做到了发动机性能的正向开发。应用发动机性能的正向开发流程，完成了CA4DD系列发动机的性能设计及开发，并应用整车的试验数据进行联合仿真平台的有效性评价及误差分析。主要的研究内容和结论总结如下：
1.介绍了建立整车与发动机性能联合仿真平台所用的GT Suite和Simulink软件，给出了CA4DD系列发动机及其相应的整车边界条件。针对联合仿真的静态受力分析模式、运动学模式和动力学模式分别建立相应的仿真模型并进行模型校正，稳态仿真模型与实测结果误差控制在5%以内。以稳态模型为基础，建立了用于动力学分析的瞬态模型。
2.通过理论分析，对整车与发动机之间的性能对应关系进行了论述，找出发动机性能对整车动力性和经济性的关键影响因素。提出了从整车到发动机再到各个子系统的正向性能开发“V”字形流程，明确实现正向开发流程的工作方法和手段。
3.应用联合仿真平台中的静态受力分析模式分别对CA4DD系列的三种机型对应的整车进行模拟，根据模拟分析结果，以整车性能指标要求为目标，进行了三个机型的动力性指标确定；应用运动学模式，对三种机型对应的整车测试循环进行模拟分析，确定三种发动机的排放控制区和常用工况，作为性能设计的重点关注区域。应用StarCD软件进行了缸内流动和燃烧的模拟，提出了燃烧组织概念，进而对供油系统、换气系统和缸内混合提出具体性能要求。子系统应用各自的CAE工具进行了性能设计，包括气道涡流、管系结构、配气相位和凸轮型线、EGR参数及燃烧室等。最终通过性能预测，子系统设计的性能开发方案能够满足发动机性能指标要求。
4.通过发动机性能试验对燃烧开发方案进行选择，确定三个机型的性能开发方案配置。在定型的开发方案上进行了发动机详细标定，输出的开发结果表明性能设计的指标基本都能够达到。应用联合仿真平台对整车性能进行评价，结果表明，CA4DD1和CA4DD3两个系列发动机开发结果能够满足整车确定的目标，匹配放气阀式增压器的CA4DD2发动机的整车加速性与性能要求相差11.2%。应用联合仿真平台的动力学模式进行了CA4DD2瞬态性能改进，最终达到了开发目标要求，加速性目标比整车性能要求高出2.3%。对匹配CA4DD1的载重卡车进行整车性能试验，应用试验结果对联合仿真平台进行误差分析，对比结果表明，最高车速的模拟误差为2.8%，最高挡80km/h等速油耗和WTVC整车试验循环的综合油耗误差分别为1.4%和1.9%，在5%的误差许可范围内，最高档加速和连续换挡加速的响应时间误差分别为14.3%和4.1%，小于瞬态过程计算控制误差15%。这说明整车与发动机联合仿真平台结果是可信的，应用联合仿真平台及其它发动机CAE工具进行整车和发动机正向开发是切实可行的。
本文提出了整车和发动机正向开发的“V”字形流程，并建立了整车与发动机联合仿真平台作为实现正向开发流程的重要手段，在CA4DD系列发动机开发中实现了整车和发动机的正向开发流程，做到了针对整车性能的发动机性能设计及开发，能够改变传统流程带来的反复的调整验证的过程，节省开发周期和开发成本，提高产品的竞争力。
Emission regulations and vehicle energy reduction requirements continuouspushed forward engine technological progress, majority innovation of combustiontheory could not be applied to the production due to various constraints, it became afocus of energy saving and emission reduction that engine performance design anddevelopment took aim at vehicle application characteristics. In traditional vehicledevelopment process, vehicle and engine is developed separately by the twodepartments, and vehicle performance test after engine finished its development work,engine result usually could not meet vehicle performance demands in verificationprocess, repeated work must be done in engine performance modification and vehiclevalidation, it was time and costs consuming. This thesis presented a "V " shapedpositive vehicle development process and established a vehicle and engineco simulation platform, it was used to decompose vehicle performance requirement toengine target in performance design process and to evaluate if vehicle performancewas met in engine development process, a positive development process could beachieved, so that engine performance was under control from vehicle point of view. Apositive development process from engine to sub system was built either within CAEsupport, for sub system, works can be done that engine performance decomposed tosub system in design and evaluate engine result in development period. Positivedevelopment process was used for CA4DD series engine performance design andperformance development, vehicle testing datas were taken to evaluation of theeffectiveness co simulation platform. The main research contents and conclusions wassummarized as follows:
1. Vehicle and engine performance co simulation platform software GT Suiteand Simulink was introduced, Co simulation platform for CA4DD series engine wasestablished and corresponding vehicle boundary conditions was given. Builtsimulation model and calibration work was done with3different simulation modes(static, kinematics and dynamic), Simulation model calibration work was done with3different simulation modes, ensure the error between test and simulation result within5%in stedy state silulation. Transient simulation model was developed base on steadystate model.
2. Theoretical analysis on corresponding relationship between vehicle and engineperformance was discussed, key factors that affecting performance of engineperformance and vehicle fuel economy was found out. A positive "V" shaped positiveprocess from vehicle to engine and then subsystem was described in detail, defineeither work method or means of the precess.
3. Vehicles corresponding to CA4DD series engine was simulated usingco simulation platform, static force analysis was done to define engine full load torque and power, kinematic simulation to define emission control and high operatingefficiency area, the area would be performance foucs in engine design anddevelopment. Engine performance parameters were settled down according simulationresults, then combustion and in cylinder flow conditions were simulated using StarCDsoftware, combustion concept was put forward according performance requirements,fuel supply system, gas exchange system and in cylinder combustion organize targetwas defined through engine proformance subdivition. Subsystem include valvetrainparameter, turbocharger, EGR, intake swirl and combustion chamber were work outwithin support of CAE tools, performance prediction result shown that subsystemdesign could satisfy engine performance requirements.
4. Performance test was carried out to compare and analysis differentdevelopment scheme, combustion development scheme ultimately determined ofCA4DD series3type engines. Detailed calibration was done in stereotypes engineswhich determined by testing, performance results were released finally, results shownthat performance targets could be achieved. Vehicle performance was evaluated usingco simulation platform, results shown that CA4DD1and CA4DD3engines could metvehicle defined target, vehicle corresponding to CA4DD2engine accelerationperformance was not achieved （11.2%worse）with a fixed geometry turbocharger,VGT matching and control strategy optimized using dynamic simulate mode ofco simulation platform, target was reached finally with2.3%higher than target.Performance of vehicle with CA4DD1engine was tested, results shown thatmaximum vehicle speed error was2.8%, fuel consumption error of top gare80km/hand WTVC were respectively1.4%and1.9%, top gare acceleration and shift gareacceleration response time error were14.3%and4.1%. Steady state error between testand simulation within acceptable range5%, transient response time error withinacceptable error range15%. It improved that vehicle and engine co simulationplatform were reliable, realizing vehicle and engine positive development by usingco simulation platform and other engine CAE tool was feasible.
This paper presented a vehicle and engine positive development "V " shapedprocess, and established a vehicle and engine co simulation platform as an importantmeans to realize this process, realized positive development process in CA4DDengine development project, engine performance could be designed and developedaiming at vehicle performance, disadvantages in traditional process of adjustment andvalidation repeatedly were changed, positive process could saved development timeand costs thus improved product competitiveness.
1.介绍了建立整车与发动机性能联合仿真平台所用的GT Suite和Simulink软件，给出了CA4DD系列发动机及其相应的整车边界条件。针对联合仿真的静态受力分析模式、运动学模式和动力学模式分别建立相应的仿真模型并进行模型校正，稳态仿真模型与实测结果误差控制在5%以内。以稳态模型为基础，建立了用于动力学分析的瞬态模型。
2.通过理论分析，对整车与发动机之间的性能对应关系进行了论述，找出发动机性能对整车动力性和经济性的关键影响因素。提出了从整车到发动机再到各个子系统的正向性能开发“V”字形流程，明确实现正向开发流程的工作方法和手段。
3.应用联合仿真平台中的静态受力分析模式分别对CA4DD系列的三种机型对应的整车进行模拟，根据模拟分析结果，以整车性能指标要求为目标，进行了三个机型的动力性指标确定；应用运动学模式，对三种机型对应的整车测试循环进行模拟分析，确定三种发动机的排放控制区和常用工况，作为性能设计的重点关注区域。应用StarCD软件进行了缸内流动和燃烧的模拟，提出了燃烧组织概念，进而对供油系统、换气系统和缸内混合提出具体性能要求。子系统应用各自的CAE工具进行了性能设计，包括气道涡流、管系结构、配气相位和凸轮型线、EGR参数及燃烧室等。最终通过性能预测，子系统设计的性能开发方案能够满足发动机性能指标要求。
4.通过发动机性能试验对燃烧开发方案进行选择，确定三个机型的性能开发方案配置。在定型的开发方案上进行了发动机详细标定，输出的开发结果表明性能设计的指标基本都能够达到。应用联合仿真平台对整车性能进行评价，结果表明，CA4DD1和CA4DD3两个系列发动机开发结果能够满足整车确定的目标，匹配放气阀式增压器的CA4DD2发动机的整车加速性与性能要求相差11.2%。应用联合仿真平台的动力学模式进行了CA4DD2瞬态性能改进，最终达到了开发目标要求，加速性目标比整车性能要求高出2.3%。对匹配CA4DD1的载重卡车进行整车性能试验，应用试验结果对联合仿真平台进行误差分析，对比结果表明，最高车速的模拟误差为2.8%，最高挡80km/h等速油耗和WTVC整车试验循环的综合油耗误差分别为1.4%和1.9%，在5%的误差许可范围内，最高档加速和连续换挡加速的响应时间误差分别为14.3%和4.1%，小于瞬态过程计算控制误差15%。这说明整车与发动机联合仿真平台结果是可信的，应用联合仿真平台及其它发动机CAE工具进行整车和发动机正向开发是切实可行的。
本文提出了整车和发动机正向开发的“V”字形流程，并建立了整车与发动机联合仿真平台作为实现正向开发流程的重要手段，在CA4DD系列发动机开发中实现了整车和发动机的正向开发流程，做到了针对整车性能的发动机性能设计及开发，能够改变传统流程带来的反复的调整验证的过程，节省开发周期和开发成本，提高产品的竞争力。
Emission regulations and vehicle energy reduction requirements continuouspushed forward engine technological progress, majority innovation of combustiontheory could not be applied to the production due to various constraints, it became afocus of energy saving and emission reduction that engine performance design anddevelopment took aim at vehicle application characteristics. In traditional vehicledevelopment process, vehicle and engine is developed separately by the twodepartments, and vehicle performance test after engine finished its development work,engine result usually could not meet vehicle performance demands in verificationprocess, repeated work must be done in engine performance modification and vehiclevalidation, it was time and costs consuming. This thesis presented a "V " shapedpositive vehicle development process and established a vehicle and engineco simulation platform, it was used to decompose vehicle performance requirement toengine target in performance design process and to evaluate if vehicle performancewas met in engine development process, a positive development process could beachieved, so that engine performance was under control from vehicle point of view. Apositive development process from engine to sub system was built either within CAEsupport, for sub system, works can be done that engine performance decomposed tosub system in design and evaluate engine result in development period. Positivedevelopment process was used for CA4DD series engine performance design andperformance development, vehicle testing datas were taken to evaluation of theeffectiveness co simulation platform. The main research contents and conclusions wassummarized as follows:
1. Vehicle and engine performance co simulation platform software GT Suiteand Simulink was introduced, Co simulation platform for CA4DD series engine wasestablished and corresponding vehicle boundary conditions was given. Builtsimulation model and calibration work was done with3different simulation modes(static, kinematics and dynamic), Simulation model calibration work was done with3different simulation modes, ensure the error between test and simulation result within5%in stedy state silulation. Transient simulation model was developed base on steadystate model.
2. Theoretical analysis on corresponding relationship between vehicle and engineperformance was discussed, key factors that affecting performance of engineperformance and vehicle fuel economy was found out. A positive "V" shaped positiveprocess from vehicle to engine and then subsystem was described in detail, defineeither work method or means of the precess.
3. Vehicles corresponding to CA4DD series engine was simulated usingco simulation platform, static force analysis was done to define engine full load torque and power, kinematic simulation to define emission control and high operatingefficiency area, the area would be performance foucs in engine design anddevelopment. Engine performance parameters were settled down according simulationresults, then combustion and in cylinder flow conditions were simulated using StarCDsoftware, combustion concept was put forward according performance requirements,fuel supply system, gas exchange system and in cylinder combustion organize targetwas defined through engine proformance subdivition. Subsystem include valvetrainparameter, turbocharger, EGR, intake swirl and combustion chamber were work outwithin support of CAE tools, performance prediction result shown that subsystemdesign could satisfy engine performance requirements.
4. Performance test was carried out to compare and analysis differentdevelopment scheme, combustion development scheme ultimately determined ofCA4DD series3type engines. Detailed calibration was done in stereotypes engineswhich determined by testing, performance results were released finally, results shownthat performance targets could be achieved. Vehicle performance was evaluated usingco simulation platform, results shown that CA4DD1and CA4DD3engines could metvehicle defined target, vehicle corresponding to CA4DD2engine accelerationperformance was not achieved （11.2%worse）with a fixed geometry turbocharger,VGT matching and control strategy optimized using dynamic simulate mode ofco simulation platform, target was reached finally with2.3%higher than target.Performance of vehicle with CA4DD1engine was tested, results shown thatmaximum vehicle speed error was2.8%, fuel consumption error of top gare80km/hand WTVC were respectively1.4%and1.9%, top gare acceleration and shift gareacceleration response time error were14.3%and4.1%. Steady state error between testand simulation within acceptable range5%, transient response time error withinacceptable error range15%. It improved that vehicle and engine co simulationplatform were reliable, realizing vehicle and engine positive development by usingco simulation platform and other engine CAE tool was feasible.
This paper presented a vehicle and engine positive development "V " shapedprocess, and established a vehicle and engine co simulation platform as an importantmeans to realize this process, realized positive development process in CA4DDengine development project, engine performance could be designed and developedaiming at vehicle performance, disadvantages in traditional process of adjustment andvalidation repeatedly were changed, positive process could saved development timeand costs thus improved product competitiveness.
引文
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