动圈式直线压缩机若干关键问题研究
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摘要
目前电冰箱上广泛使用的制冷压缩机大多数是由旋转电机驱动的往复活塞式压缩机,其中转换机构(曲柄连杆机构)必不可少,但是该机构的引入造成压缩机的整体结构庞大,传递环节增多,传动效率降低,除此之外还带来了摩擦损耗、磨损、噪音等问题。直线压缩机与常规往复式压缩机的基本差异在于没有曲柄连杆机构,减少了相对运动的零件,因而大大减少摩擦损耗,并通过调节电压实现流量调节,在整个可变流量范围内效率都非常高。正是由于直线压缩机具有的这些传统压缩机无可比拟的优点,使其成为未来冰箱压缩机的一个极其重要的研究发展方向。本文围绕动圈式直线压缩机展开了研究工作：
(1)提出了一种由多层长短不一的硅钢片排列而成的磁路结构,这种结构在降低电机涡耗的同时,尽可能地减小了电机的结构尺寸。但传统的等效电路方法和有限元方法很难计算硅钢片间有间隙的铁芯的磁通分布问题。因此针对新磁路结构的特点,提出一种新的考虑铁芯磁阻的磁路模型,对铁芯磁路进行分层处理,铁芯每一层对应一段铁芯、气隙和磁铁,然后通过使总磁阻最小确定各层的磁通。并利用该模型结合机械动力学导出了直线压缩机的动力学和电压方程。在此基础上论文进行了大量的计算工作,分析了磁路结构中的多个关键参数如内外轭铁尺寸、线圈的大小、压缩机余隙、活塞行程以及工作频率等对直线压缩机性能的影响,在此基础上完成了直线压缩机的多参数优化设计。
(2)在分析现有流量调节法的基础上,以压缩机耗功少、效率高为目标,针对双向可控硅控制方法,提出一种新的现阶段更有效的直线压缩机流量调节方法,即余隙行程综合调节法。并通过大量的计算和分析,对流量与行程、余隙的关系以及影响压缩机效率的其它因素进行研究,得到流量调节时余隙和行程的设定方案。通过与余隙容积调节法和行程容积调节法相比较,从效率方面验证了余隙行程综合调节法的高效可行性。除了对流量调节方法的研究外,根据控制系统的需求,设计了以单片机为核心、采用双向可控硅控制的直线压缩机控制系统,包括开机、负荷运行、停机以及压缩机保护等功能,并设计了电路板,编写了相关程序。
(3)在理论分析的基础上,设计制造了一台直线压缩机样机。建立了直线压缩机性能测试实验平台。通过实验测试分析了直线压缩机运行中的各种损耗。实验验证了磁路结构改进后直线压缩机的铁芯损耗有了较大的降低。通过控制电路实现了直线压缩机的运行控制及流量调节。采用余隙行程综合调节法,在流量调节过程中直线压缩机保持较高的效率。
Nowadays widely used compressor in refrigerator is reciprocating piston compressor driven by rotary motor, in which conversion mechanism (Crank) is essential. However, with this mechanism the compressor becomes cumbersome and transmission parts also increase, which not only makes efficiency lower, but also causes some other problems, such as friction loss, wear and noise. The difference between linear compressor and conventional reciprocating compressor is that linear compressor doesn't have crank and connecting rod mechanism. So relative motion parts are reduced. And the corresponding friction and noise are reduced. It is easy to regulate flow of linear compressor by adjusting the voltage. And it can keep high efficiency in the whole range of flow regulation. With these advantages linear compressor becomes an important research direction of future refrigerator compressor. This paper focuses on moving-coil linear compressor and the main contents are as follows:
(1) One magnetic circuit structure composed of several silicon steel layers with different size is developed. This structure can reduce the iron loss of motor and meanwhile decrease the size of the motor structure as much as possible. One problem is that the distribution of the magnetic field made up of silicon steels with clearance can not be solved by traditional equivalent circuit method and the finite element method. So a new magnetic circuit model considering core reluctance is developed for this kind of magnetic circuit, which involves slicing the magnetic circuit into layers and each layer corresponds to one part of iron core, gas gap and magnet. Then magnetic flux of each layer is determined by the minimum of total reluctance. System equations of linear compressor are obtained by using this model and mechnical dynamics.Based on this new model a great deal of calculation is done to analyze the influence of some key parameters such as size of inner and outer yoke, size of coil, compressor clearance, piston stroke and work frequency on the performance of linear compressor Based on the analysis the optimization of these parameters is completed.
(2) Based on the analysis about the existing model of flow regulation method for linear compressor, a new and more effective flow regulation method using triac control method aiming at low power loss and high efficiency is developed, which considers clearance and stroke together.Through a great deal of calculation and analysis on the relationship among flow.stoke and clearance and other factors influencing compressor efficiency, The scheme how to set the clearance and stoke at flow regulation is obtained. The new method is proved to be highly efficient and feasible by comparing it with other flow rugulation methods of chaning clearrance and storke. Besides the study on flow regulation, according to the requirement of control system, a new control method of linear compressor is designed, using MCU (Microprogrammed Control Unit) as the core control device and triac as cut-off wave device. It contains functions such as start, stop, load operation and protect of compressor. The control curcuit and relative programs are also completed.
(3) A linear compressor prototype is designed and manufactureed based on the theoretical analysis. The experiment test platform of linear compressor is established. All kinds of losses in the operation of linear compressor are analyzed by the experiment test.Experiments prove that the iron core loss decreases after improvement of magnetic circuit. Control and flow regulation of linear compressor are achieved by control circuit. With the flow regulation method that considers clearance and stroke together,the efficiency of linear compressor is kept in high level during the course of flow regulation.
(1)提出了一种由多层长短不一的硅钢片排列而成的磁路结构,这种结构在降低电机涡耗的同时,尽可能地减小了电机的结构尺寸。但传统的等效电路方法和有限元方法很难计算硅钢片间有间隙的铁芯的磁通分布问题。因此针对新磁路结构的特点,提出一种新的考虑铁芯磁阻的磁路模型,对铁芯磁路进行分层处理,铁芯每一层对应一段铁芯、气隙和磁铁,然后通过使总磁阻最小确定各层的磁通。并利用该模型结合机械动力学导出了直线压缩机的动力学和电压方程。在此基础上论文进行了大量的计算工作,分析了磁路结构中的多个关键参数如内外轭铁尺寸、线圈的大小、压缩机余隙、活塞行程以及工作频率等对直线压缩机性能的影响,在此基础上完成了直线压缩机的多参数优化设计。
(2)在分析现有流量调节法的基础上,以压缩机耗功少、效率高为目标,针对双向可控硅控制方法,提出一种新的现阶段更有效的直线压缩机流量调节方法,即余隙行程综合调节法。并通过大量的计算和分析,对流量与行程、余隙的关系以及影响压缩机效率的其它因素进行研究,得到流量调节时余隙和行程的设定方案。通过与余隙容积调节法和行程容积调节法相比较,从效率方面验证了余隙行程综合调节法的高效可行性。除了对流量调节方法的研究外,根据控制系统的需求,设计了以单片机为核心、采用双向可控硅控制的直线压缩机控制系统,包括开机、负荷运行、停机以及压缩机保护等功能,并设计了电路板,编写了相关程序。
(3)在理论分析的基础上,设计制造了一台直线压缩机样机。建立了直线压缩机性能测试实验平台。通过实验测试分析了直线压缩机运行中的各种损耗。实验验证了磁路结构改进后直线压缩机的铁芯损耗有了较大的降低。通过控制电路实现了直线压缩机的运行控制及流量调节。采用余隙行程综合调节法,在流量调节过程中直线压缩机保持较高的效率。
Nowadays widely used compressor in refrigerator is reciprocating piston compressor driven by rotary motor, in which conversion mechanism (Crank) is essential. However, with this mechanism the compressor becomes cumbersome and transmission parts also increase, which not only makes efficiency lower, but also causes some other problems, such as friction loss, wear and noise. The difference between linear compressor and conventional reciprocating compressor is that linear compressor doesn't have crank and connecting rod mechanism. So relative motion parts are reduced. And the corresponding friction and noise are reduced. It is easy to regulate flow of linear compressor by adjusting the voltage. And it can keep high efficiency in the whole range of flow regulation. With these advantages linear compressor becomes an important research direction of future refrigerator compressor. This paper focuses on moving-coil linear compressor and the main contents are as follows:
(1) One magnetic circuit structure composed of several silicon steel layers with different size is developed. This structure can reduce the iron loss of motor and meanwhile decrease the size of the motor structure as much as possible. One problem is that the distribution of the magnetic field made up of silicon steels with clearance can not be solved by traditional equivalent circuit method and the finite element method. So a new magnetic circuit model considering core reluctance is developed for this kind of magnetic circuit, which involves slicing the magnetic circuit into layers and each layer corresponds to one part of iron core, gas gap and magnet. Then magnetic flux of each layer is determined by the minimum of total reluctance. System equations of linear compressor are obtained by using this model and mechnical dynamics.Based on this new model a great deal of calculation is done to analyze the influence of some key parameters such as size of inner and outer yoke, size of coil, compressor clearance, piston stroke and work frequency on the performance of linear compressor Based on the analysis the optimization of these parameters is completed.
(2) Based on the analysis about the existing model of flow regulation method for linear compressor, a new and more effective flow regulation method using triac control method aiming at low power loss and high efficiency is developed, which considers clearance and stroke together.Through a great deal of calculation and analysis on the relationship among flow.stoke and clearance and other factors influencing compressor efficiency, The scheme how to set the clearance and stoke at flow regulation is obtained. The new method is proved to be highly efficient and feasible by comparing it with other flow rugulation methods of chaning clearrance and storke. Besides the study on flow regulation, according to the requirement of control system, a new control method of linear compressor is designed, using MCU (Microprogrammed Control Unit) as the core control device and triac as cut-off wave device. It contains functions such as start, stop, load operation and protect of compressor. The control curcuit and relative programs are also completed.
(3) A linear compressor prototype is designed and manufactureed based on the theoretical analysis. The experiment test platform of linear compressor is established. All kinds of losses in the operation of linear compressor are analyzed by the experiment test.Experiments prove that the iron core loss decreases after improvement of magnetic circuit. Control and flow regulation of linear compressor are achieved by control circuit. With the flow regulation method that considers clearance and stroke together,the efficiency of linear compressor is kept in high level during the course of flow regulation.
引文
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