热管中冷器及其在车辆冷却系统中的应用研究
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摘要
随着排放法规日益严格,发动机强化程度越来越高,对增压压比的要求变高,增压器能达到的压比也越来越高,同时废气再循环(Exhaust Gas Recirculation, EGR)技术的采用,促使增压空气的温度也要越来越高,大幅度增加热交换器的热应力,同时发动机舱空间日益拥挤,限制了空气流动,不利于散热器更及时的散热。铝材抗拉强度在温度140℃多开始变差,在超过200℃严重恶化。因此涡轮增压高应力运行时间对目前铝中冷器的耐温性能和散热性能提出了严峻的挑战,在某些情况下已达到铝材的耐热极限。鉴于热管具有高效的传热特性和高热流密度等技术特点,本文针对某型载重车冷却系统设计了一种热管中冷器,研究热管中冷器在车辆冷却系统上的应用可行性。采用理论分析计算和数值模拟技术以及试验研究相结合的方法对热管中冷器的传热与阻力性能,以及结构优化设计进行了研究,同时对该载重车前端冷却模块进行优化匹配设计研究,在满足载重车散热要求的前提下,对铝中冷器进行结构优化设计,研制出新型高效紧凑式冷却系统模块。本文的主要研究内容包括：
1.结合载重车冷却系统对中冷器的散热要求和发动机舱空间的限制,采用对数平均温差法和有效度-传热单元数方法,对热管中冷器进行了初步设计计算,并对热管间距、热管冷凝度长度、热管根数和冷热流体进出口条件等对热管中冷器的传热与阻力性能的宏观影响进行了讨论研究。
2.采用计算流体力学(Computational Fluid Dynamics, CFD)仿真技术对热管中冷器单层换热单元和整体热交换器的内部流动传热过程进行了仿真分析,结合场协同理论研究了换热器结构参数和冷热流体进口条件等对热管中冷器流动传热特性的影响机制。
3.采用BP神经网络方法来预测分析热管中冷器的传热与阻力性能,基于少量试验数据建立网络预测模型,训练好的传热性能网络预测模型的最大相对误差为8.0%,平均相对误差为3.5%；阻力性能网络预测模型的最大相对误差为13.1%,平均相对误差为5.1%。采用BP神经网络模型和试验技术相结合的方法可以很好的预测热管中冷器的传热与阻力性能,同时能够对热管中冷器的结构进行优化设计,最后提出了一个比较优化的结构参数组合。
4.在风洞试验台架A上对热管中冷器的传热与阻力性能进行了试验研究,详细分析了冷侧空气流速、热侧空气进口温度、热侧空气流量等因素和热管间距、冷凝段长度和热管列数等结构参数对热管中冷器的流动与传热性能的影响,并与理论计算值进行了对比分析,同时对冷风出口温度场和热流体通道内温度分布进行了试验与仿真对比分析,最后利用多元线性回归拟合得到传热和阻力性能的试验关联式。
5.对前端冷却模块和热管中冷器的组合模块进行了流动与传热仿真研究,并在风洞试验台架B上对其进行了试验研究,最后对铝中冷器的结构进行了优化设计,可以明显改善流体的流量分配均匀性和阻力损失,用CFD数值模拟技术和试验方法相结合对其进行了验证和分析讨论,铝中冷器优化后冷却模块中中冷器能够满足该载重车散热要求,同时水箱换热量相比原冷却模块的水箱换热量有3.36%-13.08%的提高。
With increasingly stringent emissions regulations and increasing degree of engine enhancement, the requirement of compression ratio becomes much higher and the compression ratio of turbocharger compressor can achieve higher and higher. Furthermore, exhaust gas recirculation (EGR) technology is adopted, hence the charge air temperature becomes even higher, promoting a substantial increase of the heat exchanger thermal stress. In addition, the vehicle underhood space is increasingly crowded, the air flow is limited and the heat exchanger cannot reject heat timely. Tensile strength of aluminum begins to aggravate above the temperature of more than140· and deteriorate seriously above2009℃. Therefore, high stress operating time of turbo is a challenge to the mechanical and fatigue resistance properties and thermal performance of the current word wide aluminum charge air cooler. In some cases, it has reached the inherent material performance limitations of aluminum at high temperatures. In view of the technical features of heat pipe, such as highly efficient heat transfer characteristics and high heat flux, a kind of heat pipe heat exchanger is designed for the cooling system of the commercial vehicle in this research. Then the application feasibility of heat pipe charge air cooler in the vehicle cooling system is conducted. The heat transfer and pressure drop performance of heat pipe charge air cooler and the optimization design of heat pipe charge air cooler are studied by theoretical analysis, numerical simulation and experimental research. Meanwhile the matching optimization of the heat pipe heat exchanger and front cooling module is investigated. Under the premise of meeting the cooling requirements of the truck, the structure of the aluminum charge air cooler is improved and finally a new compact and efficient cooling system module is developed. The main contents of this paper include:
1. Considering the requirements of heat transfer performance for the charge air cooler and vehicle underhood space limitation, a heat pipe heat exchanger is designed and the influence of tube pitch, condenser length, number of pipes, inlet and outlet conditions of cooling and hot air on the heat transfer and pressure drop characteristics of the heat pipe charge air cooler are investigated using the logarithmic mean temperature difference method and ε-NTU (effectiveness-number of heat transfer units) method.
2. For the heat pipe charge air cooler, a single heat exchanger unit model and an overall heat exchanger model are established and simulated using the CFD (Computational Fluid Dynamics) method. Finally, the effects of the structural parameters of heat exchanger and the inlet conditions of cooling and hot air on the flowing and heat transfer characteristics of the heat pipe charge air cooler are analyzed according to the field synergy theory.
3. Heat transfer performance and resistance performance prediction model of heat pipe intercooler are established based on a small amount of test data. Then the heat transfer performance and resistance performance of the heat pipe charge air cooler are predicted by means of the BP neural network method, the prediction results-are compared with the experimental results and it is found that the prediction results are in good agreement with the experimental results. For the heat transfer performance network model, the maximum relative error is8.0%and the average relative error is3.5%; For the resistance performance network model, the maximum relative error is13.1%and the average relative error is5.1%, which means that the prediction model can predict the thermal performance of the heat pipe charge air cooler well and can be used for engineering design combining with experimental method. Finally, the structural parameters are optimized by the BP neural network model and the optimal design parameters are obtained.
4. The heat transfer and pressure drop characteristics of the heat pipe charge air cooler are investigated in a small wind tunnel A. The influence of cooling air velocity, inlet temperature of hot air, mass flow of hot air, tube pitch, condenser length, pipe line on the flowing and heat transfer characteristics of the heat pipe heat exchanger are discussed. Then, the experimental results are compared to the theoretical results. Meanwhile, the outlet temperature field of cooling air and the temperature distribution of hot air channel are discussed by means of experiments and CFD simulations. Finally, by multi-parameter linear regression analysis of a large number of experimental results, the correlations of Nu and Eu are obtained.
5. The flowing and heat transfer characteristics of the package of a heat pipe charge air cooler and front cooling module are studied by CFD simulation and experimental research in the wind tunnel B. Then, two kinds of optimization of the intercooler are done to improve the performance. The results show that the airflow uniformity index and the pressure drop are improved efficiently; the heat pipe intercooler could well reduce the inlet temperature of the aluminum intercooler, while the optimized intercooler can satisfy the cooling requirements well, and thereby the aluminum intercooler has further room for improvement. On this basis, compared to the original, the heat rejection of radiator has a larger enhancement between3.36%-13.08%. Thus the cooling module can be optimized to be more compact to meet the cooling requirements, which is very significant to the optimization of the front-end cooling module and improvement of the overall heat transfer.
1.结合载重车冷却系统对中冷器的散热要求和发动机舱空间的限制,采用对数平均温差法和有效度-传热单元数方法,对热管中冷器进行了初步设计计算,并对热管间距、热管冷凝度长度、热管根数和冷热流体进出口条件等对热管中冷器的传热与阻力性能的宏观影响进行了讨论研究。
2.采用计算流体力学(Computational Fluid Dynamics, CFD)仿真技术对热管中冷器单层换热单元和整体热交换器的内部流动传热过程进行了仿真分析,结合场协同理论研究了换热器结构参数和冷热流体进口条件等对热管中冷器流动传热特性的影响机制。
3.采用BP神经网络方法来预测分析热管中冷器的传热与阻力性能,基于少量试验数据建立网络预测模型,训练好的传热性能网络预测模型的最大相对误差为8.0%,平均相对误差为3.5%；阻力性能网络预测模型的最大相对误差为13.1%,平均相对误差为5.1%。采用BP神经网络模型和试验技术相结合的方法可以很好的预测热管中冷器的传热与阻力性能,同时能够对热管中冷器的结构进行优化设计,最后提出了一个比较优化的结构参数组合。
4.在风洞试验台架A上对热管中冷器的传热与阻力性能进行了试验研究,详细分析了冷侧空气流速、热侧空气进口温度、热侧空气流量等因素和热管间距、冷凝段长度和热管列数等结构参数对热管中冷器的流动与传热性能的影响,并与理论计算值进行了对比分析,同时对冷风出口温度场和热流体通道内温度分布进行了试验与仿真对比分析,最后利用多元线性回归拟合得到传热和阻力性能的试验关联式。
5.对前端冷却模块和热管中冷器的组合模块进行了流动与传热仿真研究,并在风洞试验台架B上对其进行了试验研究,最后对铝中冷器的结构进行了优化设计,可以明显改善流体的流量分配均匀性和阻力损失,用CFD数值模拟技术和试验方法相结合对其进行了验证和分析讨论,铝中冷器优化后冷却模块中中冷器能够满足该载重车散热要求,同时水箱换热量相比原冷却模块的水箱换热量有3.36%-13.08%的提高。
With increasingly stringent emissions regulations and increasing degree of engine enhancement, the requirement of compression ratio becomes much higher and the compression ratio of turbocharger compressor can achieve higher and higher. Furthermore, exhaust gas recirculation (EGR) technology is adopted, hence the charge air temperature becomes even higher, promoting a substantial increase of the heat exchanger thermal stress. In addition, the vehicle underhood space is increasingly crowded, the air flow is limited and the heat exchanger cannot reject heat timely. Tensile strength of aluminum begins to aggravate above the temperature of more than140· and deteriorate seriously above2009℃. Therefore, high stress operating time of turbo is a challenge to the mechanical and fatigue resistance properties and thermal performance of the current word wide aluminum charge air cooler. In some cases, it has reached the inherent material performance limitations of aluminum at high temperatures. In view of the technical features of heat pipe, such as highly efficient heat transfer characteristics and high heat flux, a kind of heat pipe heat exchanger is designed for the cooling system of the commercial vehicle in this research. Then the application feasibility of heat pipe charge air cooler in the vehicle cooling system is conducted. The heat transfer and pressure drop performance of heat pipe charge air cooler and the optimization design of heat pipe charge air cooler are studied by theoretical analysis, numerical simulation and experimental research. Meanwhile the matching optimization of the heat pipe heat exchanger and front cooling module is investigated. Under the premise of meeting the cooling requirements of the truck, the structure of the aluminum charge air cooler is improved and finally a new compact and efficient cooling system module is developed. The main contents of this paper include:
1. Considering the requirements of heat transfer performance for the charge air cooler and vehicle underhood space limitation, a heat pipe heat exchanger is designed and the influence of tube pitch, condenser length, number of pipes, inlet and outlet conditions of cooling and hot air on the heat transfer and pressure drop characteristics of the heat pipe charge air cooler are investigated using the logarithmic mean temperature difference method and ε-NTU (effectiveness-number of heat transfer units) method.
2. For the heat pipe charge air cooler, a single heat exchanger unit model and an overall heat exchanger model are established and simulated using the CFD (Computational Fluid Dynamics) method. Finally, the effects of the structural parameters of heat exchanger and the inlet conditions of cooling and hot air on the flowing and heat transfer characteristics of the heat pipe charge air cooler are analyzed according to the field synergy theory.
3. Heat transfer performance and resistance performance prediction model of heat pipe intercooler are established based on a small amount of test data. Then the heat transfer performance and resistance performance of the heat pipe charge air cooler are predicted by means of the BP neural network method, the prediction results-are compared with the experimental results and it is found that the prediction results are in good agreement with the experimental results. For the heat transfer performance network model, the maximum relative error is8.0%and the average relative error is3.5%; For the resistance performance network model, the maximum relative error is13.1%and the average relative error is5.1%, which means that the prediction model can predict the thermal performance of the heat pipe charge air cooler well and can be used for engineering design combining with experimental method. Finally, the structural parameters are optimized by the BP neural network model and the optimal design parameters are obtained.
4. The heat transfer and pressure drop characteristics of the heat pipe charge air cooler are investigated in a small wind tunnel A. The influence of cooling air velocity, inlet temperature of hot air, mass flow of hot air, tube pitch, condenser length, pipe line on the flowing and heat transfer characteristics of the heat pipe heat exchanger are discussed. Then, the experimental results are compared to the theoretical results. Meanwhile, the outlet temperature field of cooling air and the temperature distribution of hot air channel are discussed by means of experiments and CFD simulations. Finally, by multi-parameter linear regression analysis of a large number of experimental results, the correlations of Nu and Eu are obtained.
5. The flowing and heat transfer characteristics of the package of a heat pipe charge air cooler and front cooling module are studied by CFD simulation and experimental research in the wind tunnel B. Then, two kinds of optimization of the intercooler are done to improve the performance. The results show that the airflow uniformity index and the pressure drop are improved efficiently; the heat pipe intercooler could well reduce the inlet temperature of the aluminum intercooler, while the optimized intercooler can satisfy the cooling requirements well, and thereby the aluminum intercooler has further room for improvement. On this basis, compared to the original, the heat rejection of radiator has a larger enhancement between3.36%-13.08%. Thus the cooling module can be optimized to be more compact to meet the cooling requirements, which is very significant to the optimization of the front-end cooling module and improvement of the overall heat transfer.
引文
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