高效低振动循环泵设计与试验研究
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摘要
本文是在国家杰出青年科学基金(50825902)资助下开展工作。循环泵是应用最广泛的离心泵之一,主要用于暖通空调和家用热水循环系统。目前循环泵主要存在效率较低、振动噪声水平较高等问题。随着新能效法规的出台和用户对振动噪声指标的更高要求,如何在传统离心泵设计方法的基础上,通过优化几何参数提高循环泵的水力效率和降低循环泵的振动噪声水平,成为一个重要的研究课题。本文采用理论分析、数值计算和试验验证相结合的方法对循环泵水力性能和振动噪声特性进行了研究,旨在于建立一套基于CFD的高效低振动循环泵水力设计方法。本文的主要工作和创造性成果有：
1.在传统离心泵设计方法的基础上,在保证流量、扬程不变的前提下,通过优化设计转速,使设计比转速位于40～70的高效区,并结合正交试验对循环泵的关键水力部件叶轮和蜗壳进行优化设计,采用理论分析和数值计算的方法对循环泵的水力性能指标和振动特性进行研究。结果表明：优化后B50和C100循环泵的泵效率分别为82.3%和81.1%,满足了设计能效指标要求并且超过了欧洲标准定义的离心泵最高可实现效率指标。同时,较高的转速,降低了叶轮的外径,使循环泵整体结构更为紧凑,进而降低了生产制造成本。
2.改进了循环泵蜗壳水力损失数学模型,考虑了叶轮与蜗壳间过渡段内的水力损失及螺旋蜗壳内的扩散损失,预测循环泵整体水力性能,指导蜗壳水力优化设计,试验表明：蜗壳水力损失数学模型能较为准确地预测循环泵内的水力损失,计算损失误差控制在5%之内。
3.结合正交试验和数值计算对循环泵叶轮和蜗壳进行了优化设计,分别以水力性能、叶片表面载荷、压力脉动强度、径向力脉动幅值这四个指标作为水力模型最优方案的判断标准,通过对比不同方案的计算结果,得到最优方案B50S0和C100S0。从水力优化设计过程中得出几点结论：1)叶片流线安放角β是影响叶片载荷的关键参数,合理的流线安放角能有效地降低叶片上的载荷,改善叶轮流道内的流动状态,降低叶轮的振动水平。对于B50和C100叶轮研究对象而言,当流线安放角β为25°时,叶片表面的压力载荷和相对速度载荷均最小。2)压力脉动强度与蜗壳基圆直径和喉部面积的大小成反比；径向力脉动幅值与蜗壳基圆直径的大小成反比；较大的蜗壳基圆直径和适中的喉部面积能有效地降低循环泵的压力脉动强度和径向力脉动幅值,进而降低振动。对于B50和C100循环泵而言,当蜗壳基圆直径D3分别为1.25D2和1.3D2时,具有较好的水力性能、较低的压力脉动强度和较小的径向力脉动幅值。3)首次提出了压力脉动强度与蜗壳基圆直径、喉部面积呈二次多项式的函数关系,随着蜗壳基圆直径、喉部面积的变大,压力脉动幅值逐渐变小,并最终趋近于一个极小值；径向力脉动幅值与蜗壳基圆直径呈二次多项式函数关系,随着蜗壳基圆直径的逐渐变大,径向力脉动幅值逐渐趋近于一个极小值。
4.对B50SO和C100S0方案进行了结构设计和样机试制,同时,为了降低泄露损失,创新设计了新型双道口环密封结构,以B50S0循环泵为研究对象,水力性能试验表明：与单道口环密封结构相比,双道口环密封结构的泵效率提升了6%。
5.首次在背景噪声小于16dB的半消音室和固有频率小于10Hz的振动试验平台上,根据ISO9906、ISO20361和ISO10816测试标准,采用麦克风传感器、压力传感器和振动加速度传感器分别对B50S0模型和C100SO模型进行了水力性能及振动噪声试验,试验结果表明：B50S0模型和C100SO模型达到了设计要求。
6.为了深入研究循环泵振动噪声特性,以B50SO模型为研究对象,测量了不同流量和转速下的振动噪声信号,采用1/3倍频程滤波法对振动噪声信号进行提取,分析了振动噪声与流量、转速及压力脉动之间的关系,发现了由流动分离引起的低频噪声主要存在于非设计工况下；噪声水平、压力脉动水平及结构振动水平与转速呈线性函数关系。研究发现：1)整个声压频域范围内,噪声水平从低频段到高频段呈先升高,后下降的趋势。2)非设计工况下的噪声水平、振动水平及压力脉动水平高于设计工况。3)由电机转子和定子的电磁感应所激励的高频振动主要存在于电机和电机座上。4)结构振动水平从大到小的排序依次为电机、法兰、电机座和泵体：靠近蜗舌区域和蜗壳出口扩散段处的振动水平高于泵体其它区域；法兰轴向上的振动小于径向振动。
7.优化后的B50SO和C100S0水力模型已用于格兰富相关产品(TPE3),效率分别超过欧洲最高可实现效率目标的5%和1%,振动和噪声水平(B50SO为1.05mm/s和65dB(A),C100SO为0.77mm/s和59dB(A))分别低于产品设计要求规定的1.8mm/s和68dB(A)。
This research is supported by the national outstanding youth fund (No.50825902). Circulator pump is one of the most widely used centrifugal pumps. It is mainly used for HVAC(Heating, Ventilation and Air Conditioning) systems and domestic hot water circulation systems. Currently, low efficiency and high vibration/noise level are the main issues in circulator pump. By considering the new energy and efficiency regulations are released and more strict requirements on vibration and noise level from customers, which makes people to think how to improve the hydraulic efficiency and reduce the vibration and noise level of circulator pump by optimizing the geometry parameters based on traditional centrifugal pump design methods. In this paper, the theoretical analysis, numerical simulation and experimental verification were used to study the hydraulic performance and vibration/noise characteristics of circulator pump. The purpose is to establish a set of hydraulic design methods, based on CFD, for circulator pump with high efficiency and low vibration. The main research contents and important conclusions of this paper are below:
1. Based on traditional centrifugal pump design methods, the nominal specific speed of circulator is optimized for the high efficiency range from40to70, which is made by adjusting the nominal speed with the constant flow rate and head.Based on this design method, the Design of Experiments (DOE) is conducted to optimize the critical hydraulic parts-impeller and volute. Afterwards, the hydraulic performance and vibration characteristics of circulator pumps are studied by using theoretical and numerical analysis. The results show that the efficiency of the post-optimized B50and C100circulator pumps are82.3%and81.1%, respectively. It satisfied new energy and efficiency regulation and exceeded the attainable highest pump efficiencies which are defined in European standard. It is generally known that the higher the speed, the smaller the outlet diameter of impeller. Therefore, it is a big production cost saving due to more compact design.
2. A hydraulic loss mathematical model of the circulator pump volute is improved by taking the hydraulic loss of transition section between impeller and volute and the diffusion loss of volute into consideration, to predict the overall hydraulic performance of the circulator pump, and give a guideline for the hydraulic optimization design process of volute. The performance measurements show that the hydraulic loss mathematical model can accurately predict the hydraulic loss of the circulator pump, and the calculated loss deviation is less than5%.
3. The impeller and volute of circulator pumps are optimized according to DOE and numerical calculation method. The hydraulic performance, blade loads, pressure pulsation amplitude and radial force amplitude, those four targets are taken as success criteria. The final optimized scenarios B50S0and C100S0are obtained by comparing the calculation results from different design scenarios. Results getting from hydraulic optimizing design progress are:1) the blade flow angle β is a critical parameter affecting the blade loads. The blade loads can be reduced and unsteadiness of flow can be improved with a proper blade flow angle, which indeed helps on reducing the vibration level of the impeller. For the impeller of B50and C100, when the blade flow angle β is25°, both the pressure load and the relative velocity load on the blade are at the minimum.2) Pressure pulsation amplitude is inversely proportional to the size of base circle diameter and throat area. The radial force pulsation amplitude is also inversely proportional to the size of base circle diameter. Both the amplitudes of pressure pulsation and radial force pulsation are effectively reduced by taking bigger base circle diameter and modest throat area into pump design. For B50and C100circulator pumps, they have better hydraulic performance, lower pressure pulsation amplitude and smaller radial force pulsation amplitude when the base circle diameter(D3), are1.25D2and1.3D2, respectively.3) The functional relationship of quadratic polynomial for pressure pulsation with base circle diameter and throat area is first proposed. The base circle diameter and throat area are larger, the pressure pulsation amplitude is lower and eventually tends to a minimum. The radial force pulsation amplitude has the functional relationship of quadratic polynomial with base circle diameter, and it tends to a minimum with increasing of the base circle diameter.
4. The mechanical design and prototyping are applied to both B50S0and C100S0scenarios. Meanwhile, the new double seal ring structure is taken into the design to reduce the leakage loss. For the B50circulator pump, the performance test results indicate that the pump efficiency is increased by6%by using the double seal ring structure, on comparison with the single seal ring structure.
5. Pump performance, air-borne noise level, fluid-borne noise level and structural vibration level are measured by utilizing the microphones, pressure sensors and vibration acceleration sensors according to the ISO9906, ISO20361and ISO10816, in the condition of hemi-anechoic room with background noise level lower than16dB and vibration test bed with natural frequency lower than10Hz.Experimental results show that the B50S0and C100S0scenarios fulfills the design requirements.
6. To get a deep understanding of noise and vibration characteristics of circulator pump, the vibration and noise signals is measured in different flow rates and speeds for B50S0prototype. The findings are vibration caused by low frequencies mainly does exist at off-design condition and the overall noise level, pressure pulsation level and structural vibration level are linear functions with speed. The experimental results show that:1) In the whole sound pressure frequencies range, the noise level is increasing from low frequency bands to middle frequency bands first, and then it is dropping to the end of high frequency bands.2) The noise level, vibration level and pressure pulsation level at off-design conditions are higher than best efficiency point's.3) The high-frequency vibration of the motor and motor stool is induced by electromagnetic induction force between rotor and stator of motor.4) The sort of amplitude of structural vibration is motor>flanges>motor stool>pump casing and the vibration level of tongue and diffuser areas is higher than other areas of pump casing. Moreover, the radial vibration level is higher than axial.
7. The final optimized hydraulic models B50S0and C100S0had been applied for Gundfos new generation circulator pumps(TPE3). Efficiency of B50S0and C100S0is higher than European Maximum Attainable Efficiency by5%and1%, separately. The vibration and noise levels(B50S0is1.05mm/s and65dB(A), C100S0is0.77mm/s and59dB(A)) are lower than1.8mm/s and68dB(A) that is defined by product specification.
1.在传统离心泵设计方法的基础上,在保证流量、扬程不变的前提下,通过优化设计转速,使设计比转速位于40～70的高效区,并结合正交试验对循环泵的关键水力部件叶轮和蜗壳进行优化设计,采用理论分析和数值计算的方法对循环泵的水力性能指标和振动特性进行研究。结果表明：优化后B50和C100循环泵的泵效率分别为82.3%和81.1%,满足了设计能效指标要求并且超过了欧洲标准定义的离心泵最高可实现效率指标。同时,较高的转速,降低了叶轮的外径,使循环泵整体结构更为紧凑,进而降低了生产制造成本。
2.改进了循环泵蜗壳水力损失数学模型,考虑了叶轮与蜗壳间过渡段内的水力损失及螺旋蜗壳内的扩散损失,预测循环泵整体水力性能,指导蜗壳水力优化设计,试验表明：蜗壳水力损失数学模型能较为准确地预测循环泵内的水力损失,计算损失误差控制在5%之内。
3.结合正交试验和数值计算对循环泵叶轮和蜗壳进行了优化设计,分别以水力性能、叶片表面载荷、压力脉动强度、径向力脉动幅值这四个指标作为水力模型最优方案的判断标准,通过对比不同方案的计算结果,得到最优方案B50S0和C100S0。从水力优化设计过程中得出几点结论：1)叶片流线安放角β是影响叶片载荷的关键参数,合理的流线安放角能有效地降低叶片上的载荷,改善叶轮流道内的流动状态,降低叶轮的振动水平。对于B50和C100叶轮研究对象而言,当流线安放角β为25°时,叶片表面的压力载荷和相对速度载荷均最小。2)压力脉动强度与蜗壳基圆直径和喉部面积的大小成反比；径向力脉动幅值与蜗壳基圆直径的大小成反比；较大的蜗壳基圆直径和适中的喉部面积能有效地降低循环泵的压力脉动强度和径向力脉动幅值,进而降低振动。对于B50和C100循环泵而言,当蜗壳基圆直径D3分别为1.25D2和1.3D2时,具有较好的水力性能、较低的压力脉动强度和较小的径向力脉动幅值。3)首次提出了压力脉动强度与蜗壳基圆直径、喉部面积呈二次多项式的函数关系,随着蜗壳基圆直径、喉部面积的变大,压力脉动幅值逐渐变小,并最终趋近于一个极小值；径向力脉动幅值与蜗壳基圆直径呈二次多项式函数关系,随着蜗壳基圆直径的逐渐变大,径向力脉动幅值逐渐趋近于一个极小值。
4.对B50SO和C100S0方案进行了结构设计和样机试制,同时,为了降低泄露损失,创新设计了新型双道口环密封结构,以B50S0循环泵为研究对象,水力性能试验表明：与单道口环密封结构相比,双道口环密封结构的泵效率提升了6%。
5.首次在背景噪声小于16dB的半消音室和固有频率小于10Hz的振动试验平台上,根据ISO9906、ISO20361和ISO10816测试标准,采用麦克风传感器、压力传感器和振动加速度传感器分别对B50S0模型和C100SO模型进行了水力性能及振动噪声试验,试验结果表明：B50S0模型和C100SO模型达到了设计要求。
6.为了深入研究循环泵振动噪声特性,以B50SO模型为研究对象,测量了不同流量和转速下的振动噪声信号,采用1/3倍频程滤波法对振动噪声信号进行提取,分析了振动噪声与流量、转速及压力脉动之间的关系,发现了由流动分离引起的低频噪声主要存在于非设计工况下；噪声水平、压力脉动水平及结构振动水平与转速呈线性函数关系。研究发现：1)整个声压频域范围内,噪声水平从低频段到高频段呈先升高,后下降的趋势。2)非设计工况下的噪声水平、振动水平及压力脉动水平高于设计工况。3)由电机转子和定子的电磁感应所激励的高频振动主要存在于电机和电机座上。4)结构振动水平从大到小的排序依次为电机、法兰、电机座和泵体：靠近蜗舌区域和蜗壳出口扩散段处的振动水平高于泵体其它区域；法兰轴向上的振动小于径向振动。
7.优化后的B50SO和C100S0水力模型已用于格兰富相关产品(TPE3),效率分别超过欧洲最高可实现效率目标的5%和1%,振动和噪声水平(B50SO为1.05mm/s和65dB(A),C100SO为0.77mm/s和59dB(A))分别低于产品设计要求规定的1.8mm/s和68dB(A)。
This research is supported by the national outstanding youth fund (No.50825902). Circulator pump is one of the most widely used centrifugal pumps. It is mainly used for HVAC(Heating, Ventilation and Air Conditioning) systems and domestic hot water circulation systems. Currently, low efficiency and high vibration/noise level are the main issues in circulator pump. By considering the new energy and efficiency regulations are released and more strict requirements on vibration and noise level from customers, which makes people to think how to improve the hydraulic efficiency and reduce the vibration and noise level of circulator pump by optimizing the geometry parameters based on traditional centrifugal pump design methods. In this paper, the theoretical analysis, numerical simulation and experimental verification were used to study the hydraulic performance and vibration/noise characteristics of circulator pump. The purpose is to establish a set of hydraulic design methods, based on CFD, for circulator pump with high efficiency and low vibration. The main research contents and important conclusions of this paper are below:
1. Based on traditional centrifugal pump design methods, the nominal specific speed of circulator is optimized for the high efficiency range from40to70, which is made by adjusting the nominal speed with the constant flow rate and head.Based on this design method, the Design of Experiments (DOE) is conducted to optimize the critical hydraulic parts-impeller and volute. Afterwards, the hydraulic performance and vibration characteristics of circulator pumps are studied by using theoretical and numerical analysis. The results show that the efficiency of the post-optimized B50and C100circulator pumps are82.3%and81.1%, respectively. It satisfied new energy and efficiency regulation and exceeded the attainable highest pump efficiencies which are defined in European standard. It is generally known that the higher the speed, the smaller the outlet diameter of impeller. Therefore, it is a big production cost saving due to more compact design.
2. A hydraulic loss mathematical model of the circulator pump volute is improved by taking the hydraulic loss of transition section between impeller and volute and the diffusion loss of volute into consideration, to predict the overall hydraulic performance of the circulator pump, and give a guideline for the hydraulic optimization design process of volute. The performance measurements show that the hydraulic loss mathematical model can accurately predict the hydraulic loss of the circulator pump, and the calculated loss deviation is less than5%.
3. The impeller and volute of circulator pumps are optimized according to DOE and numerical calculation method. The hydraulic performance, blade loads, pressure pulsation amplitude and radial force amplitude, those four targets are taken as success criteria. The final optimized scenarios B50S0and C100S0are obtained by comparing the calculation results from different design scenarios. Results getting from hydraulic optimizing design progress are:1) the blade flow angle β is a critical parameter affecting the blade loads. The blade loads can be reduced and unsteadiness of flow can be improved with a proper blade flow angle, which indeed helps on reducing the vibration level of the impeller. For the impeller of B50and C100, when the blade flow angle β is25°, both the pressure load and the relative velocity load on the blade are at the minimum.2) Pressure pulsation amplitude is inversely proportional to the size of base circle diameter and throat area. The radial force pulsation amplitude is also inversely proportional to the size of base circle diameter. Both the amplitudes of pressure pulsation and radial force pulsation are effectively reduced by taking bigger base circle diameter and modest throat area into pump design. For B50and C100circulator pumps, they have better hydraulic performance, lower pressure pulsation amplitude and smaller radial force pulsation amplitude when the base circle diameter(D3), are1.25D2and1.3D2, respectively.3) The functional relationship of quadratic polynomial for pressure pulsation with base circle diameter and throat area is first proposed. The base circle diameter and throat area are larger, the pressure pulsation amplitude is lower and eventually tends to a minimum. The radial force pulsation amplitude has the functional relationship of quadratic polynomial with base circle diameter, and it tends to a minimum with increasing of the base circle diameter.
4. The mechanical design and prototyping are applied to both B50S0and C100S0scenarios. Meanwhile, the new double seal ring structure is taken into the design to reduce the leakage loss. For the B50circulator pump, the performance test results indicate that the pump efficiency is increased by6%by using the double seal ring structure, on comparison with the single seal ring structure.
5. Pump performance, air-borne noise level, fluid-borne noise level and structural vibration level are measured by utilizing the microphones, pressure sensors and vibration acceleration sensors according to the ISO9906, ISO20361and ISO10816, in the condition of hemi-anechoic room with background noise level lower than16dB and vibration test bed with natural frequency lower than10Hz.Experimental results show that the B50S0and C100S0scenarios fulfills the design requirements.
6. To get a deep understanding of noise and vibration characteristics of circulator pump, the vibration and noise signals is measured in different flow rates and speeds for B50S0prototype. The findings are vibration caused by low frequencies mainly does exist at off-design condition and the overall noise level, pressure pulsation level and structural vibration level are linear functions with speed. The experimental results show that:1) In the whole sound pressure frequencies range, the noise level is increasing from low frequency bands to middle frequency bands first, and then it is dropping to the end of high frequency bands.2) The noise level, vibration level and pressure pulsation level at off-design conditions are higher than best efficiency point's.3) The high-frequency vibration of the motor and motor stool is induced by electromagnetic induction force between rotor and stator of motor.4) The sort of amplitude of structural vibration is motor>flanges>motor stool>pump casing and the vibration level of tongue and diffuser areas is higher than other areas of pump casing. Moreover, the radial vibration level is higher than axial.
7. The final optimized hydraulic models B50S0and C100S0had been applied for Gundfos new generation circulator pumps(TPE3). Efficiency of B50S0and C100S0is higher than European Maximum Attainable Efficiency by5%and1%, separately. The vibration and noise levels(B50S0is1.05mm/s and65dB(A), C100S0is0.77mm/s and59dB(A)) are lower than1.8mm/s and68dB(A) that is defined by product specification.
引文
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