摩托车电控发动机匹配标定
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摘要
本研究在FY125-3P摩托车上进行电控发动机匹配标定,旨在降低摩托车排放,满足国Ⅲ标准的要求,同时提高动力性和燃油经济性。
本文从摩托车电控技术特点入手,综合考虑电控系统的性能、零部件的成熟性、产品成本控制等,设计了六传感器(发动机转速、进气压力、进气温度、发动机缸体温度、排气氧含量、节气门开度)、闭环电控配三元催化净化器、具有自适应功能的电控系统技术方案,具有结构简单、成本低、安装方便、控制精度高和可靠性好的特点。
通过改装发动机磁钢的信号轮,在信号轮上均布34个齿及空缺2个齿,利用转速传感器采集到信号轮齿的脉冲信号,再通过软件分析发动机的瞬时速度脉冲得出发动机所处的冲程与上止点,实现了冲程的判断,取代了相位传感器。
试验对比了三家催化器厂家提供的三元排气催化净化器的性能,综合考虑催化转化效果及其对发动机功率的影响,选择出最佳的催化净化器。
进行了摩托车电控发动机节气门体设计。研究节气门体内径、阀片转轴结构、内管的结构等对发动机动力性能的影响,应用谐振理论进行节气门的内径设计,试制了样件,通过发动机台架实验来筛选设计方案。设计的节气门体内径为28mm、阀片减薄及转轴削平、锥型进气口的节气门体设计方案,可使电控发动机功率有效提高,实现了设计目标。
根据发动机及整车的各种性能要求(动力性、经济性和排放性能等),综合利用工况分析法、排气分析法、空燃比分析法,通过发动机台架实验、整车实验进行电控系统匹配标定,调整、优化和确定电控系统的运行参数和控制参数,完成了发动机进气负荷采样点匹配、喷油时间的电源电压修正匹配、排气背压匹配、进气负荷匹配、喷油角匹配、点火提前角匹配、起动性能匹配、第二负荷匹配、过渡工况喷油控制、λ闭环控制匹配、海拔高度与高、低温环境匹配实验等。得到了一系列的匹配参数、曲线、MAP,使发动机在排放性能、动力性、经济性得到综合的优化。
对所开发电控FY125-3P摩托车、FM156FMI发动机进行了性能验证实验。相比原化油器式摩托车,电控摩托车工况法CO、HC和NO_x的排放量显著减少,低于国Ⅲ排放限值的70%,发动机外特性燃油耗下降了5.8%,加速性能优于化油器车,尤其是超越加速性能提高明显。
In order to reduce motorcycle emission, and meet the Chinese emission standard at third stage, improve motorcycle fuel economy and dynamic performance, the paper studied the calibration of electronic control engine on FY125-3P motorcycle.
Based on the characteristic of electronic control technology, considering the maturation and the cost of electronic control system parts synthetically, the paper designed a technology scheme of electronic control system, which has 6 sensors(engine speed sensor, inlet air temperature sensor, inlet air temperature sensor, engine temperature sensor, oxygen sensor, throttle valve position sensor ), closed loop control with three-way catalyst and self-adaptive function. This system has a characteristic of simple configuration, low cost, convenient for installation, high precision and reliability.
By retrofitting engine flywheel signal wheel, using the pulse signal of signal wheel, and analyzing the engine instantaneous speed pulse with software, the judgment for stroke of the engine was realized, which replaced the conventional phase sensor.
Three catalytic converter samples from different factories were compared by tests. Then in order to select optimum converter, the conversion results of catalytic converter and the effect to engine power were considered comprehensively.
The throttle body for electronic control motorcycle engine was designed optimum in this paper. It was studied the influence of the inner diameter, configuration of valve and its axe and inside configuration of inner pipe of throttle body on the engine performance. The inner diameter of throttle body was designed on the basis of resonance theory. And the samples of throttle body designed were manufactured and tested by engine experiment. Results showed that the engine power was improved effectively when applying the option design throttle body with a thin valve and a taper inlet port, the size of inner diameter increased from 26mm to 28mm and the thickness of the valve decreased. And the optimization throttle body can meet the design target.
According to performance requirements of engine and vehicle, such as power performance fuel economy,emission,etc, combining with the matching and calibration methods of working condition analysis, exhaust analysis and X analysis, engine test bench and vehicle tests were done to calibrate the electronic control system, optimize the running and control parameter. After completed a mass of calibration experiment, such as intake load sampling point calibration, response time of injector validation, exhaust back pressure calibration, intake load calibration, injection angle calibration, starting performance calibration, second load calibration, transition condition calibration, X closed-loop control calibration, altitude test calibration, winter and summer tests, it was gained a series of control parameters, curves and MAP for engine fuel injection,ignition advance angle,etc. That can made engine optimization synthetically on emission performance, dynamic performance and economy.
In the end the performances of the engine and vehicle developed were validated by experiment.Comparing with the original carburetor motorcycle, the emissions of CO, HC and NOx for electronic control engine motorcycle were reduced largely, and lower than 70% of limit value of Chinese emission standard at III stage. And the fuel consumption was reduced by 5.8% at full load, drive power of rear wheel was little lower, accelerated performance, especially, the overtaken acceleration was improved obviously.
本文从摩托车电控技术特点入手,综合考虑电控系统的性能、零部件的成熟性、产品成本控制等,设计了六传感器(发动机转速、进气压力、进气温度、发动机缸体温度、排气氧含量、节气门开度)、闭环电控配三元催化净化器、具有自适应功能的电控系统技术方案,具有结构简单、成本低、安装方便、控制精度高和可靠性好的特点。
通过改装发动机磁钢的信号轮,在信号轮上均布34个齿及空缺2个齿,利用转速传感器采集到信号轮齿的脉冲信号,再通过软件分析发动机的瞬时速度脉冲得出发动机所处的冲程与上止点,实现了冲程的判断,取代了相位传感器。
试验对比了三家催化器厂家提供的三元排气催化净化器的性能,综合考虑催化转化效果及其对发动机功率的影响,选择出最佳的催化净化器。
进行了摩托车电控发动机节气门体设计。研究节气门体内径、阀片转轴结构、内管的结构等对发动机动力性能的影响,应用谐振理论进行节气门的内径设计,试制了样件,通过发动机台架实验来筛选设计方案。设计的节气门体内径为28mm、阀片减薄及转轴削平、锥型进气口的节气门体设计方案,可使电控发动机功率有效提高,实现了设计目标。
根据发动机及整车的各种性能要求(动力性、经济性和排放性能等),综合利用工况分析法、排气分析法、空燃比分析法,通过发动机台架实验、整车实验进行电控系统匹配标定,调整、优化和确定电控系统的运行参数和控制参数,完成了发动机进气负荷采样点匹配、喷油时间的电源电压修正匹配、排气背压匹配、进气负荷匹配、喷油角匹配、点火提前角匹配、起动性能匹配、第二负荷匹配、过渡工况喷油控制、λ闭环控制匹配、海拔高度与高、低温环境匹配实验等。得到了一系列的匹配参数、曲线、MAP,使发动机在排放性能、动力性、经济性得到综合的优化。
对所开发电控FY125-3P摩托车、FM156FMI发动机进行了性能验证实验。相比原化油器式摩托车,电控摩托车工况法CO、HC和NO_x的排放量显著减少,低于国Ⅲ排放限值的70%,发动机外特性燃油耗下降了5.8%,加速性能优于化油器车,尤其是超越加速性能提高明显。
In order to reduce motorcycle emission, and meet the Chinese emission standard at third stage, improve motorcycle fuel economy and dynamic performance, the paper studied the calibration of electronic control engine on FY125-3P motorcycle.
Based on the characteristic of electronic control technology, considering the maturation and the cost of electronic control system parts synthetically, the paper designed a technology scheme of electronic control system, which has 6 sensors(engine speed sensor, inlet air temperature sensor, inlet air temperature sensor, engine temperature sensor, oxygen sensor, throttle valve position sensor ), closed loop control with three-way catalyst and self-adaptive function. This system has a characteristic of simple configuration, low cost, convenient for installation, high precision and reliability.
By retrofitting engine flywheel signal wheel, using the pulse signal of signal wheel, and analyzing the engine instantaneous speed pulse with software, the judgment for stroke of the engine was realized, which replaced the conventional phase sensor.
Three catalytic converter samples from different factories were compared by tests. Then in order to select optimum converter, the conversion results of catalytic converter and the effect to engine power were considered comprehensively.
The throttle body for electronic control motorcycle engine was designed optimum in this paper. It was studied the influence of the inner diameter, configuration of valve and its axe and inside configuration of inner pipe of throttle body on the engine performance. The inner diameter of throttle body was designed on the basis of resonance theory. And the samples of throttle body designed were manufactured and tested by engine experiment. Results showed that the engine power was improved effectively when applying the option design throttle body with a thin valve and a taper inlet port, the size of inner diameter increased from 26mm to 28mm and the thickness of the valve decreased. And the optimization throttle body can meet the design target.
According to performance requirements of engine and vehicle, such as power performance fuel economy,emission,etc, combining with the matching and calibration methods of working condition analysis, exhaust analysis and X analysis, engine test bench and vehicle tests were done to calibrate the electronic control system, optimize the running and control parameter. After completed a mass of calibration experiment, such as intake load sampling point calibration, response time of injector validation, exhaust back pressure calibration, intake load calibration, injection angle calibration, starting performance calibration, second load calibration, transition condition calibration, X closed-loop control calibration, altitude test calibration, winter and summer tests, it was gained a series of control parameters, curves and MAP for engine fuel injection,ignition advance angle,etc. That can made engine optimization synthetically on emission performance, dynamic performance and economy.
In the end the performances of the engine and vehicle developed were validated by experiment.Comparing with the original carburetor motorcycle, the emissions of CO, HC and NOx for electronic control engine motorcycle were reduced largely, and lower than 70% of limit value of Chinese emission standard at III stage. And the fuel consumption was reduced by 5.8% at full load, drive power of rear wheel was little lower, accelerated performance, especially, the overtaken acceleration was improved obviously.
引文
[1]刘长平.我国摩托车发动机的现状与展望[J].机电工程技术,2002,31(2):18-19
[2]江洪.摩托车电子燃油喷射系统试验研究[D].重庆:重庆大学,2006
[3]Tastuji IRIE,Hironori KOCHI,Tomoya YAMAKAWA,et al..Engine management System for Motorcycle.SAE Paper,20056592
[4]Badih A.Jawad,Thomas V.Kuzak.Motorcycle Electronic Fuel Injection Retrofit.SAE Paper 2001-01-2914
[5]马翠英.摩托车用电控汽油机燃油控制策略的试验研究[D].济南:山东大学,2006
[6]任猛.我国摩托车发动机的现状与前景展望[J].摩托车技术,1997,(11):1-3
[7]欧阳涛.国内外摩托车排放标准及法规简介[J].摩托车技术,2003,(10):46-50
[8]摩托车排放污染防治技术政策
[9]李晶华.我国摩托车电控技术发展现状[J].摩托车技术,2003(10):6-9
[10]Robert T.P.Tan,Tercin Tan Seng Hung.Motorcycle Engine Management System with Microcontroiler and Smart Drivers.SAE Paper,2005-26-362
[11]谭凯.摩托车发动机电控改造的理论与实验研究[D].长沙:湖南大学,2003
[12]邹斌.小型四冲程摩托车发动机电子控制系统的开发研究[D].武汉:武汉理工大学,2002
[13]麻友良,丁卫东.汽车电器与电子控制系统[M].北京:机械工业出版社,2002
[14]冯健璋.汽车发动机原理与汽车理论[M].北京:机械工业出版社,2005
[15]李炎亮,高秀华,成凯等.汽车电子技术[M].北京:化学工业出版社,2005
[16]张金女,储江伟,朴永守.汽车电子装置与控制技术[M].黑龙江:黑龙江科学技术出版社,2005
[17]习纲,郭晓潞,王振锁等.小型汔油发动机管理系统的某些精殊功能应用[J].摩托车技术,2005,(10):14-17
[18]Brian J.Birch,Manfred Amann.Electronic Fuel System Development for Air-Cooled Motorcycles[C].SAE Paper 20044346
[19]吴远鹏,习纲,葛林.小型汽油发动机电喷系统平台——MSE2.0[J].摩托车技术,2003, (10):10-13
[20]陈家瑞.汽车构造(上册)[M].北京:机械工业出版社,2000
[21]W.James Allen.Calibration Development with Production Intent Electronic Control Units[C].SAE Paper 2000-01-1241
[22]卓斌.电控汽油机匹配标定及性能优化研究[D].上海:上海交通大学,2000
[23]August Goers,Allen Lipper,Lynn Mosher,et al.Calibration of an Aftermarket EFI Conversion System for Increased Performance and Fuel Economy with Reduced Emissions[C].SAE Paper 2003-01-1051
[24]http://www.etas.com/zh/products/hardware_products.php
[25]Brian J.Birch,Manfred Amann.Electronic Fuel System Development for Air-Cooled Motorcycles[C].SAE Paper 20044346
[26]Zhengmao Ye.A Simple Linear Approach for Transient Fuel Control[C].SAE Paper 2003-01-0360
[27]张小矛,黄荣华.发动机进排气系统稳流试验装置的设计与研制[J].小型内燃机与摩托车,2003,32(2):1-3
[28]潘陆陆,刘耀军,尚捷等.国产摩托车欧Ⅲ排放解决方案及催化净化技术的运用[J].摩托车技术,2006,(10):31-34
[29]欧阳涛.两轮摩托车应对欧Ⅲ排放标准的技术方案[J].摩托车技术,2006,(8):20-24
[30]余国核,阎祥安等.进气管道结构对单缸发动机动力性能的影响[J].中国机械工程,2006(17)增刊:140-143
[31]周龙保.内燃机学[M].北京:机械工业出版社,1999
[32]Wilson N,Watkins A,Dopson C.A Symmetric Valve Strategies and Their Effect on Combustion[C].SAE Paper 930821,1993
[33]冯明志,刘书亮.四气门火化点火式发动机缸内的空气运动[J].天津大学学报,2000,(3):355-359
[34]裴普成,刘书亮,范永健.多气门汽油机滚流进气道结构的研究[J].内燃机学报,1993,(47):13-19
[35]张会明,洪家娣.改进柴油机进气系统的研究[J].小型内燃机,1998(6):28-31
[36]肖民,张庆松.JL368Q汽油机进气系统计算及设计[J].华东船舶工业学院学报(自然科学版),2002,16(1):56-61
[37]胡春明,刘娜,宋玺娟.电控摩托车发动机的排放控制研究[J].小型内燃机与摩托车,2006,35(5):60-63
[38]GB 14622-2002摩托车排气污染物排放限值及测量方法(工况法)
[39]GB 14622-2007摩托车污染物排放限值及测量方法(工况法,中国第三阶段)
[40]胡春明,谢辉,尧命发等.摩托车电喷系统的匹配技术及其开发系统的研究[J].小型内燃机与摩托车.2002,31(2):21-24
[41]GB/T 5385-94摩托车和轻便摩托车加速性能试验方法
[42]Richard G.Ford,John McColgan.Design and Implementation of a Duel-Mode Speed Loop Controller for a Dynamometer-Based Vehicle Simulation System[J].SAE Paper 1999-01-0940
[2]江洪.摩托车电子燃油喷射系统试验研究[D].重庆:重庆大学,2006
[3]Tastuji IRIE,Hironori KOCHI,Tomoya YAMAKAWA,et al..Engine management System for Motorcycle.SAE Paper,20056592
[4]Badih A.Jawad,Thomas V.Kuzak.Motorcycle Electronic Fuel Injection Retrofit.SAE Paper 2001-01-2914
[5]马翠英.摩托车用电控汽油机燃油控制策略的试验研究[D].济南:山东大学,2006
[6]任猛.我国摩托车发动机的现状与前景展望[J].摩托车技术,1997,(11):1-3
[7]欧阳涛.国内外摩托车排放标准及法规简介[J].摩托车技术,2003,(10):46-50
[8]摩托车排放污染防治技术政策
[9]李晶华.我国摩托车电控技术发展现状[J].摩托车技术,2003(10):6-9
[10]Robert T.P.Tan,Tercin Tan Seng Hung.Motorcycle Engine Management System with Microcontroiler and Smart Drivers.SAE Paper,2005-26-362
[11]谭凯.摩托车发动机电控改造的理论与实验研究[D].长沙:湖南大学,2003
[12]邹斌.小型四冲程摩托车发动机电子控制系统的开发研究[D].武汉:武汉理工大学,2002
[13]麻友良,丁卫东.汽车电器与电子控制系统[M].北京:机械工业出版社,2002
[14]冯健璋.汽车发动机原理与汽车理论[M].北京:机械工业出版社,2005
[15]李炎亮,高秀华,成凯等.汽车电子技术[M].北京:化学工业出版社,2005
[16]张金女,储江伟,朴永守.汽车电子装置与控制技术[M].黑龙江:黑龙江科学技术出版社,2005
[17]习纲,郭晓潞,王振锁等.小型汔油发动机管理系统的某些精殊功能应用[J].摩托车技术,2005,(10):14-17
[18]Brian J.Birch,Manfred Amann.Electronic Fuel System Development for Air-Cooled Motorcycles[C].SAE Paper 20044346
[19]吴远鹏,习纲,葛林.小型汽油发动机电喷系统平台——MSE2.0[J].摩托车技术,2003, (10):10-13
[20]陈家瑞.汽车构造(上册)[M].北京:机械工业出版社,2000
[21]W.James Allen.Calibration Development with Production Intent Electronic Control Units[C].SAE Paper 2000-01-1241
[22]卓斌.电控汽油机匹配标定及性能优化研究[D].上海:上海交通大学,2000
[23]August Goers,Allen Lipper,Lynn Mosher,et al.Calibration of an Aftermarket EFI Conversion System for Increased Performance and Fuel Economy with Reduced Emissions[C].SAE Paper 2003-01-1051
[24]http://www.etas.com/zh/products/hardware_products.php
[25]Brian J.Birch,Manfred Amann.Electronic Fuel System Development for Air-Cooled Motorcycles[C].SAE Paper 20044346
[26]Zhengmao Ye.A Simple Linear Approach for Transient Fuel Control[C].SAE Paper 2003-01-0360
[27]张小矛,黄荣华.发动机进排气系统稳流试验装置的设计与研制[J].小型内燃机与摩托车,2003,32(2):1-3
[28]潘陆陆,刘耀军,尚捷等.国产摩托车欧Ⅲ排放解决方案及催化净化技术的运用[J].摩托车技术,2006,(10):31-34
[29]欧阳涛.两轮摩托车应对欧Ⅲ排放标准的技术方案[J].摩托车技术,2006,(8):20-24
[30]余国核,阎祥安等.进气管道结构对单缸发动机动力性能的影响[J].中国机械工程,2006(17)增刊:140-143
[31]周龙保.内燃机学[M].北京:机械工业出版社,1999
[32]Wilson N,Watkins A,Dopson C.A Symmetric Valve Strategies and Their Effect on Combustion[C].SAE Paper 930821,1993
[33]冯明志,刘书亮.四气门火化点火式发动机缸内的空气运动[J].天津大学学报,2000,(3):355-359
[34]裴普成,刘书亮,范永健.多气门汽油机滚流进气道结构的研究[J].内燃机学报,1993,(47):13-19
[35]张会明,洪家娣.改进柴油机进气系统的研究[J].小型内燃机,1998(6):28-31
[36]肖民,张庆松.JL368Q汽油机进气系统计算及设计[J].华东船舶工业学院学报(自然科学版),2002,16(1):56-61
[37]胡春明,刘娜,宋玺娟.电控摩托车发动机的排放控制研究[J].小型内燃机与摩托车,2006,35(5):60-63
[38]GB 14622-2002摩托车排气污染物排放限值及测量方法(工况法)
[39]GB 14622-2007摩托车污染物排放限值及测量方法(工况法,中国第三阶段)
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[41]GB/T 5385-94摩托车和轻便摩托车加速性能试验方法
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