柴油机高压共轨系统电控单元及电控开发系统的研究
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摘要
高压共轨电控燃油喷射系统是柴油机能够达到更好经济性和排放性的关键技术之一,其中电控部分是实现对燃油喷射柔性控制和油压调节的核心。本文作者对高压共轨燃油喷射系统的电控单元ECU和基于微机的柴油机电控开发系统进行了研究。
在电控单元ECU的开发中,介绍了ECU的总体结构以及各个模块的主要功能。为节省微处理器的TPU资源,运用MAX7000S系列的复杂可编程逻辑器件和支持该器件的开发软件,结合硬件描述语言,通过设计输入、编译、调试和仿真,完成了喷油器控制信号的产生和逻辑合成,并将程序固化到CPLD中,最后通过了电路实验的验证。DC-DC升压变换器是为提高喷油器电磁阀响应速度而设计的,为了改善变换器输出电压的性能,在仿真结果的基础上,本文对影响DC-DC变换器输出性能指标的参数——储能电容、储能电感、电路工作频率和控制脉宽进行了实验研究,归纳出参数影响升压变换器性能的规律,并在此基础上设计了性能相对最佳的升压变换器。
为对电控喷油器和高压油泵的性能参数进行全面正确的评价,获得满足发动机运行要求的喷油压力和喷油量等MAP,同时确定控制策略,作者进行了柴油机电控开发系统的研究。作者利用微机的丰富资源,结合定时卡和采集卡,进行了硬件设计,实现了供油系统参数采集、控制信号产生及合成和功率驱动等功能,并采取了必要的抗电磁干扰措施;本文选用实时的DOS操作系统和C语言、按照模块化设计原则进行软件设计,实现了供油系统参数采集、发动机运行控制和状态参数显示等功能。在此基础上,对电控喷油器进行了标定实验,实验结果表明,该喷油器具有极快的开启响应速度和很小的循环变动。
High-pressure common rail fuel injection system is one of the key technologies to enable diesel engine more efficient and cleaner. Electronic control is the most important part to realize fuel injection’s flexible control and fuel pressure’s regulation. The Electronic control unit (ECU) and the development system for diesel engine based on microcomputer are studied in this thesis.
The gross structure of ECU and main function of every part are introduced in this thesis. In order to save microprocessor resource, complex programmable logic device (CPLD) of MAX7000S series, the software MAX+plusII and the very high speed hardware description language (VHDL) are used in the research. After design, compilation, debugging and simulation, the hardware circuit function was realized. Finally the program was solidified into the CPLD device and was verified by the circuit experiment. DC-DC power supply unit is used to improve the electromagnetic response of the injector. To improve unit’s performance, three parameters (capacitance, inductance and circuit frequency) and the control pulse are investigated by experiment based on the simulation result. The effects of these parameters on unit performances are concluded. The injection rate of injector and electromagnetic response is studied for different units.
The Electronic control development system for diesel engine is designed to evaluate the performance of injector and high pressure fuel pump, also to obtain the required MAP. The function of signal acquisition, control signal generation and power drive is achieved through hardware design. Many measures of anti electromagnetic interference are also considered. According to the principle of modularization, the modules of engine control, display and pressure acquisition are accomplished. The calibration results of the injector reveal that the injector has satisfying linearity, small cyclical fluctuation and very high speed opening response.
在电控单元ECU的开发中,介绍了ECU的总体结构以及各个模块的主要功能。为节省微处理器的TPU资源,运用MAX7000S系列的复杂可编程逻辑器件和支持该器件的开发软件,结合硬件描述语言,通过设计输入、编译、调试和仿真,完成了喷油器控制信号的产生和逻辑合成,并将程序固化到CPLD中,最后通过了电路实验的验证。DC-DC升压变换器是为提高喷油器电磁阀响应速度而设计的,为了改善变换器输出电压的性能,在仿真结果的基础上,本文对影响DC-DC变换器输出性能指标的参数——储能电容、储能电感、电路工作频率和控制脉宽进行了实验研究,归纳出参数影响升压变换器性能的规律,并在此基础上设计了性能相对最佳的升压变换器。
为对电控喷油器和高压油泵的性能参数进行全面正确的评价,获得满足发动机运行要求的喷油压力和喷油量等MAP,同时确定控制策略,作者进行了柴油机电控开发系统的研究。作者利用微机的丰富资源,结合定时卡和采集卡,进行了硬件设计,实现了供油系统参数采集、控制信号产生及合成和功率驱动等功能,并采取了必要的抗电磁干扰措施;本文选用实时的DOS操作系统和C语言、按照模块化设计原则进行软件设计,实现了供油系统参数采集、发动机运行控制和状态参数显示等功能。在此基础上,对电控喷油器进行了标定实验,实验结果表明,该喷油器具有极快的开启响应速度和很小的循环变动。
High-pressure common rail fuel injection system is one of the key technologies to enable diesel engine more efficient and cleaner. Electronic control is the most important part to realize fuel injection’s flexible control and fuel pressure’s regulation. The Electronic control unit (ECU) and the development system for diesel engine based on microcomputer are studied in this thesis.
The gross structure of ECU and main function of every part are introduced in this thesis. In order to save microprocessor resource, complex programmable logic device (CPLD) of MAX7000S series, the software MAX+plusII and the very high speed hardware description language (VHDL) are used in the research. After design, compilation, debugging and simulation, the hardware circuit function was realized. Finally the program was solidified into the CPLD device and was verified by the circuit experiment. DC-DC power supply unit is used to improve the electromagnetic response of the injector. To improve unit’s performance, three parameters (capacitance, inductance and circuit frequency) and the control pulse are investigated by experiment based on the simulation result. The effects of these parameters on unit performances are concluded. The injection rate of injector and electromagnetic response is studied for different units.
The Electronic control development system for diesel engine is designed to evaluate the performance of injector and high pressure fuel pump, also to obtain the required MAP. The function of signal acquisition, control signal generation and power drive is achieved through hardware design. Many measures of anti electromagnetic interference are also considered. According to the principle of modularization, the modules of engine control, display and pressure acquisition are accomplished. The calibration results of the injector reveal that the injector has satisfying linearity, small cyclical fluctuation and very high speed opening response.
引文
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[3] M. Badami, P. Nuccio and G. Trucco, Influence of Injection Pressure on the Performance of a DI Diesel Engine with a Common Rail Fuel Injection System, SAE Paper 1999-01-0193, 1999
[4] 梁超,强添纲, 机械柴油喷射与电控共轨柴油喷射的差异,汽车电器,2006, 第 10 期
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[2] 谢辉,车用柴油机新型共轨蓄压式电控燃油系统及其开发系统的开发研究,[博士学位论文],天津,天津大学,1998
[3] M. Badami, P. Nuccio and G. Trucco, Influence of Injection Pressure on the Performance of a DI Diesel Engine with a Common Rail Fuel Injection System, SAE Paper 1999-01-0193, 1999
[4] 梁超,强添纲, 机械柴油喷射与电控共轨柴油喷射的差异,汽车电器,2006, 第 10 期
[5] 徐家龙,藤泽英也,日本电装公司的柴油机共轨喷油系统——ECD-U2,国外内燃机,2000,第 2 期
[6] E.Haas,Optimization of Combustion of Truck Diesel Engines for Future European Emission and Noise Limits,SAE Paper 945117
[7] Ulrich Flaig, Wilhelm Polach and Gerhard Ziegler, Common Rail System (CR-System) for Passenger Car DI Diesel Engines; Experiences with Applications for Series Production Projects, SAE Paper 1999-01-0191, 1999
[8] 李伟军,喷油定时对柴油机经济性和排放的影响,柴油机设计与制造,2004,第2期,42～45
[9] Minami T,Takeuchi K,Shimazaki N,采用预喷射减少柴油机的NOx排放,国外内燃机,1998,第1期,44～50
[10]Maiorana G,Fiat 公司的共轨式发动机,国外内燃机,1999,第 1 期
[11]豪彦,博世公司柴油机系统先进技术,汽车与配件,2003-48,20～22,2003
[12]Wanhua Su,Hui Wang and Bin Liu,Injection Mode Modulation for HCCI Diesel Combustion,SAE Paper 2005-01-0117,2005
[13]王辉,苏万华,刘斌,基于调制多脉冲喷油模式的柴油预混合燃烧和排放特性的研究,内燃机学报,2005,23(4),289～296
[14]Wanhua Su,Tiejian Lin and Yiqiang Pei,A Compound Technology for HCCI Combustion in a DI Diesel Engine Based on the Multi-Pulse Injection and the BUMP Combustion Chamber,SAE Paper 2003-01-0741,2003
[15]苏万华,林铁坚,张晓宇等,MULINBUMP-HCCI 复合燃烧放热特征及其对排放和热效率的影响,内燃机学报,2004,22(3),193～202
[16]Susumu Kohketsu, Keiki Tanabe and Koji Mori,Flexibly Controlled InjectionRate Shape with Next Generation Common Rail System for Heavy Duty DI Diesel Engines,SAE Paper 2000-01-0705,2000
[17]Hummel K,Boecking F,GroB J 等,Bosch 等第三代轿车用压电直接控制式喷油器共轨喷油系统,国外内燃机,2005,第 1 期,25～29
[18]王钧效,陆家祥,谭丕强等,柴油机高压共轨喷油系统的发展动态,柴油机,2001,第 5 期,1～11
[19]范明强,新颖的德尔福共轨喷射系统及其低排放控制策略,现代车用动力,2003,第 2,3 期
[20]豪彦,德尔福集团公司燃油共轨喷射技术,汽车与配件,2003,第 2 期,29～31
[21]刘斌彬,李国岫,郑亚银,柴油机高压共轨燃油喷射系统现状与发展趋势,内燃机,2006,第 2 期,1～3
[22]J. W. Hwang, H. J. Kal and M. H. Kim,Effect of Fuel Injection Rate on Pollutant Emissions in DI Diesel Engine,SAE Paper 1999-01-0195,1999
[23]M. A. Ganser,Common Rail Injectors for 2000 bar and Beyond,SAE Paper 2000-01-0706,2000
[24]M. F. Russell, G. Greeves and N. Guerrassi,More Torque, Less Emissions and Less Noise,SAE Paper 2000-01-0942,2000
[25]Joachim Schommers,Frank Duvinage and Marco Stotz,Potential of Common Rail Injection System for Passenger Car DI Diesel Engines,SAE Paper 2000-01-0944,2000
[26]Toehltaica Minaml,Reduction of Diesel Engine NOx Using Pilot Injection,SAE Paper 950611,1995
[27]M. A. Ganser,Common Rail Injector with Injection Rate Control,SAE Paper 981927,1998
[28]邹于丰,用 MAX+PLUS II开发 Altera CPLD,电子工程师,2002,28(7), 7~9
[29]宋万杰,罗丰,吴顺君,CPLD 技术及其应用,西安:西安电子科技大学出版社,2001
[30]谭会生,张昌凡,EDA技术及应用,西安:西安电子科技大学出版社,2001
[31]侯伯亨,顾新,VHDL 硬件描述语言与数字逻辑电路设计,西安电子科技大学出版社,1999
[32]王晓峰,可编程逻辑器件及硬件描述语言的EDA方法,长春大学学报,2005,15(4),14～16
[33]Synario Design Automation,VHDL Reference Manual,March 1997
[34]Douglas L.Perry,VHDL: Programming by Example,McGraw-Hill inc,2002
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