大功率阀控液力偶合器设计理论及关键技术研究
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摘要
阀控充液型液力偶合器是采煤工作面大功率刮板输送机最有效软启动装置之一,作为联系工作机和原动机之间的“纽带”,其采用纯水作为工作介质,适应频繁带载起动并具备过载保护和调速等功能,成为800kW(单驱动)以上大功率刮板输送机软启动设备的主导机型。阀控偶合器是复杂的机、电、液(液压、液力)一体化系统,设计加工难度大,目前国内还没有此类产品,相关研究也很少,已成为制约我国大型刮板输送机进一步发展的瓶颈。
泵轮和涡轮形成的工作腔是偶合器的技术核心,功率的增大使得偶合器结构强度和散热问题突出,因此工作腔结构及控制阀组是阀控偶合器的技术关键。本文以解决大采高综放工作面后部刮板输送机(2×1000kW)软启动问题为目标,围绕阀控偶合器的关键技术,理论分析和实验相结合,从工作腔流场分析和优化、液相分布规律、工作轮结构力学特性分析以及控制阀组开发等方面对阀控偶合器展开了研究。相关研究工作主要包括以下几个方面:
根据刮板输送机阻力计算模型和后部刮板输送工作特点,指出后部刮板输送机受落煤量大幅变化等因素影响,具有负载波动大和起动困难等特点;进一步分析了阀控偶合器的基本特性,确定了阀控偶合器与电动机和刮板输送机间参数匹配关系。以“长壁形”特性曲线为目标,在对现有偶合器循环圆特性比较的基础上,选择桃形腔为阀控偶合器的原始腔型,作为进一步研究分析的基础。
在对计算流体动力学(CFD)基本模型分析比较的基础上,确定了偶合器多流动区域耦合的三维流场计算方法。采用可实现k-ε湍流模型模拟了标准桃形腔满充情况下稳态流场,网格划分采用多边形网格,并将力矩预测结果与相似模型的试验值比较,验证了计算模型的正确性。CFD预测表明标准桃形腔过载系数太大,无法满足刮板输送机需求,进一步分析了叶片厚度、叶片形状和挡圈等因素对桃形腔流场和力矩特性的影响,力矩预测表明“高低相间叶片+挡圈”的结构组合具有相对较高的效率,满足限矩性能要求。
运用VOF两相流模型,基于“准瞬态”流场分析,对工作腔部分充液时气-液两相流动进行了研究,仿真得到的液相分布与相关文献中GAMMA射线和平面阵列传感器检测结果基本一致,显示出VOF在液相运动界面追踪方面较强适用性。对不同转差和充液量下的液相分布及流动规律进行了仿真,并进一步比较了不同充液量下的力矩特性,为变充液量调速提供了理论依据。
引入单向流体-结构耦合(FSI)方法,将CFD流场仿真结果和有限元分析(FEA)相结合,对双腔结构中载荷最恶劣部件输入端泵轮不同工况下受力情况进行分析,并基于分析结果对结构进行了改进。FSI分析提高了计算准确度,得到了常规有限元计算中未有的规律:偶合器叶片所受载荷为交变载荷,易致疲劳破坏。对泵轮模态进行了分析,研究结构的静频和不同载荷作用下的动频,较全面掌握了泵轮的动态特性。
按照半开式回路设计了电磁控制阀组,指出低压大流量是阀控偶合器控制阀组的基本特性,且要求具有一定耐阻塞能力。建立了先导式电磁阀串联液阻理论模型,基于该模型得到主阀芯开启必须满足的压力和结构条件。液阻是先导式电磁阀的敏感参数,为此搭建了纯水液压试验台模拟节流孔和先导阀间压力分配关系,对不同直径和长度节流孔压力-流量特性的试验研究表明:对于水介质而言,小孔对长度和工作液粘度不敏感,因此可选择粗短孔、并尽可能选择大通径先导阀以提高抗阻塞能力。主阀口采用平面和锥阀两级节流,通过AMESim仿真软件对弹簧、节流孔等参数对阀的动、静态特性的影响进行了分析,确定了电磁阀组的优化参数组合。
研制出电磁阀组和阀控偶合器样机并进行了相关试验。搭建了简易试验平台,对电磁阀组的开启压力、稳定工作压降、响应性以及循环口的压力波动等进行测试,试验表明所研制的电磁阀组满足低压大流量特性,且具有较快的响应速度;对阀控偶合器进行了台架试验,获得了满充下力矩特性,与仿真值较为一致,所研制阀控偶合器的原始特性曲线基本符合“长壁形”曲线特征。试验结果与和仿真值间的高度吻合,为阀控偶合器的现代设计方法提供了重要理论支撑。
本为最后总结了阀控偶合器的分析设计过程,以腔型、结构力学特性、控制阀组等关键技术为主线,CFD,FSI,AMESim系统仿真等现代分析工具为辅助手段,开发出了阀控偶合器产品,可实现大功率刮板输送机的软启动功能并保障其可靠运行;初步建立了阀控偶合器的现代设计理论,为提升阀控偶合器品质、缩短其开发周期和降低研制成本提供了有效参考。
该论文有图122幅,表16个,参考文献160篇。
As the link between working machine and driving machine, valve-control hydrodynamic coupling, which using pure water as working medium, is one of the most effective soft-start equipments for large power AFC (Armoured Face Conveyor) in the mining face. Valve-control coupling is suitable for the frequency start with heavy load and has the function of overload protection and speed control, so it has been the leading soft-start equipment for AFC installed more than 800kW capacity motor for single drive. As it is a complicated system which integrates mechanism, electronic, hydraulic and hydrodynamic, so there is no valve-control coupling product in domestic now,and the related studies are also rare. It has been a bottle-neck of the development of large AFC.
The working chamber formed by pump wheel and turbine wheel is the core technique of a coupling, and a serial of problems such as structure strength and heat exchange become outstanding with the increasing of power. Aiming at the soft starting of AFC behind supports(2×1000kW) and focusing on the key technologies,research work such as flow field analysis of working chamber, laws of liquid distribution, structural mechanics of working pump and develop of control valve block were done. The main research work of this dissertation includes:
According to the resistance calculation formula and the working mode of AFC behind supports, it was pointed out that the wildly load varying even overload were the main features influenced by the coal drop. Then the parameters matching relationships among coupling, electric motor and AFC were established. In order to get the perfect“long wall characteristic curve”, the peach shaped chamber were chosen as the original chamber to be further analyzed after comparing the existing loop circles.
The 3-D flow field calculation method was established by analyzing the basic CFD models. The full-filled steady flow field of standard peach shaped chamber was simulated using realizable k-εturbulence model and polyhedron meshes. The difference between predicated torque coefficient and the one from literature was very small,so the validity of calculation model was verified according to similarity theory. The simulation result shows that the overload coefficient is too large to satisfy the demand of AFC, then the working chamber was adjusted from thickness and blade shapes, retainer height, and the new chambers were analyzed by CFD again. Predicated torques show that the structure“height low internal blades+retainer”has high efficient and can satisfy the torque limiting demand.
The quasi-transient flow of air-water two phase flow in the optimized charmer was studied utilizing VOF model. The liquid distribution comparisons between simulation and test results from GAMMA tomography method and array sensor method proved that the VOF model was suitable for tracking the moving interface between air and water. The distribution and flow laws were further studied and the torques of different filled rates were predicated, which can be taken as the theoretical reference for speed regulation.
One-way FSI method was introduced and the structure mechanics was analyzed using CFD and FEA softwares. The pump wheel at the driving end of a dual-chamber bears the harshest loading condition, so the strength of which was analyzed using CFD result, and the weak places were strengthened. While improving calculation accuracy of strength,new phenomenon which cannot appear in common FEA was found by FSI analyzing that the blades bear alternating load, so fatigue failure is easier to happen. The static frequency and dynamic frequency at different loads were got by modal analysis based on FSI, and more overall dynamic characteristics of the pump wheel were mastered.
The pilot operated solenoid valve block was designed following the half-opened circuit, and the performance demand of which was low pressure, large flow and owing anti-blocking ability. The serial hydraulic resistances model of the pilot operated valve was built, according to which the pressure and structure conditions were obtained. In order to simulate the relationship between nozzle and piloted valve, the water pressure test platform was built and the characteristics of different nozzles were tested on it. The influences of spring and nozzle on the static and dynamic characteristics were investigated by AMESim software and the optimized parameters of valve block were established.
The opening pressure, pressure at steady flow, response time and pressure varying at the cycle inlet of solenoid valve block were tested on an simple test system. Then the combined experiment of valve block and the coupling were carried on the 2000kW test stand. The torque coefficients of full-filled were obtained which meet well with CFD simulate one and conform to the“long wall characteristic curve”. The good consistency between simulation and testing results provides a very important tool for the modern design of valve-control coupling.
At last, The valve-control coupling was developed taking key technologies such as chamber type, wheel structure and control valve block main line, using CFD,FSI and AMESim ect. aided approach and it can ensure the soft-start of a large power AFC. The modern design theory and method of valve-control coupling is preliminary established which can improve the quality it and reduce the R & D period and cost.
There are 122 figures, 16 tables and 160 references in the dissertation.
泵轮和涡轮形成的工作腔是偶合器的技术核心,功率的增大使得偶合器结构强度和散热问题突出,因此工作腔结构及控制阀组是阀控偶合器的技术关键。本文以解决大采高综放工作面后部刮板输送机(2×1000kW)软启动问题为目标,围绕阀控偶合器的关键技术,理论分析和实验相结合,从工作腔流场分析和优化、液相分布规律、工作轮结构力学特性分析以及控制阀组开发等方面对阀控偶合器展开了研究。相关研究工作主要包括以下几个方面:
根据刮板输送机阻力计算模型和后部刮板输送工作特点,指出后部刮板输送机受落煤量大幅变化等因素影响,具有负载波动大和起动困难等特点;进一步分析了阀控偶合器的基本特性,确定了阀控偶合器与电动机和刮板输送机间参数匹配关系。以“长壁形”特性曲线为目标,在对现有偶合器循环圆特性比较的基础上,选择桃形腔为阀控偶合器的原始腔型,作为进一步研究分析的基础。
在对计算流体动力学(CFD)基本模型分析比较的基础上,确定了偶合器多流动区域耦合的三维流场计算方法。采用可实现k-ε湍流模型模拟了标准桃形腔满充情况下稳态流场,网格划分采用多边形网格,并将力矩预测结果与相似模型的试验值比较,验证了计算模型的正确性。CFD预测表明标准桃形腔过载系数太大,无法满足刮板输送机需求,进一步分析了叶片厚度、叶片形状和挡圈等因素对桃形腔流场和力矩特性的影响,力矩预测表明“高低相间叶片+挡圈”的结构组合具有相对较高的效率,满足限矩性能要求。
运用VOF两相流模型,基于“准瞬态”流场分析,对工作腔部分充液时气-液两相流动进行了研究,仿真得到的液相分布与相关文献中GAMMA射线和平面阵列传感器检测结果基本一致,显示出VOF在液相运动界面追踪方面较强适用性。对不同转差和充液量下的液相分布及流动规律进行了仿真,并进一步比较了不同充液量下的力矩特性,为变充液量调速提供了理论依据。
引入单向流体-结构耦合(FSI)方法,将CFD流场仿真结果和有限元分析(FEA)相结合,对双腔结构中载荷最恶劣部件输入端泵轮不同工况下受力情况进行分析,并基于分析结果对结构进行了改进。FSI分析提高了计算准确度,得到了常规有限元计算中未有的规律:偶合器叶片所受载荷为交变载荷,易致疲劳破坏。对泵轮模态进行了分析,研究结构的静频和不同载荷作用下的动频,较全面掌握了泵轮的动态特性。
按照半开式回路设计了电磁控制阀组,指出低压大流量是阀控偶合器控制阀组的基本特性,且要求具有一定耐阻塞能力。建立了先导式电磁阀串联液阻理论模型,基于该模型得到主阀芯开启必须满足的压力和结构条件。液阻是先导式电磁阀的敏感参数,为此搭建了纯水液压试验台模拟节流孔和先导阀间压力分配关系,对不同直径和长度节流孔压力-流量特性的试验研究表明:对于水介质而言,小孔对长度和工作液粘度不敏感,因此可选择粗短孔、并尽可能选择大通径先导阀以提高抗阻塞能力。主阀口采用平面和锥阀两级节流,通过AMESim仿真软件对弹簧、节流孔等参数对阀的动、静态特性的影响进行了分析,确定了电磁阀组的优化参数组合。
研制出电磁阀组和阀控偶合器样机并进行了相关试验。搭建了简易试验平台,对电磁阀组的开启压力、稳定工作压降、响应性以及循环口的压力波动等进行测试,试验表明所研制的电磁阀组满足低压大流量特性,且具有较快的响应速度;对阀控偶合器进行了台架试验,获得了满充下力矩特性,与仿真值较为一致,所研制阀控偶合器的原始特性曲线基本符合“长壁形”曲线特征。试验结果与和仿真值间的高度吻合,为阀控偶合器的现代设计方法提供了重要理论支撑。
本为最后总结了阀控偶合器的分析设计过程,以腔型、结构力学特性、控制阀组等关键技术为主线,CFD,FSI,AMESim系统仿真等现代分析工具为辅助手段,开发出了阀控偶合器产品,可实现大功率刮板输送机的软启动功能并保障其可靠运行;初步建立了阀控偶合器的现代设计理论,为提升阀控偶合器品质、缩短其开发周期和降低研制成本提供了有效参考。
该论文有图122幅,表16个,参考文献160篇。
As the link between working machine and driving machine, valve-control hydrodynamic coupling, which using pure water as working medium, is one of the most effective soft-start equipments for large power AFC (Armoured Face Conveyor) in the mining face. Valve-control coupling is suitable for the frequency start with heavy load and has the function of overload protection and speed control, so it has been the leading soft-start equipment for AFC installed more than 800kW capacity motor for single drive. As it is a complicated system which integrates mechanism, electronic, hydraulic and hydrodynamic, so there is no valve-control coupling product in domestic now,and the related studies are also rare. It has been a bottle-neck of the development of large AFC.
The working chamber formed by pump wheel and turbine wheel is the core technique of a coupling, and a serial of problems such as structure strength and heat exchange become outstanding with the increasing of power. Aiming at the soft starting of AFC behind supports(2×1000kW) and focusing on the key technologies,research work such as flow field analysis of working chamber, laws of liquid distribution, structural mechanics of working pump and develop of control valve block were done. The main research work of this dissertation includes:
According to the resistance calculation formula and the working mode of AFC behind supports, it was pointed out that the wildly load varying even overload were the main features influenced by the coal drop. Then the parameters matching relationships among coupling, electric motor and AFC were established. In order to get the perfect“long wall characteristic curve”, the peach shaped chamber were chosen as the original chamber to be further analyzed after comparing the existing loop circles.
The 3-D flow field calculation method was established by analyzing the basic CFD models. The full-filled steady flow field of standard peach shaped chamber was simulated using realizable k-εturbulence model and polyhedron meshes. The difference between predicated torque coefficient and the one from literature was very small,so the validity of calculation model was verified according to similarity theory. The simulation result shows that the overload coefficient is too large to satisfy the demand of AFC, then the working chamber was adjusted from thickness and blade shapes, retainer height, and the new chambers were analyzed by CFD again. Predicated torques show that the structure“height low internal blades+retainer”has high efficient and can satisfy the torque limiting demand.
The quasi-transient flow of air-water two phase flow in the optimized charmer was studied utilizing VOF model. The liquid distribution comparisons between simulation and test results from GAMMA tomography method and array sensor method proved that the VOF model was suitable for tracking the moving interface between air and water. The distribution and flow laws were further studied and the torques of different filled rates were predicated, which can be taken as the theoretical reference for speed regulation.
One-way FSI method was introduced and the structure mechanics was analyzed using CFD and FEA softwares. The pump wheel at the driving end of a dual-chamber bears the harshest loading condition, so the strength of which was analyzed using CFD result, and the weak places were strengthened. While improving calculation accuracy of strength,new phenomenon which cannot appear in common FEA was found by FSI analyzing that the blades bear alternating load, so fatigue failure is easier to happen. The static frequency and dynamic frequency at different loads were got by modal analysis based on FSI, and more overall dynamic characteristics of the pump wheel were mastered.
The pilot operated solenoid valve block was designed following the half-opened circuit, and the performance demand of which was low pressure, large flow and owing anti-blocking ability. The serial hydraulic resistances model of the pilot operated valve was built, according to which the pressure and structure conditions were obtained. In order to simulate the relationship between nozzle and piloted valve, the water pressure test platform was built and the characteristics of different nozzles were tested on it. The influences of spring and nozzle on the static and dynamic characteristics were investigated by AMESim software and the optimized parameters of valve block were established.
The opening pressure, pressure at steady flow, response time and pressure varying at the cycle inlet of solenoid valve block were tested on an simple test system. Then the combined experiment of valve block and the coupling were carried on the 2000kW test stand. The torque coefficients of full-filled were obtained which meet well with CFD simulate one and conform to the“long wall characteristic curve”. The good consistency between simulation and testing results provides a very important tool for the modern design of valve-control coupling.
At last, The valve-control coupling was developed taking key technologies such as chamber type, wheel structure and control valve block main line, using CFD,FSI and AMESim ect. aided approach and it can ensure the soft-start of a large power AFC. The modern design theory and method of valve-control coupling is preliminary established which can improve the quality it and reduce the R & D period and cost.
There are 122 figures, 16 tables and 160 references in the dissertation.
引文
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