工程机械散热模块传热性能研究
摘要
改革开放以来，我国经济飞速发展，大批基础建设随即展开。为了适应社会发展与技术进步，作为建设工程的主要施工设备—工程机械，也面临着一系列新的挑战，高效、节能、环保重要性逐步凸显，国家对节能减排的要求也日趋严格。当前,国家正努力向工程机械国III排放标准推进，这些都对产品设计提出了更为严格的要求。
作为工程机械的代表机型—双钢轮振动压路机，受施工条件影响，工作环境温度较高，同时，动力舱内存在多个发热部件，如果系统热量不能及时散去，将会出现整机性能不稳定等现象。工程机械采用“冷却风扇+散热器组”作为散热模块，利用冷却风扇产生的压差，使空气流经散热器，通过翅片与热流体进行热交换。散热模块性能主要由散热量与功耗表述，散热量与散热器性能相关，功耗与风扇性能相关，散热模块传热性能越好，同功耗下散热量越大，节能效果也就越加明显，因此，对散热模块传热性能研究应分别从冷却风扇、散热器、两者匹配等方面入手。
论文结合“十二五”国家科技支撑计划课题“面向节能与安全的集成智能化工程机械装备研发”（课题编号：2013BAF07B04），利用CFD技术分别对冷却风扇、散热器、动力舱流场进行数值仿真与性能改进。
（1）基于改善空气流动状态的冷却风扇研究
以国内工程机械较为常见的某款冷却风扇作为分析对象，利用CFD数值仿真技术，在虚拟风道内对其性能进行模拟，对比试验数据，验证仿真的正确性。结合孤立翼型法对风扇进行设计，结果表明：新风扇进出口处空气流动状态得到改善，有利于提高散热器性能。
（2）散热器和风扇间的交互影响分析
对导风罩内具有散热器阻力特征的风扇性能进行分析，以风扇所能提供的空气流量作为性能评价标准，分别对散热器与风扇距离、散热器厚度、多个散热器组合特征下的风扇性能进行分析，结果表明：随着散热器与风扇距离增加，流量呈先上升再下降的变化趋势；增大散热器厚度，会削弱风扇转速对流量的作用效果；当多个散热器组合后，若中间散热器高度为导风罩高度一半时，受轴流风扇中心低压区偏移影响，空气流量迅速下降。
（3）基于翼型热管特征的散热器传热性能强化
结合国内某型双钢轮振动压路机，对其所使用的管片式散热器进行了CFD单元体数值仿真，以强化传热、降低流动阻力为目标，采用NACA0018翼型作为热管外形特征，引入JF综合评价因子对翅片性能进行评价，结果表明：与原翅片相比，当空气流速为12m/s时，新翅片JF综合评价因子高出约15.97%。
（4）多工况下动力舱流场分析及试验验证
利用CFD技术，对国内某型双钢轮振动压路机动力舱进行多工况流场分析，并对样机进行现场试验，结果表明：仿真值误差较小；受热空气回流影响，后退工况中的散热器性能好于前进工况，速度越高，差异越大；受风扇偏置影响，中冷器降温幅度较大，液压油散热器较小。
（5）建立随环境温度变化的风扇转速模型
以效能—传热单元数法中散热量计算公式为基础，分别针对散热器效能、流体物理性能参数、空气体积流量、冷热流体入口温度等方面，得到以风扇转速与环境温度为自变量的散热量计算模型。在保持散热量不变的前提下，建立各工况下随环境温度变化的风扇转速模型，结果表明：在环境温度-30—45℃区间内，工况2的风扇转速、轴功率整体较高，工况4较低；当环境温度较低时，各工况中风扇轴功率差异较小，当环境温度达到45℃时，差异趋于明显；CFD仿真与一维理论计算相结合是有效的研究途径。
（6）以降低流通阻力、增大进风量为目标的系统改进
以降低流通阻力、增大进风量为目标，分别从风扇与散热器位置、动力舱外形特征、散热器阻力特征、冷却风扇特征等方面入手，对国内某型双钢轮振动压路机散热模块进行研究，结果表明：在一定范围内拉大风扇与散热器间距，可以提升散热器性能；改进动力舱几何特征，避免热空气回流，可以提升散热器性能；改进出口方案，确定侧出口方案中的散热器性能较好；改进冷却液散热器阻力特征，散热器性能提升；改进风扇特征，散热器性能有所提升；将单冷却风扇改进为双冷却风扇，转速需与工况相配合，方能提高散热效果。
China’s economy has leapt forward and a large number of infrastructure has startedsince we followed the policy of reform and opening. In order to adapt to socialdevelopment and technical progress, construction machinery is also facing a series of newchallenges as the main construction equipment. Importance of efficiency, energyconservation and environmental protection gradually becomes prominent and thegovernment is more and more strict in energy conservation and emission reduction. Ourcountry is trying to formulate and implement National Ⅲ emission standard forconstruction machinery at present, which means there would be more stringentrequirements for product design.
Double-drum vibratory roller is widely used in the construction of airports and roadsas a representative of construction machinery. There are many heating parts inside theengine cabin of double-drum vibratory roller, and ambient temperature is high duringworking. If the heat generated by system could not be removed in time, it would makeworking performance unstable. Construction machinery uses “cooling fan&radiatorgroup” as the heat-dissipation module, which uses the differential pressure generated bythe cooling fan to make cold air flow through the radiator for heat exchange between coldair and thermal fluid. The performance of the heat-dissipation module includes heattransfer capacity and power consumption, the former is related to the performance ofradiator and the latter is related to the performance of cooling fan. If the heat-dissipationmodule has better performance, there would be more heat transferred with same powerconsumption, and the energy conservation effect would be more obvious. Therefore, doingresearch on the performance of the heat-dissipation module should start respectively fromcooling fan, radiator and their matching etc.
Based on the project in the National Science&Technology Pillar Program during theTwelfth Five-year Plan Period,"Intelligent Construction Machinery Design for EnergyConservation and Safety"(NO.2013BAF07B04), aiming to improve performance of theheat-dissipation module, CFD numerical simulation was used in this paper to makeimprovement in performance of cooling fan, radiator and flow field of engine cabin.
(1) Research on cooling fan for improving inlet air status of radiator
Based on a cooling fan that is widely used in domestic construction machinery, itsperformance is simulated with CFD numerical method in a virtual wind tunnel. Thesimulation result was compared with the experimental data to verify the correctness ofmodel. The cooling fan is redesigned with single aerofoil method. The results show that theinlet and outlet air status of new fan is improved, which would benefit enhancing radiatorperformance.
(2) Analysis of interaction between cooling fan and radiator
The performance of cooling fan in the shroud with radiator resistance was analyzed,actual air flow generated by the fan was taken as the evaluation criterion, the performanceof cooling fan was analyzed under different conditions, which include distance betweenradiator and cooling fan, thickness of radiator and combination of radiators. The resultsshow that the air flow increases at first and decreases then as distance increases. Impact ofrotation speed of fan on the air flow decreases as the thickness increases. With the lowpressure zone near center of rotation offset, air flow decreases rapidly when the height ofradiator is equal to half of shroud height.
(3) Heat transfer performance enhancement of radiator based on airfoil tube
CFD was used to simulate performance of element unit of tube-fin radiator that isused by a domestic double-drum vibratory roller. In order to enhance heat transferperformance and reduce flow resistance, NACA0018airfoil was taken as tube geometricalprofile. JF comprehensive evaluation factor was taken to assess fin performance. Theresults show that JF comprehensive evaluation factor of new fin increases about15.97%compared with the original fin.
(4) Analysis and experimental verification of airflow field of engine cabin undermulti-working condition
CFD method was used to analyze the airflow field of engine cabin of the domesticdouble-drum vibratory roller under multi-working condition, and the prototype machinewas tested. The results show that the error between the simulation results and experimentdata is small. With the influence of hot-air backflow, The radiator performance underbackward working condition is better than that under forward working condition, vehiclespeed is related to the discrepancy. With the influence of cooling fan excursion, the outlettemperature of thermal fluid of inter-cooler decreases and outlet temperature of thermalfluid of oil radiator changes slightly.
(5) Building a fan rotation speed model that changes with ambient temperature
Considering ε, physical parameters, volume flow rate of air and inlet temperature ofcold and thermal fluid, the calculation model that takes cooling fan rotation speed andambient temperature as independent variables was built based on the formula for heatdissipating capacity in ε—NTU. Based on the domestic double-drum vibratory roller, a fanrotation speed model that changes with the ambient temperature was built on the premiseof keeping heat dissipating capacity constant. The results show that within the range from-30℃to45℃, rotation speed and shaft power are higher under forward condition withhigh vehicle speed and they are lower under backward working condition with high vehiclespeed. When ambient temperature is low, there is little discrepancy between shaft powerunder each condition. When the ambient temperature is45℃, the discrepancy becomesobvious. It is an effective research way to combine CFD simulation and one-dimensionaltheoretical calculation.
(6) System improvement for decreasing flow resistance and increasing air flow
In order to decrease flow resistance and increase air flow, the improvement ofperformance of heat-dissipation module for the domestic double-drum vibratory roller wasmade in several ways, such as adjusting distance between cooling fan and radiator,changing shape characteristics of the engine cabin, reducing resistance characteristics ofradiator and enhancing performance characteristics of cooling fan. The results show thatradiator performance can be enhanced by the ways mentioned above.
作为工程机械的代表机型—双钢轮振动压路机，受施工条件影响，工作环境温度较高，同时，动力舱内存在多个发热部件，如果系统热量不能及时散去，将会出现整机性能不稳定等现象。工程机械采用“冷却风扇+散热器组”作为散热模块，利用冷却风扇产生的压差，使空气流经散热器，通过翅片与热流体进行热交换。散热模块性能主要由散热量与功耗表述，散热量与散热器性能相关，功耗与风扇性能相关，散热模块传热性能越好，同功耗下散热量越大，节能效果也就越加明显，因此，对散热模块传热性能研究应分别从冷却风扇、散热器、两者匹配等方面入手。
论文结合“十二五”国家科技支撑计划课题“面向节能与安全的集成智能化工程机械装备研发”（课题编号：2013BAF07B04），利用CFD技术分别对冷却风扇、散热器、动力舱流场进行数值仿真与性能改进。
（1）基于改善空气流动状态的冷却风扇研究
以国内工程机械较为常见的某款冷却风扇作为分析对象，利用CFD数值仿真技术，在虚拟风道内对其性能进行模拟，对比试验数据，验证仿真的正确性。结合孤立翼型法对风扇进行设计，结果表明：新风扇进出口处空气流动状态得到改善，有利于提高散热器性能。
（2）散热器和风扇间的交互影响分析
对导风罩内具有散热器阻力特征的风扇性能进行分析，以风扇所能提供的空气流量作为性能评价标准，分别对散热器与风扇距离、散热器厚度、多个散热器组合特征下的风扇性能进行分析，结果表明：随着散热器与风扇距离增加，流量呈先上升再下降的变化趋势；增大散热器厚度，会削弱风扇转速对流量的作用效果；当多个散热器组合后，若中间散热器高度为导风罩高度一半时，受轴流风扇中心低压区偏移影响，空气流量迅速下降。
（3）基于翼型热管特征的散热器传热性能强化
结合国内某型双钢轮振动压路机，对其所使用的管片式散热器进行了CFD单元体数值仿真，以强化传热、降低流动阻力为目标，采用NACA0018翼型作为热管外形特征，引入JF综合评价因子对翅片性能进行评价，结果表明：与原翅片相比，当空气流速为12m/s时，新翅片JF综合评价因子高出约15.97%。
（4）多工况下动力舱流场分析及试验验证
利用CFD技术，对国内某型双钢轮振动压路机动力舱进行多工况流场分析，并对样机进行现场试验，结果表明：仿真值误差较小；受热空气回流影响，后退工况中的散热器性能好于前进工况，速度越高，差异越大；受风扇偏置影响，中冷器降温幅度较大，液压油散热器较小。
（5）建立随环境温度变化的风扇转速模型
以效能—传热单元数法中散热量计算公式为基础，分别针对散热器效能、流体物理性能参数、空气体积流量、冷热流体入口温度等方面，得到以风扇转速与环境温度为自变量的散热量计算模型。在保持散热量不变的前提下，建立各工况下随环境温度变化的风扇转速模型，结果表明：在环境温度-30—45℃区间内，工况2的风扇转速、轴功率整体较高，工况4较低；当环境温度较低时，各工况中风扇轴功率差异较小，当环境温度达到45℃时，差异趋于明显；CFD仿真与一维理论计算相结合是有效的研究途径。
（6）以降低流通阻力、增大进风量为目标的系统改进
以降低流通阻力、增大进风量为目标，分别从风扇与散热器位置、动力舱外形特征、散热器阻力特征、冷却风扇特征等方面入手，对国内某型双钢轮振动压路机散热模块进行研究，结果表明：在一定范围内拉大风扇与散热器间距，可以提升散热器性能；改进动力舱几何特征，避免热空气回流，可以提升散热器性能；改进出口方案，确定侧出口方案中的散热器性能较好；改进冷却液散热器阻力特征，散热器性能提升；改进风扇特征，散热器性能有所提升；将单冷却风扇改进为双冷却风扇，转速需与工况相配合，方能提高散热效果。
China’s economy has leapt forward and a large number of infrastructure has startedsince we followed the policy of reform and opening. In order to adapt to socialdevelopment and technical progress, construction machinery is also facing a series of newchallenges as the main construction equipment. Importance of efficiency, energyconservation and environmental protection gradually becomes prominent and thegovernment is more and more strict in energy conservation and emission reduction. Ourcountry is trying to formulate and implement National Ⅲ emission standard forconstruction machinery at present, which means there would be more stringentrequirements for product design.
Double-drum vibratory roller is widely used in the construction of airports and roadsas a representative of construction machinery. There are many heating parts inside theengine cabin of double-drum vibratory roller, and ambient temperature is high duringworking. If the heat generated by system could not be removed in time, it would makeworking performance unstable. Construction machinery uses “cooling fan&radiatorgroup” as the heat-dissipation module, which uses the differential pressure generated bythe cooling fan to make cold air flow through the radiator for heat exchange between coldair and thermal fluid. The performance of the heat-dissipation module includes heattransfer capacity and power consumption, the former is related to the performance ofradiator and the latter is related to the performance of cooling fan. If the heat-dissipationmodule has better performance, there would be more heat transferred with same powerconsumption, and the energy conservation effect would be more obvious. Therefore, doingresearch on the performance of the heat-dissipation module should start respectively fromcooling fan, radiator and their matching etc.
Based on the project in the National Science&Technology Pillar Program during theTwelfth Five-year Plan Period,"Intelligent Construction Machinery Design for EnergyConservation and Safety"(NO.2013BAF07B04), aiming to improve performance of theheat-dissipation module, CFD numerical simulation was used in this paper to makeimprovement in performance of cooling fan, radiator and flow field of engine cabin.
(1) Research on cooling fan for improving inlet air status of radiator
Based on a cooling fan that is widely used in domestic construction machinery, itsperformance is simulated with CFD numerical method in a virtual wind tunnel. Thesimulation result was compared with the experimental data to verify the correctness ofmodel. The cooling fan is redesigned with single aerofoil method. The results show that theinlet and outlet air status of new fan is improved, which would benefit enhancing radiatorperformance.
(2) Analysis of interaction between cooling fan and radiator
The performance of cooling fan in the shroud with radiator resistance was analyzed,actual air flow generated by the fan was taken as the evaluation criterion, the performanceof cooling fan was analyzed under different conditions, which include distance betweenradiator and cooling fan, thickness of radiator and combination of radiators. The resultsshow that the air flow increases at first and decreases then as distance increases. Impact ofrotation speed of fan on the air flow decreases as the thickness increases. With the lowpressure zone near center of rotation offset, air flow decreases rapidly when the height ofradiator is equal to half of shroud height.
(3) Heat transfer performance enhancement of radiator based on airfoil tube
CFD was used to simulate performance of element unit of tube-fin radiator that isused by a domestic double-drum vibratory roller. In order to enhance heat transferperformance and reduce flow resistance, NACA0018airfoil was taken as tube geometricalprofile. JF comprehensive evaluation factor was taken to assess fin performance. Theresults show that JF comprehensive evaluation factor of new fin increases about15.97%compared with the original fin.
(4) Analysis and experimental verification of airflow field of engine cabin undermulti-working condition
CFD method was used to analyze the airflow field of engine cabin of the domesticdouble-drum vibratory roller under multi-working condition, and the prototype machinewas tested. The results show that the error between the simulation results and experimentdata is small. With the influence of hot-air backflow, The radiator performance underbackward working condition is better than that under forward working condition, vehiclespeed is related to the discrepancy. With the influence of cooling fan excursion, the outlettemperature of thermal fluid of inter-cooler decreases and outlet temperature of thermalfluid of oil radiator changes slightly.
(5) Building a fan rotation speed model that changes with ambient temperature
Considering ε, physical parameters, volume flow rate of air and inlet temperature ofcold and thermal fluid, the calculation model that takes cooling fan rotation speed andambient temperature as independent variables was built based on the formula for heatdissipating capacity in ε—NTU. Based on the domestic double-drum vibratory roller, a fanrotation speed model that changes with the ambient temperature was built on the premiseof keeping heat dissipating capacity constant. The results show that within the range from-30℃to45℃, rotation speed and shaft power are higher under forward condition withhigh vehicle speed and they are lower under backward working condition with high vehiclespeed. When ambient temperature is low, there is little discrepancy between shaft powerunder each condition. When the ambient temperature is45℃, the discrepancy becomesobvious. It is an effective research way to combine CFD simulation and one-dimensionaltheoretical calculation.
(6) System improvement for decreasing flow resistance and increasing air flow
In order to decrease flow resistance and increase air flow, the improvement ofperformance of heat-dissipation module for the domestic double-drum vibratory roller wasmade in several ways, such as adjusting distance between cooling fan and radiator,changing shape characteristics of the engine cabin, reducing resistance characteristics ofradiator and enhancing performance characteristics of cooling fan. The results show thatradiator performance can be enhanced by the ways mentioned above.
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