航天机械泵驱动两相流冷却环路循环特性的研究
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摘要
机械泵驱动两相流冷却系统(MPCL)是一种新型的主动式航天热控冷却技术,该技术与毛细泵热管或者环路热管有很多相似的地方,均是采用两相流将电力电子设备或者发热元件所产生的废热排放出去。本论文首先对系统设计和地面实验台的搭建进行介绍,本研究以二氧化碳为循环工质,以机械泵为驱动力,最大散热量可以达到1000瓦。
本文首先对系统循环工质的选择进行理论分析和计算机模拟。在理论分析中提出了MPCL系统工质选择的基本依据。在模拟计算中,采用Sinda/Fluint软件建立系统的计算机模型,模拟氨、丙烯和二氧化碳三种常用工质的运行特性,结果表明:在目前散热量小于1000W的航空主要应用背景下,氨的循环工质量较少,稳定性和机械泵流量的控制方面效果较差;丙烯由于沿蒸发段的温度梯度大,因此等温性差;二氧化碳在散热量小于1000瓦的条件下具有较大的优势,主要因为循环阻力较小,泵的能耗和压头较小。此外其热物性品质较高,液/气密度比较小,使得蒸发段的温度梯度大大减小,更适合于散热区域分散或等温化程度要求较高的设备使用。
接下来的实验研究主要包括系统的启动、工作点的控制以及稳态和瞬态的运行特性分析。其中启动过程是MPCL两相系统运行的基础,实验部分首先对启动过程的动态响应进行分析。MPCL系统的启动主要分为压力稳定阶段、机械泵启动和加载热负荷三个基本过程。实验结果表明,在机械泵启动过程中,系统的蒸发段将出现过热现象,在过热的亚稳态向两相态闪蒸的同时对系统产生力脉冲(系统绝对压力激增)和阻力脉冲(泵前后的差压激增)。其中过热度的大小与设定温度、流量和热流密度等条件有关,启动温度越高,过热度越小;热流密度越高,过热时间越短,阻力脉冲越大;流量越大过热时间变长,阻力脉冲越高。为了减小阻力脉冲,实验还发现采用高热流密度预热器的方法可以有效的减小阻力脉冲。
在随后关于MPCL系统工作点的温度控制方面研究发现采用半导体制冷片和主回路支路协同工作的方案是目前该类系统的最优控温方法。实验结果表明,该方法使得储液器的控温精度达到±0.1℃,在制冷片10瓦的输入功率下降温速度提高到0.36℃/min,较常用控温方案既保证储液器的控温精度和降温速度又提高了半导体制冷片的工作效率。
在系统的运行特性研究中,实验重点是研究稳态运行和瞬态运行的工质散热及循环规律,寻找决定系统稳定性的影响因素。研究内容包括边界条件恒定与边界条件周期性变化实验、变流量或热负荷实验、系统支路热负荷不平衡性实验等。结果表明,系统具有较高的可靠性,当外界扰动发生时,系统通过自身调整很快进入稳定状态。其中,储液器的设计和系统工质的充灌量在很大程度上决定了系统的稳定程度,当运行参数或者边界条件发生改变时,储液器和主回路之间将发生液体的交换,系统的主要压力与温度参数将发生改变,当储液器内的汽液相界面稳定到新的位置,系统进入稳定状态。
综上所述,在机械泵和储液器合理设计的前提下,只要保证泵的入口为液态、蒸发段的出口干度小于0.5、冷凝器有足够的放热能力而温度小于循环工质的三相点,系统就能够稳定可靠的运行。该类系统具有等温性高、传输距离远、可控性强、多支路运行等特点,并且同毛细泵相比较在启动、工作点控制和处理瞬态扰动及热负荷不平衡问题方面有较为明显的优势。以二氧化碳为循环工质大大降低了蒸发段的温度梯度,减小了系统的设计尺寸,提高了运行的稳定性和可靠性,在保证散热的同时又使得系统的结构和能耗得到进一步优化。总之,机械泵两相冷却系统将成为未来空间主动式热控系统的发展趋势。
Two-phase mechanically pumped cooling loop (MPCL) is a promising thermal control system which is just like a loop heat pipe or capillary pumped loops to realize heat extraction from energetic electrical or electronic equipments efficiently. In this paper, a brief review of system design and work principle is presented and a proposed experimental system was described. The testing system was able to accomplish the thermal management of up to 1000 W by using CO2 as the working fluid. Then ,a serial tests were carried out ot investigate the MPCL systematically. It mainly includes the system startup, working set point controlling and running characteristic tests.
The startup of a two-phase cooling system is a complex transient phenomenon, especially for the feasibility application of an MPCL. The experiments on the startup processes under variety of conditions were carried out. Special attention has been paid to the startups of the system in different evaporative temperature, various mass flow or heating load and some abnormal startup prehistory. The transient flow exchange between the main loop and accumulator was observed and discussed according to 3 different startup step which have been identified as pre-condition, pump startup and heat load startup. During the startup processes, the system presents a good stability and each part of the system performs a reasonable temperature wave, except some superheat phenomena in the evaporator. The superheat is mainly related to startup conditions such as evaporative temperature, mass flow, heat load or initial liquid distributions in a loop. In general, the lower the evaporative temperature is, the higher superheat occurs. A lower heat load or a larger mass flow may lead to a huge pressure impact and a long time superheat. In the following , experiments have been carried out on how to cool the accumulator and realize a stable set point temperature. The paper points out a novel method to combine thermoelectric coolers (TEC) with the branch of a main loop. The novel method is realized by the use of the cold plate of TEC to control the set point while the hot plate is cooled down by the subcooled liquid in branch loop. Tests result have proved the feasibility and stability of the new design which not only uprates the accuracy from±0.4℃to±0.1℃and increases the cooling speed to 0.36℃/min under 10W TEC input power ,but also finds a novel way to improve the efficiency of a TEC by using subcooled fluid to dissipate heat from the hot plate.
During the running characteristic tests, the stable and transient experiments have been investigated. Tests mainly included sinusoidal temperature variations of boundary condition, heat load or mass flow fluctuation , unbalanced heat load on the evaporators and so on. According to the experimental findings, The transient liquid distribution between the main loop and accumulator was analyzed to find the factors for system stability. From the experiments, it is found that the system presents a good pressure performance of the loop and is able to handle large temperature wave and heat impacts perfectly.
In conclusion, important performance characteristics demonstrated by this paper included: 1) Operation of an active two-phase thermal system driven by mechanical pump with dual-evaporator; 2) sussessful startup processes in different situations; 3) Effectiveness of TECs and a rapid dropping speed in controlling the MPCL operating temperature and a higher controlling accuracy of the evaporators; 4)Robustness and reliability running of the system under various test conditions if temperature at the pump's inlet has enough sub-cooling to keep a liquid state and vapor quality is less than 0.5 at the evaporator outlet.
本文首先对系统循环工质的选择进行理论分析和计算机模拟。在理论分析中提出了MPCL系统工质选择的基本依据。在模拟计算中,采用Sinda/Fluint软件建立系统的计算机模型,模拟氨、丙烯和二氧化碳三种常用工质的运行特性,结果表明:在目前散热量小于1000W的航空主要应用背景下,氨的循环工质量较少,稳定性和机械泵流量的控制方面效果较差;丙烯由于沿蒸发段的温度梯度大,因此等温性差;二氧化碳在散热量小于1000瓦的条件下具有较大的优势,主要因为循环阻力较小,泵的能耗和压头较小。此外其热物性品质较高,液/气密度比较小,使得蒸发段的温度梯度大大减小,更适合于散热区域分散或等温化程度要求较高的设备使用。
接下来的实验研究主要包括系统的启动、工作点的控制以及稳态和瞬态的运行特性分析。其中启动过程是MPCL两相系统运行的基础,实验部分首先对启动过程的动态响应进行分析。MPCL系统的启动主要分为压力稳定阶段、机械泵启动和加载热负荷三个基本过程。实验结果表明,在机械泵启动过程中,系统的蒸发段将出现过热现象,在过热的亚稳态向两相态闪蒸的同时对系统产生力脉冲(系统绝对压力激增)和阻力脉冲(泵前后的差压激增)。其中过热度的大小与设定温度、流量和热流密度等条件有关,启动温度越高,过热度越小;热流密度越高,过热时间越短,阻力脉冲越大;流量越大过热时间变长,阻力脉冲越高。为了减小阻力脉冲,实验还发现采用高热流密度预热器的方法可以有效的减小阻力脉冲。
在随后关于MPCL系统工作点的温度控制方面研究发现采用半导体制冷片和主回路支路协同工作的方案是目前该类系统的最优控温方法。实验结果表明,该方法使得储液器的控温精度达到±0.1℃,在制冷片10瓦的输入功率下降温速度提高到0.36℃/min,较常用控温方案既保证储液器的控温精度和降温速度又提高了半导体制冷片的工作效率。
在系统的运行特性研究中,实验重点是研究稳态运行和瞬态运行的工质散热及循环规律,寻找决定系统稳定性的影响因素。研究内容包括边界条件恒定与边界条件周期性变化实验、变流量或热负荷实验、系统支路热负荷不平衡性实验等。结果表明,系统具有较高的可靠性,当外界扰动发生时,系统通过自身调整很快进入稳定状态。其中,储液器的设计和系统工质的充灌量在很大程度上决定了系统的稳定程度,当运行参数或者边界条件发生改变时,储液器和主回路之间将发生液体的交换,系统的主要压力与温度参数将发生改变,当储液器内的汽液相界面稳定到新的位置,系统进入稳定状态。
综上所述,在机械泵和储液器合理设计的前提下,只要保证泵的入口为液态、蒸发段的出口干度小于0.5、冷凝器有足够的放热能力而温度小于循环工质的三相点,系统就能够稳定可靠的运行。该类系统具有等温性高、传输距离远、可控性强、多支路运行等特点,并且同毛细泵相比较在启动、工作点控制和处理瞬态扰动及热负荷不平衡问题方面有较为明显的优势。以二氧化碳为循环工质大大降低了蒸发段的温度梯度,减小了系统的设计尺寸,提高了运行的稳定性和可靠性,在保证散热的同时又使得系统的结构和能耗得到进一步优化。总之,机械泵两相冷却系统将成为未来空间主动式热控系统的发展趋势。
Two-phase mechanically pumped cooling loop (MPCL) is a promising thermal control system which is just like a loop heat pipe or capillary pumped loops to realize heat extraction from energetic electrical or electronic equipments efficiently. In this paper, a brief review of system design and work principle is presented and a proposed experimental system was described. The testing system was able to accomplish the thermal management of up to 1000 W by using CO2 as the working fluid. Then ,a serial tests were carried out ot investigate the MPCL systematically. It mainly includes the system startup, working set point controlling and running characteristic tests.
The startup of a two-phase cooling system is a complex transient phenomenon, especially for the feasibility application of an MPCL. The experiments on the startup processes under variety of conditions were carried out. Special attention has been paid to the startups of the system in different evaporative temperature, various mass flow or heating load and some abnormal startup prehistory. The transient flow exchange between the main loop and accumulator was observed and discussed according to 3 different startup step which have been identified as pre-condition, pump startup and heat load startup. During the startup processes, the system presents a good stability and each part of the system performs a reasonable temperature wave, except some superheat phenomena in the evaporator. The superheat is mainly related to startup conditions such as evaporative temperature, mass flow, heat load or initial liquid distributions in a loop. In general, the lower the evaporative temperature is, the higher superheat occurs. A lower heat load or a larger mass flow may lead to a huge pressure impact and a long time superheat. In the following , experiments have been carried out on how to cool the accumulator and realize a stable set point temperature. The paper points out a novel method to combine thermoelectric coolers (TEC) with the branch of a main loop. The novel method is realized by the use of the cold plate of TEC to control the set point while the hot plate is cooled down by the subcooled liquid in branch loop. Tests result have proved the feasibility and stability of the new design which not only uprates the accuracy from±0.4℃to±0.1℃and increases the cooling speed to 0.36℃/min under 10W TEC input power ,but also finds a novel way to improve the efficiency of a TEC by using subcooled fluid to dissipate heat from the hot plate.
During the running characteristic tests, the stable and transient experiments have been investigated. Tests mainly included sinusoidal temperature variations of boundary condition, heat load or mass flow fluctuation , unbalanced heat load on the evaporators and so on. According to the experimental findings, The transient liquid distribution between the main loop and accumulator was analyzed to find the factors for system stability. From the experiments, it is found that the system presents a good pressure performance of the loop and is able to handle large temperature wave and heat impacts perfectly.
In conclusion, important performance characteristics demonstrated by this paper included: 1) Operation of an active two-phase thermal system driven by mechanical pump with dual-evaporator; 2) sussessful startup processes in different situations; 3) Effectiveness of TECs and a rapid dropping speed in controlling the MPCL operating temperature and a higher controlling accuracy of the evaporators; 4)Robustness and reliability running of the system under various test conditions if temperature at the pump's inlet has enough sub-cooling to keep a liquid state and vapor quality is less than 0.5 at the evaporator outlet.
引文
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