高压共轨燃油系统喷油诱导的压力波特征试验研究

周定武1，邓志革1，李治国1，彭广宇2，张成国3

1.湖南汽车工程职业学院，湖南株洲412001；2.湖南交通职业技术学院，湖南长沙410132；

3.潍柴动力股份有限公司，山东潍坊261061

摘要：在油泵试验台架上开展喷油为主动量诱导的高压压力波动特征的试验研究，分析靠近嘴端的高压油管内以及高压油轨的轨压传感器处压力波动规律。研究表明：柴油机高压共轨燃油喷射系统中，喷油引起的压力波不受油泵引起的压力波影响；喷油引起的嘴端压力波动比轨端要显著；嘴端压力波呈现明显的波动衰减，其压力波的频率与燃油属性有关，波动的最大振幅主要与喷射压力、喷孔大小有关；高压油轨处的压力波动特征不明显，单次喷油引起的轨压下降总量不仅与喷射压力、喷孔大小有关，还与喷射脉宽有关。

关键词：柴油机；高压共轨；喷油特征；压力波动

Experimental research on the pressure wave characteristics induced

by injection in high pressure common rail fuel system

ZHOU Dingwu1, DENG Zhige1, LI Zhiguo1, PENG Guangyu2, ZHANG Chengguo3

1.Hunan Automotive Engineering Vocational College,Zhuzhou 412001,China;

2.Hunan Communication Polytchnic,Changsha 410132,China;3.Weichai Power Co.,Ltd.,Weifang 261061,China

Abstract:The high pressure fluctuation characteristics induced by the fuel injection is studied on a fuel pump test bench. The high pressure fluctuation characteristics of nearnozzle fuel pipe and the rail pressure sensor of the high pressure fuel rail is analyzed. The results show that the pressure wave caused by fuel injection and the pressure wave caused by fuel pump are separated from each other in the common rail system. The pressure wave at nozzle end caused by fuel injection is more significant than that at rail end. The pressure wave at nozzle end shows obvious fluctuation attenuation. The frequency of pressure wave is related to fuel properties, and the maximum amplitude of pressure wave is mainly related to the injection pressure and the size of spray orifice. In addition, the characteristics of pressure wave at high pressure rail is inconspicuous, and the total amount of rail pressure drop caused by single injection is not only related to the injection pressure and the size of spray orifice, but also the charging time.

Keywords:diesel engine;high pressure common rail;fuel injection characteristics;pressure fluctuation

预喷正时对柴油机燃烧与排放影响的试验研究

姜伟波，张营，李辉春，王君萍，李梅，丁传广

中国石油集团济柴动力有限公司, 山东济南,250306

摘要：通过台架试验，分析对比柴油机各参数随预喷正时的变化，研究多次喷射预喷正时对柴油机燃烧和排放性能的影响。试验表明，预喷正时决定缸内燃烧的放热始点和放热率，影响缸内的燃烧温度、爆发压力、NOx排放和碳烟的生成，预喷正时为20°时，爆发压力最大；预喷正时为35°时，热效率最高，油耗率和烟度最低；预喷正时为45°时,NOx排放最小。综合分析选择预喷正时40°作为折中优化方案，降低发动机油耗和NOx、碳烟排放，同时提高发动机的热效率。

关键词：预喷正时；燃烧；排放

Experimental research on the pilot injection timing effect of combustion and emission of diesel engine

JIANG Weibo, ZHANG Ying, LI Huichun,

WANG Junping, LI Mei, DING Chuanguang

CNPC Jichai Power Company Limited, Jinan 250306, China

Abstract:The effect of pilot injection timing in multiple injection on the combustion and emission performance of a diesel engine is studied.Tests show that the pilot injection timing determines the starting point and heat release rate of combustion, and affects the combustion temperature, explosion pressure, NOx and soot emissions. When the pilot injection timing is 20°, the explosion pressure is the largest; the thermal efficiency is highest at pilot injection timing of 35°, and the fuel consumption and smoke are the lowest; NOx emissions are the smallest at the pilot injection timing of 45°. Finally, the pilot injection timing of 40° is a compromise optimization scheme to reduce the fuel consumption and NOx and soot emissions, and improving the engine′s thermal efficiency.

Keywords: pilot injection timing; combustion; emission

分布式热电偶温度采集系统设计

李洋1，刘振革2，王仁辉3，马荣泽1，郭兴3，纪少波1*，于泽庭1

1.山东大学能源与动力工程学院，山东济南250061； 2.山东技师学院，山东济南250200；

3.龙口龙泵柴油喷射高科有限公司，山东龙口265701

摘要：基于MC9S08DZ60单片机、K型热电偶和MAX31855冷端补偿热电偶至数字输出转换器设计分布式热电偶温度采集系统，实现多路热电偶温度的数据采集及处理。采集系统的分辨率为0.5 ℃，可进行热电偶的开路及短接等故障检测，具有较高的检测速度和精度。测试试验结果表明，设计的热电偶温度采集系统能够实现温度的实时检测，具有良好的稳定性，可满足实际应用的要求。

关键词：热电偶；温度采集；模拟信号；故障检测

Design of distributed thermocouple temperature acquisition system

LI Yang1, LIU Zhen′ge2, WANG Renhui3, MA Rongze1,

GUO Xing3, JI Shaobo1*, YU Zeting1

1.School of Energy and Power Engineering, Shandong University, Jinan 250061, China;2.Shandong Technician Institute, Jinan 250200, China; 3.Longkou Longbeng Diesel Injection Technology Equipment Co., Ltd., Longkou 265701, China

Abstract:A distributed thermocouple temperature acquisition system based on MC9S08DZ60 micro controller, K thermocouple and MAX31855 coldend compensation thermocouple to digital output converter is designed, by which the temperature data acquisition and processing of multichannel thermocouple could by achieved. The resolution of the acquisition system can reach 05 ℃ and the fault detection of open circuit and short circuit of thermocouple can be realized, with high detection speed and accuracy. The test results show that realtime temperature detection could be carried out by this thermocouple temperature acquisition system stably.

Keywords:thermocouple; temperature collection; analog signal; fault detect

基于英飞凌TC275的整车控制器CCP协议底层驱动开发

聂林同，李军伟*，孙宾宾，姜世腾，阚辉玉

山东理工大学交通与车辆工程学院，山东淄博255049

摘要：针对以英飞凌TC275单片机为平台的整车控制器，进行控制器局域网络标定协议（controller area network calibration protocol，CCP）底层驱动程序的开发。依据CCP的需求开发了英飞凌TC275的控制器局域网络（controller area network,CAN）模块、系统定时器（system timer,STM）模块和FLASH模块的底层驱动程序，实现CCP标定系统的通信连接、数据上传、数据下载、数据存储等功能。为验证系统的性能,进行整车控制器的实际测试，测试结果表明：所开发的基于TC275单片机的CCP底层驱动程序能够实现CCP的功能要求。

关键词：整车控制器；英飞凌单片机；控制器局域网络标定协议；底层驱动

Development of CCP protocol underlying driver for vehicle control unit based on Infineon TC275

NIE Lintong, LI Junwei*, SUN Binbin, JIANG Shiteng, KAN Huiyu

School of Transportation and Vehicle Engineering, Shandong University of Technology, Zibo 255049, China

Abstract:The underlying driver of controller area network calibration protocol(CCP) is developed for the vehicle controller based on Infineon TC275 microcontroller. According to the requirements of CCP, the underlying driver of Infineon TC275 CAN module, STM module and FLASH module is developed, which realizes the functions of communication connection, data upload, data download and data storage of CCP calibration system. In order to verify the performance of the system, the actual test of the vehicle controller is carried out. The test results show that the CCP lowlevel driver based on TC275 microcontroller developed can meet the requirements of CCP.

Keywords:vehicle control unit；Infineon microcontroller unit；controller area network calibration protocol；underlying driver

定距螺旋桨对船用主机外特性的要求分析

尹晓青，于洪涛，靳良真，李作平，曾繁培

潍柴重机股份有限公司，山东潍坊261108

摘要：为解决定距螺旋桨与船用主机在船舶运行工况的机桨匹配问题，结合船舶系泊和航行试验的相关标准，分析和归纳船舶运行数据，将实船测试与船机桨匹配理论计算相结合，得出运输船和拖轮在常用工况及特殊工况下定距螺旋桨对主机外特性的定量要求，为配套不同细分市场时船用主机的优化和开发提供参考依据。

关键词：定距螺旋桨；船用主机；外特性

Analysis of requirements for the marine engine external characteristics

of the fixed pitch propeller

YIN Xiaoqing, YU Hongtao, JIN Liangzhen, LI Zuoping, ZENG Fanpei

Weichai Heavy Machinery Co., Ltd., Weifang 261108, China

Abstract:In order to solve the matching problem between the propeller and the marine main engine in the operating condition of the ship，the paper combines the relevant ship mooring and navigation test standards, analyzes and summarizes the ship′s operational data, and combines the actual ship test with the theoretical calculation of the ship′s paddle matching. After research and analysis, the quantitative requirements for the outer characteristics of the fixedpropellers of the ship and the tugboat under common working conditions and special working conditions are obtained，which provides reference for the optimization and development of marine mainframes for different market segments.

Keywords:fixed pitch propeller; marine engine; external characteristic

增程式电动汽车车速鲁棒自适应跟踪控制

郭峻宇1，杨君1, 任慧超2

1.山东交通学院汽车工程学院，山东济南250357；2.山东中烟工业有限责任公司济南卷烟厂动力车间，山东济南250104

摘要：针对增程式电动汽车行驶时因不确定性路面扰动导致车速出现波动的问题，设计自适应鲁棒车速跟踪控制器,使汽车跟踪理想车速，通过Matlab/Simulink仿真软件验证所设计自适应控制器算法的有效性。仿真结果表明，该控制器可以自适应调节控制增益，对路面环境未知扰动的不确定性具有良好鲁棒性。研究成果可为增程式电动汽车的车速跟踪控制设计提供参考。

关键词：增程式电动汽车；车速控制；不确定性；自适应控制

Robust adaptive tracking control for extended range electric vehicles

GUO Junyu1, YANG Jun1, REN Huichao2

1.School of Automotive Engineering, Shandong Jiaotong University, Jinan 250357,China;2.Jinan Cigarette Factory Power Workshop, Shandong Tobacco Industry Co., Ltd.,Jinan 250104,China

Abstract:For the extended range electric vehicle, the vehicle speed may fluctuate due to the uncertainty of road disturbances. In view of this problem, an adaptive robust vehicle speed tracking controller is designed to enable the extended range electric vehicle speed to track the ideal value. The validity of the algorithm of the designed adaptive controller is verified by Matlab / Simulink simulation software. Simulation results show that the controller can adaptively adjust the control gain, and has good robustness against the uncertainty of unknown road surface environment disturbance. The simulated results can provide a reference for the design of speed tracking control of rangeextended electric vehicles.

Keywords:extended range electric vehicle; vehicle speed control; uncertainty; adaptive control

车辆高速避让路径跟踪控制策略

王健1，王金波1*，于蓬2，杨君1，郑金凤2

1.山东交通学院汽车工程学院，山东济南250357；2.山东明宇新能源技术有限公司，山东济南271100

摘要：建立车辆动力学模型，研究车辆在高速避让工况下的路径跟踪控制策略。基于自抗扰控制设计车辆横摆角速度以及道路曲率2种不同的路径跟踪控制器；设计基于车辆偏航位移和偏航角度加权的线性二次最优控制器；对3种控制器控制效果进行仿真验证，分析路径跟踪侧向位移误差、侧向加速度、前轮转向角以及偏航角度变化。越野车实车测试结果表明，路径跟踪控制策略正确。

关键词：高速避让；控制策略；自抗扰控制；路径跟踪

Path tracking control strategy ofvehicle for high speed collision avoidance

WANG Jian1, WANG Jinbo1*, YU Peng2, YANG Jun1, ZHENG Jinfeng2

1.School of Automotive Engineering, Shandong Jiaotong University, Jinan 250357, China; 2.Shandong Mingyu New Energy Technology Co., Ltd., Jinan 271100, China

Abstract:High speed collision avoidance technology can avoid rearend collision of vehicles at high speed and can improve the driving safety of vehicles. On the basis of two degrees of freedom vehicle dynamics model, the path tracking control strategy for high speed collision avoidance is studied. Three path tracking controllers are designed based on vehicle yawing angular velocity, road curvature, vehicle yaw displacement and yaw angle by using active disturbance rejection control method and linear quadratic optimal control method. The control effects are compared by analyzing the lateral displacement error, vehicle yaw angle, lateral acceleration and front wheel angle. In order to verify the correctness of the path tracking control strategy, a lightduty offroad vehicle is used for real vehicle tests.

Keywords:high speed collision avoidance; control strategy; ADRC; path tracking

高负荷发动机活塞的开发

石小明1，2，刘维娟1，2，姜殿昌1，2

1.滨州渤海活塞有限公司，山东滨州256602；2.山东省发动机活塞摩擦副重点实验室，山东滨州256602

摘要：为适应市场发展需要，开发一款高负荷发动机用铝活塞。根据发动机的升功率和最高爆发压力，对活塞整体结构、活塞环岸、环槽、销孔、内冷油腔进行设计，通过采用活塞销孔镶铜套设计增加销孔的可靠性。有限元分析表明活塞满足强度要求；利用动力学仿真分析对活塞二阶运动进行评估，满足载荷要求。对装配该活塞的发动机进行1500 h台架试验，结果表明：活塞各项性能指标均满足发动机的设计和使用要求。

关键词：高负荷；活塞；铜套；有限元分析；动力学

Development of the high load engine piston

SHI Xiaoming1,2, LIU Weijuan1,2， JIANG Dianchang1,2

1.Binzhou Bohai Piston Co., Ltd.，Binzhou 256602, China;

2.Shandong Province Key Laboratory of Engine Piston Cylinder Kits, Binzhou 256602, China

Abstract:In order to meet the upgraded market requirement, a high load aluminum piston is developed. The structure, ring land, ring groove, pin bore and inner cavity are designed by calculating the specific power and max,peak cylinder pressure. The copper bushing of pin bore is designed to improve the reliability. Through the finite element calculation, the fatigue factor of the piston meets the requirements of the strength; the results of dynamic simulation analysis are meet the requirements of the engine load. After running 1500 h of the engine bench test, the performance indexes of piston piston meet the requirements of the engine.

Keywords:high load；piston；bushing；finite element analysis；dynamic analysis

高端游艇用发动机中冷器支撑系统优化设计

钟跃兰1,2,代子阳1,2,张少杰1,2，董晓婷1,2

1.内燃机可靠性国家重点实验室，山东潍坊261061；

2.潍柴动力股份有限公司发动机研究院，山东潍坊261061

摘要：从边界条件和布置方向出发，充分利用V型机体的上部空间，设计支撑柱+支撑条、支架+平板和镂空支架（球铁）+镂空平板3个固定支架方案，基于拓扑优化思维，通过仿真，从模态、强度、疲劳和滑移4个方面详细评估系统可靠性；为消除设计冗余，更换轻量化的材料得到镂空支架（铸铝）+镂空平板方案。结合游艇用途、系统结构和使用工况特点，根据经验评估，选用可靠性系数更高的镂空支架（球铁）+镂空平板方案进行产品开发，镂空支架（铸铝）+镂空平板方案作为技术储备，用于其他振动和冲击小的细分市场。

关键词：中冷器；支撑；拓扑优化；轻量化；模态；强度；疲劳；滑移

Optimal design of intercooler supporting system used in yacht engine

ZHONG Yuelan1,2, DAI Ziyang1,2, ZHANG Shaojie1,2, DONG Xiaoting1,2

1.State Key Laboratory of Engine Reliability, Weifang 261061,China;2.R&D Center, Weichai Power Co., Ltd.,Weifang 261061,China

Abstract:In order to get the optimal design, three intercooler supporting structures, column+strip, support plate and hollow support plate, are designed for a Vtype diesel, and the assembly and maintainability are analyzed. Topological optimization method is used to simulate and evaluate system reliability in terms of modality, strength, fatigue and slip. Based on lightweight design, hollow support plate (aluminum) is designed to get lighter weight and better performance.Considering the layout and using conditions of yacht, hollow support plate (cast iron) with higher safety factor is determined. The aluminum design is used for technical reserve, which can be used in other applications with slight vibration and shock.

Keywords:intercooler; bracket; topological optimization; lightweight; modal analysis; strength analysis; fatigue analysis; slip analysis

柴油机DPF驻车再生排气热管理策略试验研究

刘西文1，魏明亮1，邢首辰1，姜子刚1，张一2，张腾威1

1.洛阳拖拉机研究所有限公司，河南洛阳471039；2.中国一拖集团有限公司战略采购中心，河南洛阳471039

摘要：在一台非道路国四高压共轨柴油机上，利用试验台架研究颗粒捕集器（diesel particulate filter,DPF)驻车再生过程中不同排气热管理策略对氧化型催化器（diesel oxidation catalyst,DOC)入口温度及排放的影响。结果表明，合适的再生转速、节气门关闭角度及喷油参数对提升DOC入口温度、降低DOC入口未燃HC效果显著。研究结果可以对柴油机DPF驻车再生排气热管理策略的制定和优化提供指导。

关键词：柴油机；DPF；驻车再生；热管理策略

Experimental study on exhaust thermal management strategy during DPF parking regeneration

LIU Xiwen1, WEI Mingliang1, XING Shouchen1,

JIANG Zigang1, ZHANG Yi2, ZHANG Tengwei1

1.Luoyang Tractor Research Institute Co.,Ltd.,Luoyang 471039, China；

2.Strategy Sourcing Center,YTO Group Corporation,Luoyang 471039, China

Abstract:The influence on the diesel oxidation catalyst(DOC) inlet temperature and DOC inlet HC emission of different heating up strategy on the procedure of diesel particulate filter parking regeneration are investigated on a nonroad high pressure common rail diesel engine which meets CHINA 4. The results show that proper parameters of regeneration speed，intake throttle valve opening and injection strategy, have significant effects on rising DOC inlet temperature and reducing DOC inlet HC emission. The result provide guidance for the development and optimization of heating up strategy on the procedure of diesel particulate filter parking regeneration.

Keywords: diesel engine; DPF;parking regeneration; thermal management strategy

牵引车载荷对NOx排放和排温影响的试验研究

李建东1,2，李云刚1,2，刘刚1,2，王庆新1,2，谢成武1,2

1.内燃机可靠性国家重点实验室，山东潍坊261061；2.潍柴动力股份有限公司，山东潍坊261061

摘要：在五轴动力总成试验台架上对牵引车在不同载荷下进行同一路谱的排放试验,研究牵引车在不同载荷下NOx排放和排温的变化，得到载荷与排放物和选择性催化还原(selective catalytic reduction,SCR)上游排温的变化关系。结果表明：载荷为标定载荷的60%以下时，NOx比排放值与载荷基本呈线性相关；载荷超过标定载荷的75%时，NOx比排放值与载荷呈二次项相关；载荷在为标定载荷的23%以上时，NOx比排放值与SCR上游排温基本呈线性相关。利用该试验结论可以通过只进行单一载荷排放试验，判断车辆在其他载荷下的排放水平是否满足国家标准要求，并可通过载荷对排温的影响规律预判排放水平。

关键词：牵引车；载荷；排放；SCR上游排温

Experimental study on the influence of tractor load on NOx emission and exhaust temperature

LI Jiandong1,2, LI Yungang1,2, LIU Gang1,2, WANG Qingxin1,2, XIE Chengwu1,2

1.State Key Laboratory of Engine Reliability, Weifang, 261061, China;

2.Weichai Power Co., Ltd., Weifang 261061, China

Abstract:The emission test of the tractor under different load,the same path spectrum is carried out on the fiveaxis powertrain test bench,the changes of the NOx emission and exhaust temperature are studied,and the relationship between the load and emission and the upstream exhaust temperature of selective catalytic reduction(SCR) is obtained. It could be found that when load is less than 60% of the normal load, NOx emission show linear relationship with load; and when load is more than 75% of the normal load, NOx show a quadratic relationship with load. On the other hand, when load is above 23% of the normal load, NOx emission show linear relationship with the upstream temperature of the SCR system. Based on these conclusions, it is possible to evaluate the vehicle emission for different load by single testing,and the emission level can be predicted by the influence of load on exhaust temperature.

Keywords:tractor; load; emission; the upstream temperature of SCR

汽油机颗粒捕集器降低粒子数量试验研究

闫广义，张汉桥，蒋茂玎，钟秋月，马标

安徽江淮汽车技术中心，安徽合肥230041

摘要：为应对国六排放升级，满足粒子数量(particle numbers, PN)的排放限值要求，在全球轻型车统一测试循环（worldwide lightduty test cycle,WLTC）下，以汽油机颗粒捕集器(gasoline particulate filter,GPF)为主要研究对象，分析GPF布置位置、涂层上载量、壁厚3种因素对PN排放的影响。试验结果表明：GPF涂层上载量和壁厚不变，GPF布置方式由紧耦合式变更为底盘式时，PN排放试验结果与排放标准限值的比例由365%降低至281%；GPF布置位置和壁厚不变，GPF涂层上载量由75 g/L提高到100 g/L，PN试验结果与标准限值的比例由150%降至85%；GPF布置位置和涂层上载量不变，GPF壁厚由0.203 2 mm增加到0.304 8 mm，PN试验结果与标准限值的比例由150%降至75%。

关键词：国六排放标准；颗粒物数量；汽油机颗粒捕集器

Experimental study on particle numbers reduction

in gasoline particle filter

YAN Guangyi, ZHANG Hanqiao, JIANG Maoding, ZHONG Qiuyue, MA Biao

Technical Center,Anhui Jianghuai Automobile Group Corp.Ltd,Hefei 230041,China

Abstract: In order to meet the particle numbers (PN) limit requirement in CHINA 6 regulations, under theworldwide lightduty test cycle(WLTC), gasoline particulate filter(GPF) is taken as the main research object,the effects of GPF layout position, coating loading capacity and wall thickness are analysed.The test results show that when coating load and wall thickness of GPF are the same,the GPF layout is changed from the tight coupling type to the bottom plate type, the ratio of PN to the limits of the emission standards decreases from 365% to 281%;When GPF layout position and wall thickness are the same,the GPF coating loading increases from 75 g/L to 100 g/L, the ratio of PN to the limits of the emission standards decreases from 150% to 85%;When GPF layout position and coating load are the same,the GPF wall thickness increases from 0.203 2 mm to 0.304 8 mm, the ratio of PN to the limits of the emission standards decreases from 150% to 75%.

Keywords:CHINA 6 emission standard; particle number; gasoline particle filter

高排放标准下道路燃油车处境分析

胡金义1,2，李加强2*

1.西南林业大学机械与交通学院，云南昆明650224;2.河南科技职业大学汽车工程系，河南周口466000

摘要：针对国六排放标准实施后道路燃油车竞争和生存压力加大的问题，调查统计近5 a汽车及新能源汽车的保有量，汽车保有量以年均12%的比例增长，新能源汽车保有量以每年约50%的比例增长；研究和对比近年来机动车排放标准，分析道路燃油车节能减排存在的问题，从政策引导制约、供油企业升级改造、燃油车本身的改进优化等几方面提出时效性方案与建议。

关键词：道路燃油车；排放标准；分析研究

Analysis of the situation of road fuel vehicles under high emission standards

HU Jinyi1,2， LI Jiaqiang2*

1.School of Mechanical and Transportation，Southwest Forestry University, Kunming 650224, China;2.Department of Automotive Engineering，Henan Vocational College of Science and Technology,Zhoukou 466000, China

Abstract:Due to the implementation of the China 6 standards, the competition for road vehicles has increased. The number of automobiles and new energy vehicles in the past five years are counted and analyzed, it is found that the annual growth rate of automobiles is about 12%, that of new energy vehicles is about 50%, and the market share of fuel vehicles is decreasing year by year. In view of the competition and survival pressure faced by fuel vehicles, especially for energysaving and emission reduction, several suggestions including policy guidance and regulation, upgrading of oil supply enterprises, and improvement of fuel vehicles are introduced.

Keywords:road fuel vehicles; emission standards; analysis research

基于ABAQUS的发动机缸盖工装强度分析

姜楠1,2, 刘毅1, 龚旺1, 唐灵聪1

1.宁波吉利罗佑发动机零部件有限公司, 浙江宁波315336；2.浙江吉利动力总成有限公司, 浙江宁波315800

摘要：分析计算某型号发动机缸盖及工装的应力与局部位移，基于HyperMesh软件建立缸盖及工装的仿真模型，使用ABAQUS软件进行静力学计算，对处于夹紧状态下的发动机缸盖进行4个典型工位的加工工况分析计算,得出工件加工位置最大位移与工装所受最大应力。通过强度和位移校核,最终结果满足缸盖的加工需求，为工艺制定提供了有效的数据支持。

关键词：缸盖；应力；位移；静力学计算

Strength analysis of an engine cylinder head fixture based on ABAQUS

JIANG Nan1,2, LIU Yi1, GONG Wang1, TANG Lingcong1

1.Ningbo Geely Royal Engine Components Co., Ltd., Ningbo 315336,China;2.Zhejiang Geely Powertrain Co., Ltd., Ningbo 315800, China

Abstract:An analysis of the stress and displacement for an engine cylinder head and fixture is carried out. The finite element models of the cylinder head and fixture are built by HyperMesh, and the static stress is calculated by ABAQUS. Four types of machining conditions of the engine cylinder head under the same clamp clamping condition are calculated and analysed. Based on the comparison of the maximum stress and maximum displacement for the fixture during the machining processing of the cylinder head, the part maximum displacement of the machining position and the maximum stress on the fixture are analysed. The results provide useful data for machining process development.

Keywords:cylinder head；stress；displacement；static calculation

船用柴油机活塞销孔开裂失效分析及优化

刘召伟1,2，孙琛媛1,2，郭金朋1,2，董勃1,2

1.滨州渤海活塞有限公司，山东滨州256602；2.山东省发动机活塞摩擦副重点实验室，山东滨州256602

摘要：针对某船用柴油机活塞销孔开裂问题，对活塞进行失效分析，确认开裂的原因为销座结构和销孔设计不合理，通过有限元分析匹配不同销孔形线的销座结构对销孔接触压力和疲劳系数的影响，根据仿真结果确定优化方案，经650 h耐久试验，优化后的活塞销孔未出现开裂。研究表明，活塞销座阶梯形结构配合销孔双侧二次曲线异形结构可以改善销孔接触压力分布，使销孔承载面应力均匀进而降低销孔开裂风险。

关键词：活塞；销孔；开裂；形线；有限元分析

Analysis of piston pin bore cracking and its optimization

for a marine diesel engine

LIU Zhaowei1,2, SUN Chenyuan1,2, GUO Jinpeng1,2, DONG Bo1,2

1.Binzhou Bohai Piston Co., Ltd., Binzhou 256602, China;

2.Shandong Province Key Laboratory of Engine Piston Cylinder Kits, Binzhou 256602, China

Abstract:Failure analysis of piston pin is conducted in order to improve its performance for a marine diesel. The results indicate that the pin bore cracking is caused by improper design of pin boss and pin bore. FEA is used to study the performance of different pin boss and bore profile, as well as the pin bore contact pressure and fatigue factors. Optimization profile is confirmed by the FEA results and no cracking is found in optimized piston after engine test. It could be confirmed that the stepped pin boss designed with secondary curve of bore profile can improve pressure distribution, even bore stress and reduce the risk of cracking.

Keywords:piston; pin bore; cracking; profile; finite element analysis

正交试验设计在发动机故障分析中的应用

耿国芳1,2，曾亮1,2，李文广1,2，张志伟1,2

1.内燃机可靠性国家重点实验室，山东潍坊261061; 2.潍柴动力股份有限公司 发动机研究院，山东潍坊261061

摘要：针对全面试验排查引起发动机故障的原因耗费大、周期长的问题，研究正交试验在发动机故障排查中的应用。结合某机型发动机在市场上出现的曲轴前端法兰脱出曲轴现象，确定试验指标，设计正交试验方案，对正交试验结果进行分析。结果表明：通过正交试验只需要4根曲轴就可确定各因素对曲轴法兰脱出的影响，按照影响由大到小的顺序为锥度、擦拭程度、防锈油，达到通过最少的试验次数确定故障原因的目的。

关键词：发动机；正交试验设计；故障

Orthogonal test design application on engine failure analysis

GENG Guofang1,2, ZENG Liang1,2, LI Wenguang1,2, ZHANG Zhiwei1,2

1.State Key Laboratory of Engine Reliability, Weifang 261061, China;2.R&D Center, Weichai Power Co., Ltd., Weifang 261061, China

Abstract:Aiming at the problem of high cost and long cycle of comprehensive check and verification for various factors that may cause engine failure, the application of orthogonal test in engine troubleshooting is studied. Combined with the phenomenon that the crankshaft front flange of a certain type of engin, the test index is determined, the orthogonal test plan is designed, and the orthogonal test results are analyzed. The results show that only 4 crankshafts are needed to determine the impact of various factors on the crankshaft flange drop. According to the influence, the impact is sorted into conical degree, polishing, antirust oil. The cause of the failure is determined through the least number of tests.

Keywords:engine；orthogonal test design; failure