燃气发动机废气再循环随机调节控制器设计

杨君1，王明杰2*，李延骁1

1.山东交通学院汽车工程学院，山东济南250357; 2.山东交通学院机动车检测实验中心，山东济南250100

摘要：为研究燃气发动机废气再循环的随机调节问题，建立缸内废气总质量的离散动态模型，将下一循环的缸内废气总质量表示为当前循环的缸内废气总质量、缸内吸入空气质量、喷入缸内燃气质量、再循环废气质量的函数。基于建立的离散动态模型，设计能够将缸内废气总质量调节到设定值邻域内的随机调节器。MATLAB/Simulink数值仿真研究表明，设计的随机调节器在3种工况下均能将缸内废气总质量调节到其设定值的邻域内，随机调节器有效。

关键词：燃气发动机；废气再循环；随机调节

Design of stochastic regulation controller for exhaust gas recirculation of natural gas engine

YANG Jun1, WANG Mingjie2*, LI Yanxiao1

1.School of Automotive Engineering, Shandong Jiaotong University, Jinan 250031,China;2.Motor Vehicle Testing Center, Shandong Jiaotong University, Jinan 250100, China

Abstract:For research of stochastic regulation problem of exhaust gas recirculation of natural gas engines, the discretetime dynamic model of total mass of incylinder exhaust gas is established in which the total mass of incylinder exhaust gas at next cycle is presented as a function of the total mass of incylinder exhaust gas, air mass breathing into the cylinder, fuel mass injected into the cylinder, recirculating exhaust gas mass at the current cycle.Based on the established discretetime dynamic model, the stochastic regulator is designed by which the total mass of incylinder exhaust gas can be regulated into a neighborhood of its set value. The numerical simulation based on MATLAB/Simulink shows that the total mass of incylinder exhaust gas can be regulated into a neighborhood of its set value by the designed stochastic regulator under three working conditions, and the stochastic regulator is validated.

Keywords:natural gas engines; exhaust gas recirculation; stochastic regulation

基于反应动力学方程的尿素结晶风险预测模型

王建东1,2, 谭治学1,2, 李云刚1,2，王佳兴1,2, 杨新达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：根据尿素的结晶过程和生成机理，搭建基于反应动力学方程的结晶风险预测模型。分析影响结晶的关键因素，测试模型计算过程中的关键参数，提出以软硬结晶加权来表征尿素结晶风险程度。通过某重型柴油机尿素结晶过程的稳态工况试验和整车道路试验验证结晶风险预测模型。结果表明，结晶风险预测模型的预测一致性较好，能够及时预测结晶风险，为结晶清理时机提供最佳的判断指导。

关键词：选择性催化还原；结晶；风险；预测模型

Prediction model of urea crystallization based on reaction kinetics

WANG Jiandong1,2, TAN Zhixue1,2, LI Yungang1,2,WANG Jiaxing1,2, YANG Xinda1,2

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

Abstract:Combined with urea crystallization process and the formation mechanism, a method based on a set of reaction kinetics equations for crystallization prediction is set up. Based on the analysis of the key factors of crystallization, several key parameters are decided. The crystallization risk are designed as weighted sum of hard and soft urea crystallization. Experimental analysis of the urea crystallization process for a heavy diesel engine under different steady conditions is conducted, and the vehicle road test is performed additionally. The prediction model performed quite well, which represented as predicting the crystallization risk timely and providing the best judgment guidance for crystallization elimination.

Keywords:selective catalytic reduction; deposit; risk; prediction model

基于嵌入式Linux的智能重型拖拉机远程监控系统开发

朱青松1，李军伟1*，王进2，李德芳2，高松1

1.山东理工大学交通与车辆工程学院，山东淄博255049；2.雷沃重工股份有限公司，山东潍坊261200

摘要：为监控重型拖拉机运行状态，提高运行可靠性，设计开发基于嵌入式Linux的智能重型拖拉机远程监控系统。将监控系统作为一个控制器局域网络(controller area network,CAN)节点挂载到重型拖拉机整车控制器(vehicle control unit,VCU)的CAN总线网络上，通过Linux对监控系统的CAN模块、全球定位系统(global positioning system,GPS)模块和4G模块进行程序设计，实时接收重型拖拉机VCU的CAN报文并解析出车速等重型拖拉机运行状态参数，获取重型拖拉机位置和速度信息，将所获得的数据发送到服务器。对设计的监控系统进行测试，结果表明：基于嵌入式Linux的智能重型拖拉机监控系统能够准确地获取重型拖拉机运行时的各项数据，上传到服务器并在客户端显示，远程监控系统满足设计要求。

关键词：嵌入式Linux；重型拖拉机；CAN总线；监控系统

Development of remote monitoring system for intelligent heavy tractor based on embedded Linux

ZHU Qingsong1, LI Junwei1*, WANG Jin2, LI Defang2, GAO Song1

1.School of Traffic and Vehicle Engineering, Shandong University of Technology,Zibo 255049,China;2.Lovol Heavy Industry Co., Ltd.,Weifang 261200,China

Abstract:In order to monitor the operation status of heavy tractors, and improve the reliability of heavy tractors′operation, an intelligent remote monitoring system for heavy tractors based on embedded Linuxis is designed and developed.The monitoring system is mounted as a CAN node on the CAN bus network of the heavyduty tractor VCU. The CAN module, GPS module and 4G module of the monitoring system are configured through Linux, and they are used to receive CAN messages from the heavyduty tractor VCU in real time,and parse out the running status data of heavy tractors such as vehicle speed, obtain the position and speed data of heavy tractors, and send the obtained data to the server. The designed monitoring system is tested, and the results show that the intelligent heavyduty tractor′s monitoring system based on embedded Linux can accurately obtain various data of the heavyduty tractor during operation and upload it to the server, which meets the design requirements.

Keywords:embedded Linux； heavy tractor； CAN bus； monitoring system

NOx传感器测量实际道路NOx排放的试验研究

许雪利1,2，司福帅1,2，马雁1,2，刘伟达1,2，杨立云1,2，史美丽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：针对便携式排放测试系统（portable emission measurement system，PEMS）测量实际道路排气污染物中NOx比较困难的问题，提出一种简易测量整车实际作业过程中NOx排放的试验方法。分析氮氧传感器工作原理，确定传感器安装方式及计算测量方法，对比分析氮氧传感器和PEMS设备测量实际道路NOx排放污染物的结果可知：使用氮氧传感器测量车辆实际道路的NOx排放结果具备可行性和可信性，该测量方法为测量实际道路NOx排放测量提供了思路和方法。

关键词：氮氧传感器；便携式排放测试系统；实际道路；氮氧化物排放

Experimental study on real driving NOx measurement based on NOx sensor

XU Xueli1,2, SI Fushuai1,2, MA Yan1,2, LIU Weida1,2, YANG Liyun1,2, SHI Meili1,2

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

Abstract: Considering the difficulty of measuring NOx emission from real driving exhaust pollutants by portable emission measurement system (PEMS),a simple test method for measuring NOx emission from actual vehicle operation is proposed. By analyzing the working principle of NOx sensor, the sensor installation method and calculation measurement method are determined, then the results of measuring NOx emission pollutants from actual road by NOx sensor and PEMS emission equipment are compared and analyzed. The results show that it is feasible and credible to measure the NOx emission results of actual road by using NOx sensor. The measurement method of NOx sensor provides a new method for the measurement of actual road NOx emission.

Keywords:NOx sensor; PEMS; actual road; NOx emission

动力电池二次利用一致性分选研究

朱士伟，李祥瑞，兰欣*，吴平，刘祥龙，谢国芳

山东大学能源与动力工程学院，山东济南250061

摘要：针对动力电池二次利用时单体电池不一致性影响电池储能系统整体性能的问题，研究长期使用后的退役动力电池关键参数的变化，分析现阶段动力电池的匹配成组筛选策略以及电池均衡算法，根据电池状态和参数变化信息选择合适的电池性能评价方法，通过对退役动力电池进行严格的筛选分组、均衡策略以维持整个电池组的一致性。研究表明，通过合理的电池匹配成组，结合储能系统的均衡技术，可实现退役电池的二次利用。

关键词：动力电池；二次利用；一致性；退役电池匹配成组；均衡

Study on consistency separation of power battery′s secondary utilization

ZHU Shiwei， LI Xiangrui， LAN Xin*， WU Ping， LIU Xianglong， XIE Guofang

School of Energy and Power Engineering, Shandong University, Jinan 250061,China

Abstract:In view of the problem that the inconsistency of single cell affects the overall performance of battery energy storage system during secondary utilization of battery, the change of key parameters of retired batteries after longterm use is studied. The matching strategy and battery equalization algorithm are analyzed and discussed. The results show that the secondary utilization of retired batteries can be realized by reasonable battery matching and energy storage system equalization technology. In view of the related problems of ladder utilization of power battery at present, some suggestions about future industry standard are given.

Keywords: power battery; secondary utilization; consistency; battery matched; equilibrium

基于轻量化设计的空气冷却器支架有限元静动态分析

张忠元1，2，张凤丽1，2，郭军军1，2，孙栓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：为减轻空气冷却器支架质量，在保证各项性能满足设计要求的前提下，建立空气冷却器支架的多部件接触有限元分析模型，通过整机多体动力学分析获得空气冷却器质心的冲击加速度，开展空气冷却器支架的强度、疲劳可靠性和连接可靠性分析。结果表明：轻量化设计方案的空气冷却器及支架系统的固有频率有所提升，且前3阶固有频率均大于发动机标定转速的激励频率，能够有效避开共振风险；在振动载荷作用下，轻量化设计后的支架强度、疲劳可靠性和连接可靠性均满足设计要求。

关键词：轻量化设计；冲击载荷；有限元分析；静力学特性；动力学特性

Finite element static and dynamic analysis of air cooler bracket based on lightweight design

ZHANG Zhongyuan1,2, ZHANG Fengli1,2, GUO Junjun1,2, SUN Shuan1,2

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 reduce the mass of the air cooler bracket, the finite element analysis of multicomponent contact model is established and investigated.The static stress, fatigue strength and connection reliability from the impact load which is obtained from the multibody dynamic analysis of the whole machine,are used for the static and dynamic analysis of the bracket. The results show that the natural frequency of lightweight system increased and first three order natural frequency are greater than calibration excitation frequency, which effectively avoid the resonance risk. At the same time, the static stress, fatigue strength and connection reliability of the optimized bracket meet the requirements.

Keywords:lightweight design;impact load;finite element analysis;statics characteristic;dynamic characteristic

基于CFD分析的某轻型卡车发动机舱热保护研究

周荣良1，毛洪海2，严江2，闫伟1

1.山东大学能源与动力工程学院，山东济南250061；2.潍柴动力股份有限公司，山东潍坊261001

摘要：基于计算流体动力学（computational fluid dynamics，CFD）模拟仿真与热平衡试验，对某轻型卡车的整车温度场进行分析，发现蓄电池、排气歧管与涡轮增压器附近线束的表面温度较高，出现热害现象。根据热害发生位置，对高温部件使用隔热罩削弱热辐射，使蓄电池与线束在热浸状态与发动机最大扭矩（转速为1300 r/min）工况下，温度始终低于其许用最高温度，避免零部件的高温失效甚至自燃；并根据隔热罩厚度与隔热效果的关系，在不影响隔热效果的同时，降低隔热罩厚度，实现轻量化设计。

关键词：热害；发动机舱；底盘；CFD分析

Research on thermal protection for engine compartment of a light truck based on CFD analysis

ZHOU Rongliang1, MAO Honghai2, YAN Jiang2, YAN Wei1

1.School of Energy & Power Engineering， Shandong University, Jinan 250061, China;2.Weichai Power Co.,Ltd., Weifang 261001, China

Abstract:Based on CFD simulation and heat balance experiment, the temperature field of a light truck is analyzed, and it is found that the surface temperature of the wire harness near the battery, exhaust manifold and turbocharger is higher, resulting in thermal damage. According to the location of the heat damage, the thermal radiation of the high temperature parts is weakened by using the heat shield, so that the temperature of the battery and wire harness is always lower than the allowable maximum temperature under the hot immersion state and the maximum engine torque (engine speed 1300 r/min) condition, so as to avoid the high temperature failure or even spontaneous combustion of the parts. According to the relationship between the thickness of the heat insulation cover and the heat insulation effect, the thickness of the heat insulation cover is reduced and the lightweight design of the automobile is realized without affecting the heat insulation effect.

Keywords: heat damage; engine compartment; chassis; CFD analysis

基于电磁离合器水泵的整车热管理控制策略试验研究

么丽丽1,2，王洪忠1,2，李建文1,2，张俊龙1,2，杨宇增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：为研究整车热管理技术，从整车角度优化设计一款电磁离合器水泵及其控制策略，通过整车试验验证电磁离合器水泵及其控制策略优化前后对整车热管理和经济性的影响。试验结果表明：优化后的电磁离合器水泵及其控制策略能够满足整车热管理需求，在保证发动机可靠性的同时，整车平原高速百km油耗降低了1%左右。

关键词：电磁离合器水泵；整车热管理；油耗

Experimental study on control strategy for vehicle thermal management based on electromagnetic clutch pump

YAO Lili1,2, WANG Hongzhong1,2, LI Jianwen1,2, ZHANG Junlong1,2, YANG Yuzeng1,2

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

Abstract: In oder to study vehicle thermal management technology,an electromagnetic clutch water pump and its control strategy from the perspective of the vehicle are optimized. Through the vehicle test, it focuses on verifying the influence of the electromagnetic clutch water pump and its control strategy before and after optimization on the thermal management and economy of the whole vehicle. The test results show that the optimized electromagnetic clutch water pump and its control strategy can meet the thermal management needs of the whole vehicle. The fuel consumption of the whole vehicle at 100 km high speed in plain area has been reduced by 1%.

Keywords:electromagnetic clutch pump; vehicle thermal management; fuel consumption

基于金属片积碳试验的汽油清洁剂性能测试

周子涵1，王金龙1，程莹东1，尹琪2，肖进1*

1.上海交通大学新能源动力研究所，上海200240；2.上海汽车集团股份有限公司乘用车分公司，上海201804

摘要：为研究汽油清洁剂对发动机喷油器头部积碳的影响规律，以聚醚胺、聚异丁烯胺和曼尼希碱3种汽油清洁剂为研究对象，在金属片积碳试验台架上试验研究其对汽油积碳的影响。对3种汽油清洁剂进行热重测试，在试验台架上对无清洁剂汽油和聚醚胺、聚异丁烯胺、曼尼希碱的质量分数分别为05‰和10‰的清洁剂汽油进行9个温度条件下的积碳试验，并对生成的积碳进行显微红外光谱测试。结果表明：热稳定性对汽油清洁剂的清洁效果存在重要影响；聚醚胺、聚异丁烯胺和曼尼希碱对汽油积碳的抑制作用与温度密切相关；温度高于180 ℃时，聚醚胺或聚异丁烯胺质量分数高的清洁剂汽油，金属片积碳反而增加，清洁剂的质量分数对汽油清洁剂的清洁性能存在较大影响。

关键词：积碳；汽油清洁剂；聚醚胺；聚异丁烯胺；曼尼希碱

Performance test of gasoline cleaner based on metal sheet deposition test bench

ZHOU Zihan1, WANG Jinlong1, CHENG Yingdong1, YIN Qi2, XIAO Jin1*

1. Institute of Advanced Energy and Powertrain Technology, Shanghai Jiao Tong University, Shanghai 200240, China;2. Passenger Vehicle Co., SAIC Motor Co.,Ltd., Shanghai 201804, China

Abstract: In order to study the influence of gasoline cleaners on the carbon deposit in the engine injector head, three gasoline cleaners, polyether amine, polyisobutylene amine and Mannich base, are used as the research objects and tested on a metal sheet carbon deposit test bench to study their effect on deposits. The thermogravimetric test is carried out on the three gasoline cleaners,and gasoline without additives and gasolines with 3 different gasoline cleaners added in 2 different mass concentrations are tested for deposition under 9 temperature conditions on the test bench. The results show that thermal stability has an important influence on the cleaning effect of gasoline cleaners; the inhibitory effect of polyether amine, polyisobutylene amine and Mannich base on gasoline deposition is closely related to temperature; the concentration of the gasoline cleaners has a great impact on the cleaning performance, when the temperature exceeds 180 ℃, adding high concentration of polyether amine or polyisobutylene amine will increase the deposit on the metal sheet.

Keywords:carbon deposit; gasoline cleaner; polyether amine; polyisobutylene amine; Mannich base

基于流固耦合方法的排气管低周热疲劳分析

孙晶晶1,2，马庆镇1,2，李连升1,2，王宝军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：针对某6缸发动机高镍铸铁排气管在试验过程中出现的裂纹故障，基于流固耦合方法，利用有限元分析软件对故障排气管进行温度场、应力场和低周热疲劳计算分析。计算结果表明，排气管应力幅值较大区域和低周热疲劳计算寿命较低区域均与试验过程中发生的裂纹故障位置相吻合；冷热冲击工况下较大应力幅值产生的塑性应变是造成排气管热疲劳的主要原因。改进排气管结构，去掉靠近增压器法兰的加强筋，减薄增压器法兰，并对改进方案进行仿真分析和试验验证。结果表明，改进后排气管的低周疲劳寿命提高至3000次以上，改进方案有效，为后续排气管结构设计以及可靠性研究提供参考。

关键词：排气管；裂纹；流固耦合；低周疲劳

The low cycle thermal fatigue analysis of exhaust pipe based on fluidsolid coupling method

SUN Jingjing1,2, MA Qingzhen1,2, LI Liansheng1,2, WANG Baojun1,2

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

Abstract:Based on the fluidsolid coupling method, finite element analysis software is used to calculate and analyze the temperature field, stress field and low cycle thermal fatigue of the high nickel cast iron exhaust pipe of a sixcylinder engine. The calculation results show that the large area of the stress amplitude of the exhaust pipe and the low fatigue life area of the low cycle fatigue calculation are consistent with the crack fault location during the test；the larger plastic strain caused by larger stress amplitude is the main cause of exhaust pipe thermal fatigue under cold and hot shock condition. The exhaust pipe structure is improved by removed the stiffener near the supercharger flange and thinned the supercharger flange. The simulation analysis and test verification of the improvement scheme are carried out. The results show that the low cycle fatigue life of all parts of the improved exhaust pipe is increased to more than 3000 times, and the improvement scheme is effective, which provides a reference for the subsequent exhaust pipe structure design and reliability research.

Keywords: exhaust pipe; crack; fluidsolid coupling; low cycle fatigue

280型柴油机活塞接触压应力及磨损分析

任明广，宋相明，刘国栋

潍柴动力股份有限公司，山东潍坊261061

摘要：研究280型柴油机活塞的接触压应力分布规律及磨损模式，为在设计阶段采取减小活塞磨损、提高活塞运行稳定性的措施提供依据。在确定活塞的机械负荷、换热系数和温度等边界条件的基础上，使用Abaqus软件计算得出280型柴油机活塞主推力面、次推力面以及支撑面的接触压应力及磨损模式。仿真结果表明：活塞各部位最大接触压应力都在材料强度的许可范围之内，磨损模式显示活塞裙部主推力面的中上部位置和外支撑面的外边缘为磨损最严重的部位。800 h耐久试验后拆解发现，活塞磨损模式与仿真结果拟合度达到90%以上。

关键词：活塞;接触压应力;磨损模式

Analysis of contact pressure and wear on piston of 280 diesel engine

REN Mingguang, SONG Xiangming, LIU Guodong

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

Abstract:The contact stress and wear pattern of 280 Diesel engine piston are studied, which provides the basis for reducing the piston wear and improving the stability of piston operation in the design stage. On the basis of determining the boundary conditions such as mechanical load, heat transfer coefficient and temperature of piston, the contact pressure stress and wear pattern of main thrust surface, secondary thrust surface and supporting surface of 280 Diesel engine piston are calculated by Abaqus software. The simulation results show that the maximum contact compressive stress of each part of the piston is within the allowable range of material strength, and the wear pattern shows that the middle and upper part of the main thrust surface of the piston skirt and the outer edge of the outer support surface are the most seriously worn parts. After 800 h durability test, it is found that the fitting degree between piston wear pattern and simulation result is more than 90%.

Keywords: piston; contact pressure; wear pattern

高强化船用柴油机组合活塞裙部型面设计与验证

王星全1,2,张俊青1,2,徐涛1,2,王占宜1,2,夏金宝1,2，张新超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：以某高强化船用柴油机钢顶铁裙组合活塞为研究对象，分析活塞裙部型面的纵向中凸曲线和横向椭圆设计过程，运用有限元分析软件研究不同设计方案的活塞裙部接触压力分布并进行优化，通过合理调整不同位置的横向椭圆的椭圆度及修正系数得到最优方案，并对优化设计的活塞装机进行台架试验。研究结果表明：采用横向二次椭圆和纵向中凸曲线设计时活塞裙部的接触位置及接触压力更合理；经装机试验验证，活塞裙部与缸套的贴合较好，无异常磨损等现象，达到预期设计目标。

关键词：船用柴油机；组合活塞；裙部型面

Design and verification of skirt profile of combined piston for enhanced marine diesel engine

WANG Xingquan1,2， ZHANG Junqing1,2， XU Tao1,2，

WANG Zhanyi1,2， XIA Jinbao1,2， ZHANG Xinchao1,2

1.Binzhou Bohai Piston Co., Ltd.， Binzhou 256602, China;2.Shaodong Province Key Laboratory of Engine Piston Cylinder Kites, Binzhou 256602, China

Abstract:The design process of the longitudinal convex curve and the transverse ellipse of the piston skirt profile have been studied in detail on a combined piston with steel head and iron skirt, which is designed for dieseldriven offshore ship. The contact pressure distributions of different design schemes are analyzed and optimized by using the finite element analysis software.The optimal scheme is obtained by reasonably adjusting the ovality and correction coefficient of the transverse ellipse at different positions,and the bench test of the optimized piston machine is carried out. The results show that the contact position and pressure of piston skirt are more reasonable when the design is based on transverse quadratic ellipse and longitudinal convex curve, the fit between piston skirt and cylinder liner is good, and there is no abnormal wear and so on, which achieves the design goal.

Keywords:marine diesel; combined piston; skirt profile

无静态泄漏共轨喷油器性能分析及优化

高怡，吴小军，陈小欢，奚星，孙树平，顾娇娇，李春晖

中国北方发动机研究所（天津），天津300400

摘要：基于AMESim平台建立无静态泄漏共轨喷油器性能分析模型，以提高共轨喷油器喷油速率和降低喷油器高压燃油损失为目标，开展无静态泄漏共轨喷油器的研究，并与静态泄漏共轨喷油器进行对比分析。研究表明：结构参数相同时，无静态泄漏共轨喷油器的平均喷油速率和有效喷油量效率均比静态泄漏有所提高，但无静态泄漏喷油器的最高喷油速率处于整个喷油持续期的前中阶段。通过增大回油量孔直径，减小进油量孔直径、控制柱塞直径及针阀密封座面直径等优化设计，使最大喷油速率提高了18%，且喷油持续期中最高喷油速率后移了0.15 ms，在保持回油量基本不变的情况下，提高了喷油器的有效喷油量效率。

关键词：共轨喷油器；静态泄漏；喷油速率；性能优化

The performance analysis and optimization of a common rail injector without static leakage

GAO Yi, WU Xiaojun, CHEN Xiaohuan, XI Xing,

SUN Shuping, GU Jiaojiao, LI Chunhui

China North Engine Research Institute, Tianjin 300400, China

Abstract:Based on the AMESim platform, the model of the common rail injector without static leakage is established. In order to improve the injection rate and reduce the high pressure fuel loss of the injector, the research of the common rail injector without static leakage is carried out. Compared with the static leakage common rail injector, the results show that the average fuel injection rate and the effective fuel injection efficiency of the new injector are higher than that of tradional injector when the structural parameters are the same. However, the maximum fuel injection rate of the injector without static leakage is in the middle and early stage of the whole fuel injection duration. By increasing the oil return hole, reducing the diameter of the feed hole, controlling the diameter of the plunger and the diameter of the sealing seat of the needle valve, the maximum fuel injection rate is increased by 18%, and the maximum fuel injection rate is moved back 0.15 ms, while the return oil quantity is basically unchanged, the effective fuel injection efficiency of the injector is improved.

Keywords:common rail injector; static leakage; injection rate; performance optimization

某发电柴油机挺柱底面龟裂失效分析

李康宁1,2，王刚1,2，陈广茂1,2，于健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：采用宏观分析、扫描电镜分析、金相分析、硬度分析及仿真分析等方法，对龟裂挺柱进行失效分析，挺柱材料成分、表面硬度及渗碳层深度符合设计要求，表层及基体组织正常，挺柱底面磨削时进给量过大，导致挺柱底面及内部温度过高，在冷却时产生热应力，进而产生原始裂纹。原始裂纹在挺柱底面与凸轮轴接触运行过程中进一步扩展形成麻点及龟裂。通过对挺柱工艺进行优化，合理预留磨削量，并减小磨削速度，对磨削区进行充分冷却，新批次挺柱底面未产生裂纹，故障消除。

关键词：柴油机；挺柱；磨削裂纹；失效分析

Failure analysis of tappet bottom crack of generator diesel engine

LI Kangning1,2, WANG Gang1,2, CHEN Guangmao1,2, YU Jian1,2

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

Abstract:An investigation is made on the tappet of a generator diesel engine. The morphology of cracks, microstructure, chemical composition, hardness as well as contact stress are performed by stereomicroscope, scanning electron microscopy, optical microscopy, hardometer and finite element software, respectively. The experimental results show that the chemical composition and the hardness value of the tappet reach the technique requirement. Excessive grinding is the main cause of the original crack, and the original crack expanded during the running period, dots and cracks are generated. Optimizing the manufacturing process by reducing the grinding amount and rate, and improving cooling efficiency, the production problem of tappet is solved perfectly.

Keywords:diesel engine; tappet; grinding crack; failure analysis

某型号牵引车冷却模块匹配计算方法

耿国芳1,2，陈月春1,2，李素婷3，王兴元1,2，张小田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；3.潍柴动力空气净化科技有限公司，山东潍坊261061

摘要：为缩短牵引车用冷却模块匹配选型时间，提出一种牵引车用冷却模块匹配计算方法。以某型号牵引车为计算原型，对由中冷器、散热器和风扇组成的牵引车用冷却模块进行匹配计算，并通过整车转毂热平衡试验检验计算方法的准确性。整车转毂热平衡试验结果表明：本文中提出的冷却模块匹配计算方法能成功预测冷却模块的冷却能力，整车实车试验与理论计算结果相符，计算方法能够为实际应用中改善冷却系统的性能提供指导，提升冷却模块的匹配效率。

关键词：整车；冷却模块；热平衡；匹配计算

A matching calculation method for cooling module of a truck

GENG Guofang1,2， CHEN Yuechun1,2， LI Suting3，

WANG Xingyuan1,2， ZHANG Xiaotian1,2

1. State Key Laboratory of Engine Reliability, Weifang 261061，China; 2.Weichai Power Co.,Ltd.，Weifang 261061，China;3.Weichai Power Emissions Solutions Technology Co.,Ltd.，Weifang 261061，China

Abstract:To shorten the time of tractor with cooling module matching selection, a tractor with cooling module matching calculation method is proposed. Based on a type tractor for calculating, the composed of cold, radiator and fan tractor with cooling module matching calculation, and the calculation are verified by the vehicle transfer hub heat balance test method the accuracy of the matching of the cooling module. The results of the heat balance test of the vehicle hub show that the cooling module matching calculation method proposed in this paper can successfully predict the cooling capacity of the cooling module, and the test results of the vehicle in real vehicle are consistent with the theoretical calculation results. The calculation method can provide guidance for improving the performance of the cooling system and improve the matching efficiency of the cooling module.

Keywords: vehicle; cooling module; thermal equilibrium; matching calculation

某轻型柴油机辅助制动系统开发

周兆鹏1,2，丁晓辉1,2，王慧1,2，李超1,2，杨文钊1,2,安学慧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：为某轻型柴油机开发蝶阀排气制动辅助系统，通过仿真计算得到不同排气背压下的发动机制动功率，根据整车参数对整车需求制动功率进行仿真计算，综合考虑各种配套车型发动机制动功率需求，确定所需排气背压。通过发动机台架试验及整车性能试验验证，确认辅助制动性能满足制动系统技术标准要求；进行500 h耐久试验，验证了整车制动可靠性，结果表明开发的辅助制动系统满足性能及可靠性使用要求。

关键词：轻型柴油机；制动功率；可靠性

Development of auxiliary brake for a light diesel engine

ZHOU Zhaopeng1,2， DING Xiaohui1,2， WANG Hui1,2，

LI Chao1,2， YANG Wenzhao1,2, AN Xuehui1,2

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

Abstract:The butterfly valve exhaust brake auxiliary system is developed for a light diesel engine. The relevant brake technology standards in China are studied, and the development direction is defined. The engine brake power under different exhaust back pressure is obtained through simulation calculation. According to the vehicle parameters, the vehicle brake power demand is simulated, and the engine brake power demand of various supporting models is comprehensively considered to determine the required exhaust power. The air back pressure is 260 kPa. Through the engine bench test and vehicle function test verification, it is confirmed that the auxiliary braking performance meets the technical standard requirements of the braking system; through the 500 h durability test, the development results meet the performance and reliability requirements.

Keywords:light duty diesel engine; braking power; reliability