不同发动机热力损失角测试及影响

吉一平1，冷泠2，汤旭阳2，石磊2*

1.四川航天中瑞建设工程有限公司，四川成都610213;2.上海交通大学动力机械与工程教育部重点实验室，上海200240

摘要：在D6114车用柴油机上进行上止点位移测试及基于压缩压力的上止点位置计算，分析各种方法测量误差及发动机运行条件对上止点位置的影响规律，对理想多变指数比对法和绝热压力修正法两种方法进行校核计算；进一步开展车用柴油机、车用汽油机和船用中速柴油机3种不同类型发动机的热力损失角测试与估算研究，确定不同机型热力损失角范围。结果表明：采用两种方法都可以较好地预测车用柴油机热力损失角，上止点曲轴转角测试误差不超过02°，其中绝热压力修正法计算更简单直接；车用柴油机的热力损失角较大，车用汽油机次之，而船用中速柴油机的热力损失角最小，并且受转速变化的影响较小。

关键词：上止点；热力损失角；传热损失

Test of the thermal loss angle on different kinds of engine and its influence

JI Yiping1， LENG Ling2， TANG Xuyang2， SHI Lei2*

1. Sichuan Aerospace Zhongrui Construction Engineering Co., Ltd.，Chengdu 610213，China;2. Key Laboratory for Power Machinery and Engineering of Ministry of Education，Shanghai Jiao Tong University,Shanghai 200240，China

Abstract:The top dead center (TDC) position measurement and the calculation of TDC position based on compression pressure are carried out on D6114 vehicle diesel engine.Based on the error analysis of different measurements and the effects of engine operating conditions on TDC position，different thermal loss angle (TLA) methods between ideal multiple index comparison method and adiabatic pressure correction method are compared,and the TLA test and estimation of three different types of engines，including vehicle diesel engine，vehicle gasoline engine and marine medium speed diesel， are further carried out.The range of TLA calculated by different models is compared.The results show that the TLA of vehicle diesel engine can be well predicted and the test error of TDC is within 0.2°，and the adiabatic pressure correction method is simpler and more direct. The TLA of vehicle diesel is larger than that of vehicle gasoline engine, and the TLA of marine medium speed diesel is the smallest, which is less affected engine speed.

Keywords:top dead center;thermal loss angle;heat loss

永磁活塞机械-电力发动机额定工况的动力特性

梁震1，张洪信1*，赵清海2，孙芸1

1.青岛大学机电工程学院，山东青岛266071；2.青岛大学动力集成及储能系统工程技术中心，山东青岛266071

摘要：基于传统的活塞式内燃发电机组，设计一种新型动力装置——永磁活塞机械-电力发动机，对其动子组件建立发动机系统动力学模型和电动力学模型，通过编程和有限元建模，对额定工况（曲轴转速为3600 r/min）下的静磁场特性、空载特性和负载特性进行仿真分析，得到空载感应电动势、负载电流电压、电磁推力、额定输出功率和损耗等。结果显示，额定工况下机械输出功率为3 660.224 W，输出转矩为9.71 N·m，由于电磁损耗，比原发动机的机械输出功率（3700 W）和输出转矩（9.82 N·m）略有减少，但不影响正常工作。该新型动力装置不仅输出机械动力，还增加了电动力输出，电输出功率为20.33 W，达到双元动力输出，验证了该新型动力装置结构的可行性。

关键词：发动机；直线发电机；动力学模型；Maxwell；输出功率

Dynamic characteristics of permanent magnet piston mechanicalelectric engine under rated working condition

LIANG Zhen1, ZHANG Hongxin1, ZHAO Qinghai2, SUN Yun1

1. School of Electromechanical Engineering, Qingdao University, Qingdao 266071 China；2. Power Integration and Energy Storage Systems Engineering Technology Center, Qingdao University, Qingdao 266071 China

Abstract:The permanent magnet piston mechanicalelectric engine is composed of a piston type internal combustion engine and a linear generator to achieve the purpose of outputting both mechanical energy and electrical energy. The system dynamics model and electrodynamics model of the engine are established. Through programming and finite element analysis, the static magnetic field characteristics, nonload characteristics, load characteristics under rated operating conditions (the crankshaft speed is 3600 r/min) have been simulated and analyzed. It is calculated that the mechanical output power of the newtype engine is 3660.224 W and the output torque is 9.71 N·m under rated conditions, while the mechanical output power of the original engine is 3700 W and the output torque is 9.82 N·m. The comparison between the two engines shows that due to the effect of electric power, the mechanical output power and torque of the newtype engine are only slightly reduced, and normal operation is not affected. However, the newtype engine has increased electric power output, and the electric output power is 20.33 W, achieving dual power output, which verifies the feasibility of the newtype engine structure.

Keywords:engine; linear generator; dynamic model; Maxwell; output power

动力电池二次利用关键参数识别研究综述

王兴华1，兰欣1*，李祥瑞1，苏丽娜2

1.山东大学能源与动力工程学院，山东济南250061；2.山东天岳先进科技股份有限公司，山东济南250118

摘要：利用参数识别技术对退役动力电池进行分选，实现退役电池的二次利用。研究二次利用前动力电池的性能状况，对电池的剩余容量、剩余寿命、电池的荷电状态（state of charge, SOC）、电荷健康度（state of health，SOH）等影响电池性能的参数进行识别，并根据获取的相关数据来评估退役电池组当前状态下的性能，预测电池的剩余寿命，为动力电池二次利用的参数识别提供理论依据。

关键词：动力电池；二次利用；参数识别；SOC；SOH

Study on key parameters identification of power battery secondary utilization

WANG Xinghua1, LAN Xin1*, LI Xiangrui1, SU Lina2

1. School of Energy and Power Engineering, Shandong University, Jinan 250061, China；2. Shandong Tian Yue Advanced Technology Co., Ltd., Jinan 250118, China

Abstract:In order to use the parameter identification technology to sort the retired batteries and realize the secondary utilization of batteries, the performance of the retired power battery such as residual capacity, residual life, SOC, SOH and others are identified by appropriate technical method. The performance of retired batteries under the current state is evaluated according to the relevant data obtained, which provides theoretical basis for parameter identification of secondary utilization of power batteries.

Keywords:power battery; secondary utilization; parameter identification

国六天然气发动机排放技术方案分析

张腾1,2，贾红杰1，韩文涛1*，王林波1，王磊1，刘近报1

1.潍柴动力股份有限公司，山东潍坊261061；2. 潍柴西港新能源动力有限公司，山东潍坊261061

摘要：分析天然气发动机尾气中污染物控制方法，对比天然气发动机满足国六排放标准不同排放技术方案的优缺点，确定理论空燃比-三元催化-废气再循环技术方案是当前天然气发动机排放的最优技术方案。通过发动机台架进行冷、热态全球统一态测试循环（world harmoized transient cycle,WHTC)排放试验以及实际道路排放测试进行验证，结果表明使用该技术方案的天然气发动机污染物排放量满足国六排放标准的限值要求。

关键词：天然气发动机；国六排放标准；WHTC;技术方案

Analysis on emission technologies of CHINA VI nature gas engine

ZHANG Teng1,2, JIA Hongjie1, HAN Wentao1*, WANG Linbo1, WANG Lei1, LIU Jinbao1

1. Weichai Power Co., Ltd., Weifang 261061, China; 2. Weichai Westport Co., Ltd., Weifang 261061, China

Abstract:The control methods of pollutants in the exhaust gas of natural gas engine are analyzed, the advantages and disadvantages of different emission technical routes for natural gas engines meeting the CHINA VI emission regulations are compared, then the current optimal technical route of natural gas engines is obtained: theoretical airfuel ratio +EGR+TWC. The hot and cold WHTC emission test and the real road driven emission are carried out. The results show that the emission of pollutants in this route can meet the requirements of CHINA VI emission regulation.

Keywords:natural gas engine; CHINA VI emission standards; emission technology

大缸径船用柴油机曲轴复合圆角结构分析与优化

邰强娟1，徐志远2，柳海涛2 ，李继光2，王厚权2，张琳琳1

1.潍柴动力股份有限公司，山东潍坊261061; 2.潍柴重机股份有限公司，山东潍坊261108

摘要：为提升大缸径船用柴油机曲轴圆角疲劳安全系数，以现有某机型曲轴系模型为基础，利用AVl-PU软件对该机型曲轴圆角疲劳安全系数进行仿真计算，其疲劳安全系数仅为0.974，不满足大于1.05的许用限值要求；基于现有计算结果，优化曲轴复合圆角结构，设计不同的复合圆角方案，并进行仿真对比计算。结果表明：优化后圆角最小疲劳安全系数为1.064，满足限值要求。

关键词：大缸径；柴油机；复合圆角；仿真分析

Analysis of composite fillet structure of crankshaft for large marine diesel engine and its optimization

TAI Qiangjuan1, XU Zhiyuan2, LIU Haitao2, LI Jiguang2,WANG Houquan2, ZHANG Linlin1

1.Weichai Power Co.,Ltd.,Weifang 261061,China;2.Weichai Heavy Machinery Co.,Ltd.,Weifang 261108,China

Abstract:In order to improve the safety factor of crankshaft fillet fatigue of large cylinder diameter marine diesel engine,the crankshaft system model is built and AVL-PU software is used for fatigue calculation.It shows that the fatigue safety coefficient is only 0.974,which can not meet the required value 1.05.Based on the existing calculation results,the optimized structure of the crankshaft fillet is proposed,different compound fillet projects are designed, and the simulation and comparison calculation are carried out.The results show that the minimum fatigue safety factor of the optimized compound fillet is 1.064,which meets the required value.

Keywords:large cylinder diameter;diesel engine;compound fillet;simulation analysis

涡轮增压器轴向力分析与止推轴承承载力评估

张健健1，2，马敏1，2，李伟1,3，王孝丽1，2

1.康跃科技（山东）有限公司，山东寿光262718；2.机械工业内燃机增压系统重点实验室，山东寿光262718；3.山东大学能源与动力工程学院,山东济南250061

摘要：为研究涡轮增压器止推轴承评估及选用方法，利用数值模拟建立某型号涡轮增压器的有限元模型，使用NUMECA软件对涡轮增压器轴向力进行分析，将轴向力结果输入DyRoBeS，计算止推轴承不同油楔面下的油膜厚度，选择承载能力满足要求的止推轴承，并进行压气机性能试验。结果表明：压比的仿真计算与试验结果基本一致，在低速工况下重合性较好，高速工况下最大误差小于1%；效率的仿真计算结果较试验略低，误差范围为0.5%~2.0%，但仿真与试验的总体趋势一致，在小流量范围内误差更小。该方法能够在增压器初步配试阶段较精确地选择止推轴承，提高整机可靠性。

关键词：涡轮增压器；止推轴承；轴向力；油楔面

Analysis of axial force and evaluation of bearing capacity of thrust bearing for a turbocharger

ZHANG Jianjian1,2, MA Min1,2, LI Wei1,3, WANG Xiaoli1,2

1.Kangyue Technology(Shandong) Co., Ltd.,Shouguang 262718, China;2. Key Laboratory of Turbocharging system of Machinery industry, Shouguang 262718, China;3. School of Energy and Power Engineering, Shandong University, Jinan 250061, China

Abstract:In order to study the evaluation and selection method of turbocharger thrust bearing, the finite element model of a turbocharger is established by using numerical simulation, then the axial force of turbocharger is calculated by NUMECA software. The results are passed into DyRoBeS to calculate the oil film thickness under different oil wedges, the suitable thrust bearing which the load capacity meet the requirements are chosen, and the performance test of turbocharge is carried out.The results show that the pressure ratio calculated with simulation is basically consistent with the tests,the coincidence is better at low speed,and the maximum deviation is within 1% at high speed;the calculated efficiency is a little lower than the test and the deviation range is between 0.5%-2%, but the overall trend of simulation efficiency is consistent with the measured efficiency, and the deviation is less in the small flow range. This method can accurately select the thrust bearing in the preliminary matching test stage and improve the reliability of turbocharger.

Keywords:turbocharger; thrust bearing; axial force; oil wedge

轻便轴承对增压器机械效率及发动机加速性能的影响

李伟1，2，李国祥1，白书战1，桑梧海2，孙金辉2，刘莹2，张晓林2,3，韩霏2,3

1.山东大学能源与动力工程学院，山东济南250061；2.康跃科技股份有限公司，山东寿光262718；3.机械工业内燃机增压系统重点实验室，山东寿光262718

摘要：为改善涡轮增压器机械效率及发动机加速性能，分析原轴承系统和轻便轴承系统的旋转部件质量及转动惯量，试验研究原轴承系统和轻便轴承系统的机械效率及发动机加速性能。结果表明：与原轴承系统相比,增压器转速为60 000～80 000 r/min时，轻便轴承系统机械效率改善2.73%～8.08%；增压器转速为60 000～140 000 r/min时，轻便轴承系统润滑油流量减少37.44%～46.75%；发动机带载加速试验及发动机自由加速试验表明，轻便轴承系统加速时间分别减少7.7%和117%。因此,轻便轴承系统可以改善增压器低速段机械效率、发动机加速性能及低速扭矩，是增压器的发展方向。

关键词：涡轮增压器；机械效率；加速性能；转动惯量；轻便轴承系统

The influence of lightweight bearing system on mechanical efficiency of turbocharger and acceleration performance of engine

LI Wei1，2, LI Guoxiang1, BAI Shuzhan1, SANG Wuhai2,SUN Jinhui2, LIU Ying2, ZHANG Xiaolin2,3, HAN Fei2,3

1. School of Energy and Power Engineering, Shandong University, Jinan 250061, China; 2. Kangyue Technology Co., Ltd., Shouguang 262718, China;3. Key Laboratory of Turbocharging System of Machinery Industry, Shouguang 262718, China

Abstract:In order to improve the mechanical efficiency of the turbocharger and acceleration performance of the engine ,the mass and inertia of the rotating parts of the original bearing system and the lightweight bearing system are analyzed, and the mechanical efficiency and engine acceleration performance of the original bearing system and the lightweight bearing system are experimentally studied.The results show that when the speed of the turbocharger is 60 000-80 000 r/min, the mechanical efficiency of the lightweight bearing system increases by 2.73%-8.08%;when the speed of the turbocharger is 60 000-140 000 r/min, the lubricating oil flow of the lightweight bearing system decreases by 37.44%-46.75%;the acceleration time of lightweight bearing system is reduced by 7.7% and 11.7% respectively in the engine acceleration test with load and engine free acceleration test. The study shows that lightweight bearing system can improve the turbocharger′s mechanical efficiency, engine acceleration performance and low speed torque, it is the development direction of the turbocharger.

Keywords:turbocharger;mechanical efficiency;acceleration performance;moment of inertia;lightweight bearing system

某型柴油机换热器设计及仿真分析

韩荣，蒋炎坤*，陈烨欣

华中科技大学能源与动力工程学院，湖北武汉430074

摘要：设计独立的换热器，降低水下工作柴油机中高负荷工况的排气温度。运用SolidWorks建立换热器模型并进行仿真分析，研究圆柱形换热器4种换热管布置方式对换热器温降与压损的影响。分析结果表明：设计的换热器可将排气温度由550.00 ℃降低到161.94 ℃，废气在换热器中的压损为5.95 kPa，降温效果和压损均满足相关工程要求；换热管管径和管心距不变，正三角形和转角三角形布置方式的换热器换热管数量较多，换热面积较大，换热效果较好，其中正三角形布置方式换热器的换热效果更好，但压损更高。本研究可为水下动力装置排气降温系统设计提供参考。

关键词：柴油机；排气降温系统；管壳式换热器；结构设计；流体仿真

Design and simulation analysis of heat exchanger for a diesel engine

HAN Rong, JIANG Yankun*, CHEN Yexin

School of Energy and Power Engineering，Huazhong University of Science and Technology，Wuhan 430074,China

Abstract:To reduce the exhaust temperature during high load operation in a underwater diesel engine, a separate heat exchanger is designed. The heat exchanger is modeled using SolidWorks and simulated using CFD technology. The effect of four heat exchanger tube arrangements on the temperature drop and pressure loss of the heat exchanger is investigated. The results show that the designed heat exchanger can reduce the exhaust gas temperature from 55000 ℃ to 16194 ℃, the pressure loss of exhaust gas in the heat exchanger is 595 kPa, the temperature reduction and pressure loss meet the relevant engineering requirements. It is also shown that more tubes could be mounted without changing the heat exchanger tube diameter and tube centre distance for the square triangle and corner triangle arrangement of the heat exchanger,the heat transfer area is larger and the heat transfer effect is better.In contrast to the corner triangle arrangement, the square triangle arrangement has a better heat transfer coefficient, but a higher pressure loss. This study can provide a reference for the design of exhaust cooling systems for underwater power plants.

Keywords:diesel engine;exhaust cooling system; shell and tube heat exchanger; structural design; fluid simulation

某型柴油机高压油管断裂失效分析及改进

李杰1，姜明文2

1.潍柴动力扬州柴油机有限责任公司技术中心，江苏扬州225000；2.扬州中远海运重工有限公司技术中心，江苏扬州225000

摘要：为解决某型柴油机高压油管漏油率较高问题，分析故障油管断裂部位、断口形貌特征、金相组织、振动测试结果及受力，确定高压油管断裂的主要原因为墩头及过渡区域设计不合理，导致其疲劳破坏而发生脆性断裂；优化高压油管结构与管型，改进管夹布置方式，增加油管稳定性；改进油管镦头尾部结构，增大锁紧螺母与镦头贴合面装配应力。振动及耐久试验证结果表明：改进后的高压油管平均破坏循环次数提高70.94%，满足疲劳寿命要求，改进方案有效，并成功应用于市场。

关键词：柴油机；高压油管；断裂

Failure analysis of highpressure pipe for a diesel engine and its improvement

LI Jie1, JIANG Mingwen2

1. R&D Center,Weichai Power Yangzhou Diesel Engine Co.,Ltd.,Yangzhou 225000,China；2. R&D Center,Cosco Shipping Heavy Industry Co.,Ltd.,Yangzhou 225000,China

Abstract:In order to solve the problem of a high fuel leakage rate of the high pressure pipe of a diesel engine, fracture location,fracture surface morphology and metallographic, the vibration and the stress are investigated. The results show that the fracture is caused by unreasonable design of the pipe heading joint which leads to fatigue failure and brittle fracture. The structure and pipe type of highpressure tubing are optimized, the arrangement of pipe clips is improved, and the stability of tubing is increased;the structure of upsetting head tail is improved, and the assembly stress between locking nut and upsetting head is increased.The results of vibration and durability test show the average number of failure cycles of the improved high pressure tubing is increased by 70.94%, which meets the requirements of fatigue life,and the improved scheme is effective and the pipe is successfully applied to the market.

Keywords:diesel engine; high pressure fuel pipe;fracture

收割机用柴油机输出端异响分析与设计优化

史文献1,3，张军1,2，张悦3，李岩1,3

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.潍柴动力扬州柴油机有限责任公司， 江苏扬州225009

摘要：采用频谱分析、模态仿真与测试对某收割机用轻型柴油机离合器分离时各转速下存在的异响进行分析，确定噪声异响源为离合器外齿圈撞击柴油机飞轮内齿圈引起飞轮结构共振产生的表面辐射噪声。从噪声激励源、传递路径以及结构响应3方面进行系统分析，采取优化柴油机燃烧激励、增大飞轮刚度降低结构响应、增厚挡板并加密封吸音棉等改进措施。试验表明改进方案降噪效果非常明显。

关键词：异响；频谱分析；模态仿真；模态测试；传递路径分析

Abnormal noise analysis and optimal design of diesel engine output for harvester

SHI Wenxian1,3, ZHANG Jun1,2, ZHANG Yue3, LI Yan1,3

1.State Key Laboratory of Engine Reliability, Weifang 261061, China;2.Weichai Power Co., Ltd., Weifang 261061, China;3.Weichai Power Yangzhou Diesel Engine Co., Ltd., Yangzhou 225009, China

Abstract:The abnormal noise of a light diesel engine clutch used in a harvester at different speeds is analyzed by means of spectrum analysis, modal simulation and testing. The reason of abnormal noise is ascertained that the outer gear ring of clutch hints the inner gear ring of the flywheel of engine, which cause the resonance of the flywheel structure. On this basis, the noise excitation source, transfer path and structural response are systematically analyzed. Some improvement measures are taken, such as combustion optimization, increasing flywheel stiffness to reduce structural response, thickening baffle and adding sealed soundabsorbing cotton. The experimental results show that the improved scheme is very effective in noise reduction.

Keywords:abnormal noise; spectrum analysis; modal simulation; modal test; transfer path analysis

增大压缩比对国六柴油机性能的影响

陈香春1,2，高慎勇1,2，高莹1,2，吕晓惠1,2，张凌宏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：通过理论分析和试验验证，研究增大压缩比对国六增压柴油机不同负荷工况点燃油消耗率的影响规律和对后处理系统性能的影响。结果表明:增大压缩比可降低柴油机的燃油消耗率；在使用进气节流阀导致进气管压力低于环境压力的情况下，能够提供足够高的缸内压缩压力，但同时会导致排气温度降低，影响颗粒捕集器再生效率。

关键词：压缩比；国六柴油机；后处理；柴油机性能

The influence of increasing compression ratio on the performance of CHINA VI diesel engine

CHEN Xiangchun1,2, GAO Shenyong1,2, GAO Ying1,2,

L Xiaohui1,2, ZHANG Linghong1,2

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

Abstract:Through theoretical analysis and experimental verification, the influence of increasing compression ratio on the fuel consumption rate at different load conditions and the performance of aftertreatment system of CHINA Ⅵ turbocharged diesel engine are studied. The results show that increasing the compression ratio can reduce the fuel consumption of diesel engine, especially when the intake pipe pressure is lower than the ambient pressure due to the use of intake throttle valve, it can provide higher compression pressure. But it will reduce the exhaust temperature and affect the regeneration efficiency of particulate filter.

Keywords:compression ratio；CHINA VI diesel engine；exhaust after treatment system，diesel engine performance

某型号柴油机低温起动性能优化

陈月春1,2，李兰菊1,2，王霞1,2，李素婷3

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；3. 潍柴动力空气净化科技有限公司，山东潍坊261061

摘要：基于缸内燃烧理论对某型号柴油机低温起动困难问题进行分析，提出提高压缩比、采取不同进气加热方式、优化气门间隙3种措施提升缸内温度，并对改进后柴油机开展低温起动性能对比试验。结果表明：采用高压缩比可明显提升缸内压缩温度，利于改善低温起动性能；分缸加热可明显提升进气温度，相同加热时间下，分缸加热比格栅加热进气温度提升约53 ℃；气门间隙优化仅能小幅度提升缸内温度，对柴油机起动性能无明显改善。提高进气温度对提升柴油机低温起动性能有利，但小幅度提升缸内压缩温度并不能明显改善柴油机低温起动性能。

关键词：低温起动；柴油机；压缩比

Optimal design of starting performance of diesel engine at low temperature

CHEN Yuechun1,2, LI Lanju1,2, WANG Xia1,2, LI Suting3

1. State Key Laboratory of Engine Reliability, Weifang 261061, China;2. R & D Center, Weichai Power Co., Ltd., Weifang 261061, China;3. Weichai Power Emission Solutions Technology, Weifang 261061 China

Abstract:Based on the theory of combustion, the problem of low temperature staring for a diesel engine is investigated. Three schemes are proposed to increase the cylinder temperature, including increasing the compression ratio, adopting different intake heating methods and optimizing the valve clearance. The experimental results show that the high compression ratio can obviously increase the temperature in the cylinder, which improves the low temperature staring performance. Different intake heating methods can improve the intake temperature, the independent heating methods shows 53 ℃ higher than grid heating in the same time. The clearance optimization of the valve can improve the temperature in the cylinder slightly, but the starting performance of the diesel engine is not significantly improved. Therefore, the increase of intake temperature is beneficial for the low temperature staring performance of diesel engine, but it is not obvious to improve the low temperature starting performance of diesel engine.

Keywords:low temperature starting; diesel engine; compression ratio

某发动机前端轮系张紧器异响分析及改进

樊小欢1，刘刚1，杨汶坪1，周新伟2

1.重庆长安汽车股份有限公司动力研究院，重庆400023；2.盖茨集团（上海）有限公司，上海200335

摘要：针对某发动机前端轮系张紧器在特定转速下的异响问题，通过仿真与试验,分析异响产生原因并进行结构优化。对张紧器进行模态仿真分析，发现张紧器螺旋弹簧的一阶轴向伸缩变形模态频率为347 Hz，与理论计算的异响转速相关频率（344 Hz）非常接近。拆解发生异响的张紧器，发现张紧器第二圈弹簧与壳体底部卡槽凸台发生干涉，产生摩擦噪声。设计优化方案并进行可靠性试验验证，试验结果表明：卡槽凸台高度降低1 mm，可有效降低异响噪声。

关键词：张紧器；异响；模态；共振

Analysis of abnormal noise of an engine belt tensioner and its improvement

FAN Xiaohuan1, LIU Gang1, YANG Wenping1, ZHOU Xinwei2

1. Power Research Institute of Chongqing Chang′an Automobile Co., Ltd.，Chongqing 400023，China；2. Gates group (Shanghai) Co., Ltd.，Shanghai 200335，China

Abstract:Aiming at the abnormal noise problem at certain speeds of frontend belt tensioner，the causes of the abnormal noise are analyzed through simulation and test, and the structure is optimized. The modal analysis of the tensioner show that the firstorder axial expansion deformation modal frequency of the tensioner coil spring is 347 Hz, which is very close to the theoretical calculation of abnormal noise frequency (344 Hz). After disassembling the fault tensioner, it is found that the second coil spring of the tensioner interferes with the groove boss at the bottom of the shell, which produces friction noise. The optimization scheme is designed and verified by reliability test. The test results show that the abnormal noise can be effectively reduced if the height of the groove boss is reduced by 1 mm.

Keywords:tensioner; abnormal noise; modal frequency; resonance

正时皮带断裂分析及改进

王睿1,2，周兆鹏1,2，杨文钊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：为解决某轻型柴油机开发过程中正时皮带磨损断裂故障，基于故障树分析法分析此次故障的产生原因，采用测量及仿真计算等方法对各原因进行分析与排除，故障原因确定为喷油泵与正时皮带的相位匹配未达到最优，导致正时错乱。提出了正时皮带相位的优化方案，发动机耐久试验结果表明优化方案有效，最优的油泵相位为+6相位。

关键词：喷油泵；正时皮带；相位；曲轴转角

Analysis of the breakage of timing belt and its improvement

WANG Rui1,2， ZHOU Zhaopeng1,2， YANG Wenzhao1,2

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

Abstract:In order to solve the wear and fracture fault of the timing belt in the development process of a lightdiesel engine, the fault tree analysis method is used to find out the reason of the fault. The experiments and simulation results show that the cause of the fault is the phase matching between the fuel injection pump and the timing belt is not optimal, which leads to the timing disorder. An improvement of the timing belt phase is proposed, and the results of durability test show that the optimized scheme is effective, and the optimal pump phase is + 6 phase.

Keywords:fuel injection pump; timing belt; phase position; crank angle

柴油机喷油泵传动轴防护罩断裂故障分析及优化

尹晓青，吴明华，康卫超，王继勇，杨金锋

潍柴重机股份有限公司，山东潍坊261108

摘要：为解决某船用柴油机喷油泵传动轴防护罩断裂故障，提升零部件可靠性，运用Hypermesh、Abaqus以及Femfat等仿真软件，对该喷油泵传动轴防护罩断裂故障产生的原因进行仿真分析。结果显示，防护罩断裂原因为一阶模态小于激振频率的1.2倍，易产生共振。在此基础上提出两种优化方案，对两种方案进行模态、强度及疲劳仿真计算。计算结果显示，在防护罩机体上多加2个M8固定螺栓，并将断裂位置处的倒角改成倒圆角后，其一阶模态大于激振频率的1.2倍，为优选方案。经试验验证，优化后的防护罩没出现断裂故障，优化方案及仿真结果正确可行。

关键词：传动轴防护罩；模态；强度；疲劳；三维仿真

Analysis and optimization of fracture fault of transmission shaft shield of diesel engine fuel injection pump

YIN Xiaoqing， WU Minghua， KANG Weichao,WANG Jiyong, YANG Jinfeng

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

Abstract:In order to solve the failure of transmission shaft shield of a marine diesel engine fuel injection pump, the modal, strength and fatigue of the fracture transmission shaft shield are calculated by Hypermesh, Abaqus and Femfat, and the causes of the failure are analyzed. The results show that the reason for the rupture of the shield is that the first mode is less than 1.2 times of the excitation frequency, which is easy to produce resonance. Two optimization schemes are proposed, and the mode, strength and fatigue of the two optimization schemes are simulated. The calculation results show that when adding two more M8 fixing bolts on the body of the protective cover and changing the chamfer at the fracture position into a fillet, the first-order mode is greater than 1.2 times of the excitation frequency, which is the optimal scheme. The test results show that the optimized shield has no fracture fault, and the optimization scheme and simulation results are correct and feasible.

Keywords:transmission shaft shield; modal; strength; fatigue; three-dimensional simulation

柴油机气缸套四点磨损分析及机体结构优化

李玉强1,2，王有治1,2，宋娇1,2，朱海燕1,2，戴雨华1,2，周涛1,2，张红雨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：针对某柴油机在耐久试验后气缸套一环上止点处四点磨损故障，对气缸套、活塞以及活塞环进行仿真分析，结果表明：热态下机体及气缸套变形过大是气缸套四点磨损的主因。采取加宽、加厚机体上顶面，机体气缸套一环位置机体主推力、副推力两侧增加横向、竖向加强筋，加厚机体支撑肩下部等改进措施提升机体刚度。仿真结果表明：新方案气缸套一环变形平均减小了16%，与气缸套接触压力更加均匀， 与气缸套间隙平均减小了78%，改善了气缸套一环处的异常磨损。

关键词：气缸套；机体；磨损；刚度

Analysis of fourpoint wear of cylinder liner and structureoptimization of diesel engine

LI Yuqiang1,2, WANG Youzhi1,2, SONG Jiao1,2, ZHU Haiyan1,2,

DAI Yuhua1,2, ZHOU Tao1,2, ZHANG Hongyu1,2

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

Abstract:In view of the fourpoint wear failure at the top and dead center of first ring of cylinder liner after durability test, the simulation analysis of cylinder liner, piston and piston ring are proposed. The results shows that the excessive deformation of cylinder liner in hot state is the main cause of fourpoint wear of cylinder liner. The improvements such as widening and thickening the upper top surface of the engine body, adding transverse and vertical reinforcement on the main thrust side and deputy thrust side of the engine body at the first ring position of the cylinder liner, thickening the lower part of the support shoulder of the engine body, are adopted to improve the rigidity of the engine body. The simulation results show that the deformation of the first ring of the cylinder liner is 16% lower than that of the original one, the contact pressure between the first ring and the cylinder liner is more uniform, and the clearance between the first ring and the cylinder liner is reduced by 78%，the abnormal wear of the first ring of the cylinder liner is improved.

Keywords:cylinder liner; engine body; wear; stiffness