基于模型预测的卡车节油驾驶控制策略

聂林同1，李军伟1*，李兴坤2，姜世腾1，阚辉玉1

1.山东理工大学交通与车辆工程学院, 山东淄博255049；

2.中寰卫星导航通信有限公司青岛分公司，山东青岛266071

摘要：为提高卡车的燃油经济性，通过模型预测控制与非线性规划相结合的方法，研究卡车节油驾驶燃油经济性预测巡航控制（predictive cruise control, PCC）系统，通过Matlab与Trucksim联合仿真对算法进行验证。结果表明，在基于真实高速公里数据建模的24 km仿真道路上，使用PCC的车辆比使用定速巡航系统（cruise control system, CCS）的车辆燃油消耗减少0.3 kg，与PCC相比,CCS更能提高卡车的燃油经济性。

关键词：节油驾驶；模型预测控制策略；卡车；Trucksim;Matlab

Control strategy of truck fuel saving driving based on model predictive control

NIE Lintong1, LI Junwei1*, LI Xingkun2, JIANG Shiteng1, KAN Huiyu1

1.School of Transportation and Vehicle Engineering, Shandong University of Technology, Zibo 255049, China;2.Qingdao Branch of China Satellite Navigation and Communications Co., Ltd., Qingdao 266071, China

Abstract:In order to improve the fuel economy of truck, the predictive cruise control (PCC) system of fuel econmy of truck fuel caving driving is studied by combining model predictive control with nonlinear programming. The algorithm is verified by Matlab and TruckSim cosimulation, and the results showed that the fuel consumption of vehicles using PCC is 0.3 kg less than that of vehicles using cruise control system (CCS) on the 24 km simulation road based on real express way data modeling. It can be seen that PCC can improve the fuel economy of trucks more than CCS.

Keywords:fuel saving driving; model predictive control strategy; truck;Trucksim; Matlab

基于有限元分析的汽油机进气歧管设计

刘猛1，祖炳锋1，徐玉梁1，白杨1，刘丽娜1，赵礼飞2

1.天津内燃机研究所，天津300072；2.安徽江淮汽车股份有限公司，安徽合肥230601

摘要：利用AVLBoost、计算流体动力学等软件对一款3.5 L自然吸气汽油机进气歧管进行正向设计，确定进气歧管长度、管径、稳压腔容积等参数，设计5种方案，分析不同进气口直径、管路走向、截面结构及进气方向对进气歧管流量系数的影响，确定最优方案为大圆弧、变截面结构，歧管长度为540 mm，管径为50 mm，稳压腔容积为3 L，进气口直径为70 mm。试验结果表明，最优方案满足发动机的性能要求，可为进气歧管的正向开发提供参考。

关键词：汽油机；进气歧管；流场分析

Intake manifold design of gasoline engine based on FEA

LIU Meng1，ZU Bingfeng1，XU Yuliang1，BAI Yang1，LIU Lina1, ZHAO Lifei2

1.Tianjin Internal Combustion Engine Research Institute，Tianjin 300072, China；

2.Anhui Jianghuai Automobile Co., Ltd.，Hefei 230601, China

Abstract:AVLBoost and CFD code are used for an intake manifold design of a 3.5 L naturally aspirated gasoline engine. The pipe length and diameter, plenum chamber volume are chosen and five schemes are designed. The influence of different inlet diameter, pipeline direction, crosssection and intake direction on the flow coefficient of the intake manifold are analyzed. The best design is large arc and variable crosssection structure, and the length of the manifold is 540 mm, the diameter of the pipe is 50 mm, the volume of the plenum chamber is 3 L, and the diameter of the air inlet is 70 mm. The test results show that the intake manifold of the best design meets the requirements of the engine. The simulation can provide a reference for intake manifold development.

Keywords:gasoline engine；intake manifold; flow field analysis

某增压直喷汽油机进气道开发

张宗澜，陈泓，林思聪，刘明嘉，杜家坤，李钰怀

广州汽车集团股份有限公司汽车工程研究院，广东广州511434

摘要：针对某2.0 L增压直喷汽油机，设计了2种进气道方案，通过试制进气道芯盒，采用气道三维粒子图像测速（threedimensional particle image velocimetry，3DPIV）试验与三维仿真相结合的方式，分析进气道性能及进气道对缸内流动的影响。结果表明：进气道切入角是气道开发的关键参数，合适的切入角可以提高进气道滚流比，燃烧室进气门遮蔽面能大幅提高小升程下的滚流比；内外切入角为0°的进气道性能更优，平均流量系数和平均滚流比分别为0.264、3.2，满足进气道性能开发目标；且与燃烧室、活塞顶匹配更好，可以获得较高的缸内瞬态滚流、湍动能及更合理的湍动能分布。

关键词：汽油机；进气道；3DPIV；滚流比；缸内流动

Development of intake port for a turbocharged direct injection gasoline engine

ZHANG Zonglan，CHEN Hong，LIN Sicong，LIU Mingjia，DU Jiakun，LI Yuhuai

Automotive Engineering Institute, Guangzhou Automobile Group Co., Ltd., Guangzhou 511434, China

Abstract:Two intake port schemes are designed for a 2.0 L turbocharged direct injection gasoline engine. In combination with intake port core box, 3DPIV test and 3D simulation are used to evaluate the performance of intake port and the influence of intake port on incylinder flow. The results show that the entry angles are key parameters in the design of intake port, appropriate entry angle improving the tumble ratio, and the shrouded surface of the inlet valve in the combustion chamber can significantly improve the tumble ratio at small valve lift. The intake port with 0° entry angle has better performance, and the average flow coefficient and average tumble ratio are 0.264 and 3.2 respectively, which is well matched with the combustion chamber and piston crown. Higher transient tumble in cylinder and turbulent kinetic energy are achieved, as well as better distribution of turbulent kinetic energy.

Keywords:gasoline engine; intake port; 3DPIV；tumble ratio；incylinder flow

柴油机可调两级增压系统调节阀流量特性

王利民1，裴海俊1，张文1，冷泠2，石磊2*

1.广西玉柴机器股份有限公司,广西玉林537005；

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：利用GTPower仿真软件建立两级增压系统WP7柴油机仿真模型，研究不同流量特性调节阀在可调两级增压系统中的工作性能，获得两级增压系统调节特性；比较不同调节阀流量特性对增压压力调节的影响，分析不同流量特性的阀门开度对增压压力有效调节范围以及全开度范围单位调节量变化规律。结果表明：不同流量特性调节阀对可调两级增压系统调节特性不同，直线型、快开型和抛物线型流量特性调节阀对增压压力的有效调节开度相对较小，可以实现对增压压力的快速调节；等百分比流量特性在全开度范围内单位调节量基本相同，在小开度下能够降低流量敏感性、提高控制精度，大开度下提升流量敏感性、提高响应快速性，可以较好地满足两级可调增压系统大跨度、高精度增压压力调节需求。

关键词：柴油机；可调两级增压系统；调节阀；流量特性；仿真

Flow characteristics of two-stage turbocharger regulating valves for diesel engine

WANG Limin1, PEI Haijun1, ZHANG Wen1, LENG Ling2,SHI Lei2*

1.Guangxi Yuchai Machinery Group Co., Ltd.,Yulin 537005,China;

2.Key Laboratory for Power Machinery and Engineering of Ministry of Education,Shanghai Jiao Tong University,Shanghai 200240,China

Abstract：The simulation model of WP7 diesel engine with twostage turbocharging system is established using GTPower software,the performance of regulating valve with different flow characteristics in adjustable twostage turbocharging system is studied.The adjustment requirements are obtained, and the influence of the flow characteristics of different regulating valves on the regulation of boost pressure is compared. The effective range of valve opening of different flow characteristics and the equalization of full open range gain are analyzed. The results show that the regulating characteristics of regulating valves with different flow characteristic are different for the adjustable twostage turbocharging system, and the effective opening of linear, fast opening and parabolic flow characteristic regulating valves for the turbocharging pressure regulation is relatively small, which can realize the rapid regulation of the turbocharging pressure.The gain of equal percentage flow characteristics in the whole range of unit regulation is basically the same,in small opening degree, the flow sensitivity can be reduced and the control accuracy can be improved,in wide opening degree, the flow sensitivity can be increased and the responsiveness can be improved,which is complementary to the control of regulated twostage turbocharging system,which can well meet the requirements of large span and high precision turbocharging pressure regulation of twostage turbocharging system.

Keywords:disiel engine;regulated twostage turbocharging system;regulating valve;flow characteristic; simulation

基于BP神经网络的喷水汽油机性能预测

王立宇，滕勤*，庄远

合肥工业大学汽车与交通工程学院，安徽合肥230009

摘要：基于反向传播（back propagation，BP）神经网络的逼近能力和自学习能力，以汽油机工况参数、状态参数和喷水控制参数为输入，分别建立多输入/单输出的点火提前角、油耗和排放预测模型；以试验设计和发动机台架的实测数据为基础构建、训练模型，用均方差评价网络训练与拟合效果；用相关系数判断输出值与目标值之间的密切程度；用决定系数和相对误差检验模型精度。结果表明:在训练、验证、测试、整体检验阶段，3种预测模型线性相关系数均大于0.8，均方差均小于0.01，决定系数都逼近于1，相对误差均小于15%，建立的模型能够较好预测喷水汽油机不同工况的性能。

关键词：喷水汽油机；性能预测；BP神经网络模型；拟合

Performance prediction of waterinjected gasoline enginebased on BP neural network

WANG Liyu, TENG Qin*, ZHUANG Yuan

School of Automotive and Transportation Engineering, Hefei University of Technology, Hefei 230009, China

Abstract:Based on the approximation and selflearning capabilities of the back propagation (BP) neural network, a multiinput/singleoutput ignition angle prediction model, a fuel consumption prediction model, and an emission prediction model are developed with gasoline engine operating parameters, condition parameters, and water injection control parameters as inputs, respectively.These models are constructed and trained by collecting the measured data of the engine frame based on the experimental design, and the training and fitting effects of the network are evaluated by correlation coefficients and mean squared errors. The influence of input and output variables are evaluated by coefficients of determination, and the accuracy of the models are checked by relative errors. The results show that the linear correlation coefficient of the three prediction models is greater than 0.8, the mean squared deviation is less than 0.01, the coefficient of determination is close to 1, and the relative error is less than 15% in the phases of training, validation, testing, and overall inspection, and the model can predict the performance of gasoline engine under different operating conditions.

Keywords:waterinjected gasoline engine；performance prediction；BP neural network model；fitting

燃气发电机组变负荷特性对分布式能源系统选型的影响

孙景阳1，胡英华2，胡勇1，胡玉平1*

1.山东大学 能源与动力工程学院，山东济南250061；

2.山推工程机械股份有限公司，山东济宁272073

摘要：为了实现分布式能源系统的合理选型匹配，对不同负荷下燃气发电机组的发电效率和热电比曲线进行拟合，以某小区冷热电负荷及电价为计算条件，年总成本费用为目标函数，设置计算对照组，研究燃气内燃机变工况特性对分布式能源系统寻优选型的影响。结果表明：燃气发电机组变工况的热电比和发电效率对系统选型和年总成本影响显著，与采取额定参数作为计算输入条件相比，本文的计算模型和备选设备条件下，变热电比可以使年总成本减少4.02%，年可节约标准煤1 161.31 t；变发电效率可以使年总成本减少6.17%，年节约标准煤2 865.91 t；二者可以使年总成本减少5.62%，年节约标准煤2 671.17 t。

关键词：燃气发电机组；变工况特性；发电效率；热电比；分布式能源

Influence of variable load characteristic of gas generator on type selection of distributed energy system

SUN Jingyang1, HU Yinghua2, HU Yong1, HU Yuping1*

1. School of Energy and Power Engineering, Shandong University, Jinan 250061, China;2. Shantui Construction Machinery Co., Ltd., Jining 272073, China

Abstract:In order to realize the reasonable selection and matching of distributed energy system, the generation efficiency and thermal power ratio curves of gas turbine generator set under different loads are fitted. Taking the cooling,heating and power load and electricity price of a residential area as the calculation conditions,and the annual total cost as the objective function,the calculation control grop is set,the influence of offdesign performance of gas engine on the optimal selection of distributed energy system is studied.The calculation results show that considering the heattoelectric ratio and power generation efficiency of gas turbine generator sets have a significant impact on system selection and total annual cost. Under the conditions of this calculation model and alternative equipment, compared to using rated parameters as the calculation input conditions, the variable heattoelectric ratio can reduce the total annual cost by 4.02%, save 1 161.31 tons of standard coal. The variable power generation efficiency can reduce the total annual cost by 6.17% and save 2 865.91 tons of standard coal. Taking the two together can reduce the total annual cost by 5.62%, and save 2 671.17 tons of standard coal.

Keywords:gas turbine generator set; offdesign performance; power generation efficiency; heattoelectric ratio; distributed energy

柴油机缸套变形对配缸间隙特性的影响

田新伟1,2，赵忠诚1,2，褚国良1,2，江雨晨3，胡勇3，刘营4

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.山东大学能源与动力工程学院，山东济南250061;4.山推工程机械股份有限公司，山东济宁272073

摘要：为研究不同阶次缸套变形对柴油机工作状态下配缸间隙特性的影响，进行应力分析,通过耦合模型仿真得到活塞和缸套的变形;通过傅里叶变换,得到缸套各阶次变形形态，对变形幅值进行缩放，对比分析不同阶次的影响权重及显著性。分析结果表明：缸套变形各阶次幅值波动对摩擦功耗峰值和最大振动加速度幅值有较大影响，对最大油膜压力也有影响，对最小油膜厚度和最小工作配缸间隙的影响极小；缸套变形阶次越高，变形幅值波动度越低；同一特性下，2阶变形的波动度是6阶变形的9倍以上，对工作配缸间隙进行优化设计时应着重考虑缸套2阶变形。

关键词：柴油机；缸套变形；傅里叶变换；配缸间隙

Influence of cylinder liner deformation on cylinder clearance characteristics of diesel engine

TIAN Xinwei1,2, ZHAO Zhongcheng1,2, CHU Guoliang1,2,

JIANG Yuchen3，HU Yong3，LIU Ying4

1.State Key Laboratory of Engine Reliability,Weifang 261061,China;2.Weichai Power Co., Ltd., Weifang 261061,China;3.School of Energy and Power Engineering,Shandong University, Jinan 250061,China;4.Shantui Construction Machinery Co., Ltd., Jining 272073,China

Abstract：In order to study the effect of different order of cylinder liner deformation on the cylinder matching clearance characteristics of diesel engine under working conditions, the stress of the whole diesel engine is analyzed, the deformation of piston and cylinder liner is simulated by coupling model, and the deformation shape of each order is carried out by Fourier transformation.The amplitude of deformation is scaled，the influence weight and significance of the order is compared and analyzed. The analysis results show that: the amplitude fluctuation of each order of cylinder liner deformation has a great influence on the peak value of friction power consumption and the maximum amplitude of vibration acceleration among the five indicators of working cylinder clearance characteristics, and the influence on the maximum oil film pressure is the second, the influence on the minimum oil film thickness and the minimum working cylinder clearance is minimal, the higher the deformation order is, the lower the amplitude fluctuation of deformation is, the fluctuation values of the same index of the secondorder and the sixthorder are all different by more than 9 times.The secondorder deformation of the cylinder liner should be considered in the optimization design of the working cylinder clearance

Keywords:diesel engine; cylinder liner deformation; Fourier transform; cylinder clearance

基于概率统计的发动机停机位置影响因素试验研究

盛利1,刘志治1,张文1,石磊2，王俊席3*

1.广西玉柴机器股份有限公司，广西玉林537005;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;3.上海海能汽车电子有限公司，上海201806

摘要：通过大量停机试验，研究不同影响因素下发动机停机时刻曲轴位置的分布规律，并对数据进行概率统计分析，研究停机过程节气门开度、发动机转速等参数对停机位置分布的影响。试验数据分析表明：停机过程中节气门开度对停机位置的分布具有显著影响，节气门开度从0开始逐渐增大，停机位置分布更加趋于集中在压缩冲程的中间区间即上止点前曲轴转角为60°~100°；当节气门开度达到或超过20%时，停机位置分布差异很小；停机前的怠速转速对停机位置分布影响不明显。

关键词：发动机起停技术；停机位置分布；停机概率

Experimental study on influence factors of engine shutdown position based on probability and statistics analysis

SHENG Li1, LIU Zhizhi1, ZHANG Wen1, SHI Lei2, WANG Junxi3*

1.Guangxi Yuchai Machinery Group Co.,Ltd., Yulin 537005,China;2.Key Laboratory for Power Machinery and Engineering of Ministry of Education,Shanghai Jiao Tong University,Shanghai 200240,China;3.Shanghai Haineng Automotive Electronics Co.,Ltd., Shanghai 201806,China

Abstract：A large number of shutdown tests are carried out to study the distribution of crankshaft position at engine shutdown time under different factors, and the probability statistical analysis of the data is employed to study the influence of throttle opening, engine speed and other parameters on the distribution of shutdown position during the stopping process. The analysis of the test data shows that the throttle has a significant effect on the distribution of the shutdown position during the shutdown process. Increasing the throttle opening from 0 will make the shutdown position distribution more concentrated in the middle of the compression stroke, that is, the crankshaft angle before top dead center is 60°~100°. However,when the throttle opening is more than 20%, the distribution difference of the shutdown position is very small; the idle speed before shutdown has no obvious effect on the distribution of shutdown position.

Keywords:startstop technology of engine;distribution of shutdown position;shutdown probability

发动机关键部件金属材料随温度变化性能测试

曹文霞1，范习民2

1.安徽水利水电职业技术学院，安徽合肥231603；2.安徽江淮汽车集团股份有限公司，安徽合肥230601

摘要：通过拉伸试验测试发动机关键部件金属材料随温度变化的力学性能，采用闪光法测试金属材料的导热系数和比热性能，获得金属材料随温度变化的性能参数。分别使用AVL公司数据库中AC4CH的材料性能参数和测试获得的参数对某缸内直喷汽油机热-固耦合仿真分析，获得缸盖的温度分布，并与实测温度进行对比，研究测试数据的适用性。结果表明，采用测试数据的缸盖仿真温度与缸盖实测温度更接近，可作为相关仿真分析的输入。

关键词：屈服强度；拉伸强度；热传导；热膨胀系数

Performance test of metal materials varying with temperature for key components of engine

CAO Wenxia1, FAN Ximin2

1.Anhui Water Conservancy Technical College, Hefei 231603, China;2.Anhui Jianghuai Automobile Group Co., Ltd., Hefei 230601, China

Abstract:Tensile test is used to test the mechanical properties of the metal materials of the key parts of the engine with the change of temperature. Flash method is used to measure the thermal conductivity and specific heat of the metal materials, and the performance parameters of the metal materials with the change of temperature are obtained. The thermal stress of cylinder head is simulated and analyzed by using the material parameters of AC4CH in AVL database and the parameter data obtained from the test, and then compared with the actual measured temperature of cylinder head to investigate the applicability of the test data. The results show that the simulated temperature by using test data is similar to the measured temperature of the cylinder head, which can be used as the input of related simulation analysis.

Keywords:yield strength; tensile strength; heat conductivity; heat expansion coefficient

双电机串并联混动系统性能仿真分析

虞卫飞，杜成磊，代永刚，李杰

安徽江淮汽车集团股份有限公司，安徽合肥230022

摘要：基于某紧凑运动型多用途车辆开发双电机串并联混动系统，设计双电机混动控制策略，提出用于不同运行工况的纯电驱动、串联驱动、并联驱动3种稳态混动模式；通过发动机起动和停机、离合器关闭和打开4种过渡工况实现不同混动模式之间的切换。基于Matlab/Simulink搭建双电机混动系统车辆仿真模型，分析双电机串并联混动系统的经济性和动力性。结果表明：双电机串并联混动模式全球统一轻型车辆测试循环油耗为6 L/(100 km)，车速0~100 km/h的加速时间为9.1 s，双电机串并联混动节油显著，动力性良好。

关键词：串并联；混合动力；控制策略；混动模式

Simulation analysis of series and parallel hybrid system with double motors

YU Weifei, DU Chenglei, DAI Yonggang, LI Jie

Anhui Jianghuai Automobile Group Co.,Ltd.,Hefei 230022,China

Abstract：Based on a compact SUV vehicle, double motors serial and parallel hybrid system is developed, and a hybrid control strategy is built. The three steady hybrid modes: electric drive, serial drive, and parallel drive are developed for different operating conditions.Hybrid modes are switched through four transitional modes: engine starting, engine stopping, clutch closing and clutch opening.The vehicle simulation model of the double motors hybrid system is built based on Matlab/Simulink to analyze the fuel economy and driving performance of the double motors serial and parallel hybrid system.The results show that the fuel consumption of the WLTC is 6 L/(100 km), and the acceleration time from 0 to 100 km/h is 9.1 s. The double motors serial and parallel hybrid system has good fuel economy and driving performance.

Keywords:series and parallel; hybrid; control strategy; hybrid mode

发动机用旋压皮带轮故障再现仿真与改进

张晓辉1,2, 谢永胜1,2,曾超1,2,程市1,2,李超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：针对发动机试验过程中出现的旋压皮带轮故障，采用有限元分析方法，对旋压皮带轮进行故障再现仿真，仿真计算结果与实际故障点吻合。根据旋压皮带轮受力变形特点，分析故障原因发现，由于垫块与轴端法兰直径相差3.0 mm，导致旋压皮带轮两侧接触面受压不均，而危险点与轴端法兰同直径。将轴端法兰直径增加3.0 mm，与垫块直径相同。经仿真和市场验证，改进方案有效，表明仿真再现方法满足工程应用要求，对旋压皮带轮设计具有指导意义。

关键词：发动机；旋压皮带轮；故障再现仿真

Fault recurrence simulation and improvement of engine rotary pulley

ZHANG Xiaohui1,2, XIE Yongsheng1,2,

ZENG Chao1,2, CHENG Shi1,2, LI Chao1,2

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

Abstract:For the spinning pulley failure during engine test, finite element analysis is employed for fault simulation. The calculation results are similar to the actual fault.According to spinning pulley bearing deformation characteristic, it could be found that the block and the shaft end flange diameter is different, the radius is 3.0 mm, which causes spinning pulley on both sides of the contact pressure, and dangerous point with shaft end flange diameter. The diameter of the shaft end flange is increased by 3.0 mm, which is the same as that of the cushion block. The improvement is validated by the market, which proves that the simulation method meets the requirements of engineering application and has guiding significance for the design of spinning pulley.

Keywords:engine; spinning pulley; fault recurrence simulation

基于MIL的SCR效率诊断方法

闫立冰1,2，任宪丰1,2，张军1,2，张娟1,2，解同鹏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电控研究院，山东潍坊261040

摘要：针对国四排放标准实施后市场反馈的误报NOx排放超标问题，为保证选择性催化还原(selective catalytic reduction，SCR)满足车载自动诊断系统的要求，基于模型在环(model in the loop，MIL)离线仿真提出精确计算设定转换效率和转换效率限值的新方法。经MIL离线仿真和台架试验验证，新方法可以有效解决SCR效率诊断问题，为解决SCR转换效率误报问题提供了一种新思路。

关键词：MIL；离线验证；SCR效率；台架标定

SCR efficiency diagnosis method base on MIL

YAN Libing1,2, REN Xianfeng1,2, ZHANG Jun1,2,

ZHANG Juan1,2, XIE Tongpeng1,2

1.State Key Laboratory of Engine Reliability, Weifang 261061, China;2.Institute of Electronical Control, Weichai Power Co., Ltd., Weifang 261040, China

Abstract:In view of the market feedback problem that NOx emission exceeds the standard in the initial stage of the implementation of CHINA Ⅳ, in order to ensure that the selective catalytic reduction (SCR) system can meet the requirements of the onboard diagnosis system, a new method based on model in the loop (MIL) is proposed to accurately calculate and set the conversion efficiency and its limit. The results of MIL offline simulation and bench test show that the new method effectively solves the problem of SCR efficiency diagnosis, and provides a new idea to solve the problem of SCR conversion efficiency false alarm.

Keywords:MIL; offline validation; SCR efficiency; bench calibration

发动机液压锁形成模式对活塞失效的影响

祝传亮1,2，曹国帅1,2，郑洪国1,2，黄超1,2，赵昌锋1,2,张学禄1,2

1.滨州渤海活塞有限公司，山东滨州256600；2.山东省发动机活塞摩擦副重点实验室，山东滨州256600

摘要：针对某发动机在耐久试验中出现的活塞环岸断裂故障，对故障活塞进行结构强度计算、物理性能和铸造缺陷检测，确定故障原因为发动机形成液压锁；分析造成发动机液压锁液体来源，总结不同液体造成的液压锁判定方法，分析液压锁导致的活塞失效模式。结果表明：冷却液、机油和燃油是形成发动机液压锁液体的主要来源；可以通过活塞表面外观、活塞顶面积碳和发动机性能判定形成液压锁的液体类型；液压锁可以导致活塞环岸断裂和活塞顶面开裂等故障。该研究可以为液压锁形成分析提供参考。

关键词：发动机；液压锁；活塞；有限元分析；失效模式

Influence of formation mode of engine hydraulic lock on piston failure

ZHU Chuanliang1,2, CAO Guoshuai1,2, ZHENG Hongguo1,2,

HUANG Chao1,2, ZHAO Changfeng1,2, ZHANG Xuelu1,2

1.Binzhou Bohai Piston Co.,Ltd., Binzhou 256600, China;

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

Abstract：According to the failure of piston ring land breakage in endurance test, the structural strength of the piston is calculated,the physical performance and the casting defect detection of the piston are tested.It is determined that the failure is caused by the formation of a hydraulic lock in the engine,the sources of engine hydraulic lock fluid are analyzed, the determination methods of hydraulic lock caused by different liquids are summarized, and the piston failure modes caused by hydraulic lock failur are analyzed.The results show that the coolant, oil and fuel are the main liquid to form the engine hydraulic lock. The cause of the hydraulic lock can be determined by the appearance of piston surface, the carbon of piston top area and the performance of the engine. Hydraulic lock may cause the piston ring bank fracture and the piston top surface crack and other faults. This study can provide reference for the failure analysis of hydraulic lock.

Keywords:engine;hydraulic lock;piston; finite element analysis;failure mode

柴油机掉缸故障检测及排除

张悦1，史文献1,2，吴士军1,2，周帅2,3，周明胜1,2

1.潍柴动力扬州柴油机有限责任公司，江苏扬州225009；2.内燃机可靠性国家重点实验室，山东潍坊261061；3.潍柴动力股份有限公司，山东潍坊261061

摘要：针对某四缸直列轻型柴油机存在的掉缸故障，采用台架振动测试、道路振动测试、振动疲劳试验以及端子保持力测试等测试手段，系统地分析掉缸故障原因。结果表明：柴油机掉缸原因为喷油器接插件端子保持力可靠性不稳定，在线束拉扯力和振动的相互作用下导致接触件断路。通过改进喷油器接插件结构型式，采用更稳定的接插件端子，优化线束走向，重新设计大刚度的固定支架，优化高压油管管型并增加固定管夹等措施，彻底消除掉缸故障。

关键词：掉缸；振动测试；疲劳耐久；保持力测试

Diagnosis and solution of misfire on cylinder of diesel engine

ZHANG Yue1, SHI Wenxian1,2, WU shijun1,2,

ZHOU Shuai2,3, ZHOU Mingsheng1,2

1.Weichai Power Yangzhou Diesel Engine Co., Ltd., Yangzhou 225009, China;

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

Abstract:The problem of misfire for a four cylinder inline light diesel engine is investigated. Engine vibration test, road vibration test, durability test and terminal retention test are used to systematically analyze the causes of misfire. The results show that the main cause of misfire is the instability of the terminal retention force of the injector connector, which leads to the open circuit of the contact under the interaction of the pulling force and vibration of the wire harness. By improving the structure of injector connector, adopting more stable connector terminals, optimizing the direction of wiring harness, redesigning the fixed bracket with large stiffness, optimizing the highpressure oil pipe and increasing the fixed clamp, the misfire fault is completely eliminated.

Keywords:diesel misfire; vibration test; durability test; retention test

曲轴磁粉探伤工艺技术及应用

张昆鹏，牟言钦,唐灵聪

宁波吉利罗佑发动机零部件有限公司，浙江宁波315340

摘要：从曲轴探伤原理、复合磁化技术、磁化检测介质、探伤检测设备等方面研究曲轴磁粉探伤的工艺技术要求，结合实际曲轴裂纹故障研究其应用。通过金相组织分析、硬度梯度检测、能谱分析等分析裂纹产生原因，确定硫化物等非金属夹杂物超标是造成曲轴裂纹的根本原因;提出改进措施并通过实际应用进行验证。结果表明改进措施切实有效，对发动机曲轴产品开发、工艺设计和质量控制有一定的指导意义。

关键词：曲轴；磁粉探伤；工艺

Technology and application of magnaflux inspection for crankshaft

ZHANG Kunpeng, MU Yanqin, TANG Lingcong

Ningbo Geely Royal Engine components Co., Ltd., Ningbo 315340, China

Abstract:The technological requirements of crankshaft magnaflux detection are studies from the aspects of crankshaft flaw detection principle, composite magnetization technology, magnetization detection medium and flaw detection equipment, and its application is studied combined with actual crankshaft crack fault. Through metallographic structure analysis, hardness gradient test and energy spectrum analysis, it is determined that sulfide and other nonmetallic inclusions exceed the standard is the root cause of crankshaft cracks. The improvements are proposed and verified by practical application. The results show that the improvements are effective, which has a certain guiding significance for the product development, process planning and quality control of engine crankshaft.

Keywords:crankshaft, magnaflux inspection, technology

矿车用多级复合空气滤清器设计改进

刘近报1，2，史美丽1，2，胡伟1，2，郭永志1，2，郑世魁1，2，杨志浩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：为减少矿区作业发动机空滤产品的保养维护成本,减轻维护保养工作量,延长滤芯保养周期，分析油浴式、干式和多级复合空气滤清器的过滤原理及适用范围；对多级复合空气滤清器结构进行改进，增加电机驱动型旋转器，利用电机驱动提高旋转器转速。对改进后的多级复合空滤器进行滤清效率试验并在矿区使用,结果表明：改进后的多级复合滤清器总成原始滤清效率达到99.7%，粗滤效率和滤清器整体效能提高，有效解决了发动机粗滤效率低、保养周期短、故障率高等问题，满足矿区空气滤清器应用需要。

关键词：空气滤清器;矿车;油浴式;干式;多级复合

Improvement of multistage composite air filter system for mine truck

LIU Jinbao1，2, SHI Meili1，2, HU Wei1，2,

GUO Yongzhi1，2, ZHENG Shikui1，2, YANG Zhihao1，2

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

Abstract：In order to reduce the maintenance cost of the air filter of the engine in the mining area, reduce the maintenance workload, and extend the maintenance cycle of the filter, the filtering principle and application scope of the oil bath type, dry type and multistage composite air filter are analyzed. The structure of the multistage composite air filter is improved, a motordriven rotor is added, and the motor is used to increase the rotation speed of the rotor. The filtration efficiency test and the batch market verification in the mining area show that the original filtration efficiency of the improved multistage composite filter reached 99.7%, the coarse filtration efficiency and the overall efficiency of the filter are improved.The problems of the low coarse filtration efficiency,short maintenance period and high failure rate are effectively solved.The multistage composite air filter can meet the application needs of air filters in mining areas.

Keywords:air filter;mine truck;oil bath type;dry type;multistage composite