机电一体化轴流泵间隙泄漏流流动特性

    Clearance leakage flow characteristics in mechatronic axial flow pump

    • 摘要: 为研究机电一体化轴流泵间隙泄漏流对泵内流场结构的影响规律及机制,该研究基于RNG k-ε湍流模型,利用ANSYS CFX仿真软件对该泵进行不同流量工况(1674~2 510 m3/h)的全流场瞬态数值模拟。具体分析该泵压力、湍动能和涡量场分布情况,研究转子摩擦损耗和泄漏量随流量变化的关系,并揭示径向速度和叶轮效率的变化规律,明确机电一体化轴流泵的泄漏流流动特性。研究结果表明:在额定工况(2 092 m3/h)下,机电一体化轴流泵电机转子外壁面的机械摩擦损耗扭矩占泵总扭矩的19.1%,且占比随流量的增加而增大;流体流经该泵电机定转子间隙并泄漏回流至叶轮入口,形成射流,使得叶轮入口轮缘位置存在明显的径向流动。该流动导致叶轮流道内径向系数为0.9~1.0的近轮缘位置出现高湍动能、强涡量区域,引起该区域水力损失增大,水力效率降低,且流量越小,影响越为显著。因此,机电一体化轴流泵节能设计的重点在于电机与叶轮协同设计,在满足水力性能的前提下尽可能降低转子摩擦损耗以及间隙泄漏流流动对叶轮进口流场结构的破坏。研究结果可为机电一体化轴流泵的研究及性能提升提供参考。

       

      Abstract: A mechatronic axial pump has been widely used for the energy-saving machinery in sustainable agriculture. This study aims to explore the influence of the clearance leakage on the flow field structure in the mechatronic axial pump. The RNG k-ε turbulence model was also utilized to carry out the transient numerical simulation using ANSYS CFX software. The full flow field of the pump was then obtained in the different flow conditions (1 674~2 510 m3/h). Specifically, a systematic analysis was implemented on the pump pressure, turbulent kinetic energy, and vortex volume field distribution. Radial velocity and impeller efficiency were determined to establish the relationship between rotor friction loss and leakage with the flow rate. The leakage flow was finally clarified in the flow fields of mechatronic axial pump. The results show that the special structure of the stator-rotor clearance part was dominated in the efficiency of the whole mechatronic axial flow pump, compared with the traditional. The main reason was that the operating torque of the stator and rotor was greatly contributed to the friction loss power of the rotor and the total shaft power. 19.1% of the pump shaft power was accounted for the mechanical friction loss power on the outer wall of the rotor at rated operating point. There was the increase in the proportion with the increasing flow rate. The leakage and backflow of the clearance and the mixing effect in the main flow area of the blade were extend the low flow pattern to the main flow area of the internal flow channel of the impeller, thus reducing the operating efficiency of the pump. Therefore, the collaborative design of the motor and impeller was required for the energy saving in the mechatronic axial flow pump, in order to minimize the power lost from the rotor friction and then meet the requirements of hydraulic performance. There was the fluid flow through the motor stator-rotor clearance leakage back to the impeller inlet, the formation of jets, the localized area of high turbulent kinetic energy, strong vorticity, and high radial velocity near the edge wall of the impeller inlet. The inflow conditions were seriously disturbed to increase the hydraulic loss for the low efficiency, such as the uniform inflow at the impeller inlet and the assumption of cylinder independence. The closer to the wheel flange position was, the greater the effect was. A mutually constraining and promoting relationship was formed in the leakage and return flow velocity, as well as the pressure difference between the inlet and outlet of the return flow. Importantly, this relationship was also determined as the internal characteristics of the leakage and returns between the stator and rotor clearances of the pump. At the same time, the amount of leakage, the size and degree of influence of the leakage on the flow field structure were negatively correlated with the flow rate. The leakage flow rate of clearance was reduced to minimize the damage to the flow field at the impeller inlet. The finding can provide a strong reference to improve the performance of mechatronic axial flow pumps.

       

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