基于类别形状函数变换的液力缓速器叶片参数优化

    Blade parameter optimization of hydrodynamic retarder based on class-shape-transformation

    • 摘要: 为满足液力缓速器三维流动设计的需要,解决传统直叶片缓速器制动性能低和叶片造型适应性低的缺点,该研究提出基于类别形状函数变换(class-shape-transformation,CST)的弯曲叶片缓速器三维造型方法。弯曲叶片缓速器循环圆、叶片骨线和厚度曲线均采用CST曲线参数化表征,将某型号直叶片缓速器的制动性能试验与计算流体动力学(computational fluid dynamics,CFD)模拟结果进行对比,最大误差为4.92%,最小误差为4.43%,均小于8%,验证了CFD计算结果有效性。采用CST函数对直叶片缓速器进行重构优化得到弯曲叶片缓速器,对比直叶片缓速器和弯曲叶片缓速器CFD结果,验证了弯曲叶片缓速器的构造可行性及性能优越性。为了进一步提高弯曲叶片缓速器制动性能与降低空损功率,采用DOE(design of experiments)方法构建弯曲叶片缓速器叶栅参数与制动转矩Tl、空损功率Pa的响应面模型,并对其进行主效应分析,其中,叶片骨线峰值高度对弯曲叶片缓速器TlPa起正向调控作用,叶片偏转角、叶片安装角及叶片厚度因子均与弯曲叶片缓速器TlPa呈负相关关系。采用第二代非支配排序遗传算法(non-dominated sorting genetic algorithm-II,NSGA-II)对弯曲叶片缓速器叶栅参数进行寻优,将优化前后弯曲叶片缓速器的外特性与内流场进行对比,结果表明,优化叶片缓速器相较于弯曲叶片缓速器制动性能提升23.5%,空损功率下降30.9%。本文提出的缓速器叶片造型方法可为涡轮机械叶栅系统设计与优化提供参考。

       

      Abstract: Hydrodynamic retarders are often required for the three-dimensional flow behavior. Specifically, the conventional straight blade configurations are limited to low braking performance and geometric adaptability. In this study, a three-dimensional geometric modeling was proposed for the cambered blade retarders using the class-shape-transformation (CST) approach. The toroidal circulation path, blade camber line, and thickness distribution were all parameterized using CST curves, particularly for the highly flexible and precise representation of the blade geometry. A comparative analysis was conducted to verify the reliability and accuracy of the computational approach. A comparison was also made on the experimental braking performance data and numerical simulations using computational fluid dynamics (CFD) with the baseline model of a straight blade retarder. The results revealed that there was a maximum deviation of 4.92% and a minimum deviation of 4.43% between the simulated and experimental values, both of which fell below the generally accepted threshold of 8%. The CFD model was also verified for the subsequent optimization. An improved cambered blade retarder was reconstructed to combine the simulation framework and CST-based parameterization. A CFD analysis was then conducted between the straight and cambered blade configurations. The cambered blade retarder fully met the feasibility requirements from a structural standpoint. The braking performance also outperformed the conventional straight blade variant. Both the structural viability and performance of the cambered blade were implemented in the retarder applications. The braking torque was reduced due to the idling loss of power. A design of experiments (DOE) was employed to systematically explore the influence of the key blade cascade parameters on the retarder performance. A response surface model (RSM) was developed to quantitatively describe the relationship between the cambered blade cascade parameters and two critical performance metrics: braking torque and idling loss power. A main effects analysis was then conducted on the RSM in order to identify the individual contributions of each design parameter. The analysis revealed that the peak height of the blade camber line had a significant positive impact on the retarder performance, thus enhancing the braking torque to mitigate the idling loss of power. Conversely, the blade deflection angle, incidence, and thickness factor were all found to exhibit negative correlations with the overall retarder efficiency. These variables were also optimized to avoid performance degradation. The optimal combination of the blade parameters was determined to balance the performance. A multi-objective evolutionary optimization was utilized as the non-dominated sorting genetic algorithm II (NSGA-II). The NSGA-II optimization generated a set of optimal solutions, from which an optimal blade configuration was selected using design priorities. An optimally cambered blade retarder was evaluated to compare with the pre-optimization, in terms of its external performance and internal flow field. The braking performance of the optimal blade retarder was 23.5 % higher than that of the original. The idling loss of power was reduced by 30.9 %. In conclusion, a robust CST-based approach was presented for the geometric modeling and performance optimization of 3D cambered blade hydrodynamic retarders. Advanced parameterization techniques were integrated to validate the CFD analysis and evolutionary multi-objective algorithm. The finding can offer a comprehensive framework for the high-performance retarders. Beyond the immediate application to hydrodynamic braking systems, the modeling and optimization techniques can provide a valuable reference in the broader field of turbomachinery. Some insights and tools can also be extended to improve the efficiency of the turbines and rotating fluid machinery.

       

    /

    返回文章
    返回