康明斯发动机涡轮增压技术介绍

Turbocharging for Turbocharging for Heavy Duty Off-Heavy Duty Off- Highway Applicationsg ay pp cat o s 非道路重型机械的涡轮增压 技术 Henry Tennant Beijing, January 2008 Contents目录 ƒ Company background and marketsƒ Company background and markets 公司背景和市场简介 ƒ Off highway emissions 非道路排放法规 ƒ Engine technical developments 发动机技术的进步发动机技术的进步 ƒ Turbocharging and wastegates 涡轮增压和旁通技术 ƒ Turbocharger durabilityƒ Turbocharger durability 增压器的耐久性 ƒ Two stage systems for altitude performance 高原性能出色的二级增压系统 ƒ Other turbocharging systems 其他涡轮增压系统 2 其他涡轮增压系统 康明斯涡轮增压技术公司简介 Cummins Turbo Technologies Overview ■ 康明斯增压技术隶属于康明斯汽车零部件 Cummins Turbo Technologies is an automobile Components Group of Cummins Inc. ■ 我们是3升以上商业用柴油和气体发动机用增压器的设计和制造领先者。 We are the leading designer and manufacturer of turbochargers for diesel and gas- derivative engines above 3 litresderivative engines above 3 litres. ■ 全球有2000名员工，在巴西、中国、荷兰、印度、英国和美国拥有业务设施。全球有 名员 ，在巴西、中国、荷兰、印度、英国和美国拥有业务设施 We have over 2000 employees globally and have operations in; Brazil, China, Holland, India, UK and USA. ■ 总部和技术中心在英国，在中国也建立了亚洲技术中心，印度有工程研发资源。 Our Headquarters and dedicated technical centre are in the UK with an Asian regional technical centre in China and additional engineering development 3 resources in India. 无锡康明斯涡轮增压技术主要客户 Wuxi Cummins Turbo Technologies Major Customers 4 英国工厂 UK Operations Name: Cummins Turbo Technologies Ltd Established: In 1952 Location: Headquartered in Huddersfield, UK Employees: 1,018 Product Range: Light Duty, Mid Range, Heavy Duty, HHP: Holset HX20-25, HX30-35, HX40, HX50/55, HX60, HX80 Capacity: 500k Activities: Customer Account Teams, Manufacturing Technical Centre Aftermarket Other Facts: Cummins took ownership in 1973 5 无锡康明斯涡轮增压技术简介 Wuxi Cummins Turbo Technologies Profile „ 无锡康明斯现拥有429名员工 Number of Employees: 429 „ 生产霍尔塞特中等功率，重功率和大马力的涡 轮增压器 Products: Holset TurbochargersProducts: Holset Turbochargers Mid-range, Heavy Duty, High Horse Power „ 2006年的生产能力为560，000台，2007年生产 能力达700 000台能力达700，000台 Capacity 560,000 units in 2006 700 000 units in 2007700,000 units in 2007 „ Markets Truck, Bus, Industrial, construction, Marine, Rail 面向的市场包括货车 客车 工业用车 建筑 6 面向的市场包括货车，客车，工业用车，建筑 用车，船舶和轨道机械 Off highway emission legislation 非道路排放法规 ƒ China has recently introduced Stage l emission legislationlegislation 中国最近引入一阶段排放法规 ƒ Stage ll will be introduced in October 2009 2009年将引入二阶段排放法规 ƒ Stage ll has 35% reduction in NOx and 63% reduction in particulates compared to Stage l 二阶段比一阶段的法规要求NOx降低35%，颗粒物降 低63% 7 Off highway emissions legislation 非道路排放法规 0.6 Tier/Stage 1 0.4 0.5 h ) Tier/Stage 1 Euro 1 0.3 M ( g m / k W h 0 1 0.2P M Tier/Stage 2Tier/Stage 3 Euro 2 0 0.1 0 1 2 3 4 5 6 7 8 9 10 Euro 3 Eu 4Eu5Tier/Stg 4 Eu6 8 0 1 2 3 4 5 6 7 8 9 10 NOx (gm/kWh) Eu6 T h i l d l t f St I t Technical developments from Stage I to Stage II 从一阶段到二阶段的技术进步从 阶段到二阶段的技术进步 ƒ Electronic control of fuel system to give variable full- and part-load injection timing ƒ NOx control 采用电控供油系统 及时调节全负荷和部分负荷时的喷油 时采用电控供油系统，及时调节全负荷和部分负荷时的喷油正时 可降低NOx ƒ Air-air aftercooling to give low charge temperatures ƒ For NOx and particulate controlƒ For NOx and particulate control ƒ Improved fuel consumption 用空冷中冷器降低发动机的进气温度 可降低NOx和颗粒物排放可降低NOx和颗粒物排放 改善燃油经济性 ƒ Turbochargers with wastegates or modulating wastegates ƒ For air-fuel ratio control for low particulates and high torque 有旁通阀或可调节式旁通阀的增压器 可控制空燃比，降低颗粒物排放，提升扭矩 9 Compressor Map 压气机性能图 5 The compressor must supply sufficient air 112.941 4 4.5 p pp y flow at all conditions to ensure the correct combustion system air/fuel ratio for the required particulates. 所有工况下，压气机必须提供足够的空气量确 98.209 74 1600 3.5 4 a t i o 所有工况下，压气机必须提供足够的空气量确 保合适的空燃比满足颗粒物排放要求 The compressor flow range must match the engine operating range 78.567 88.388 1600 1800 1200 1400 1900 3 P r e s s u r e R a t g p g g 压气机流量范围必须与发动机的运行范围匹配 Compressor efficiency should be as high as possible to give low compressor outlet 68.746 78.567 66 70 74 76 78 1000 9002 2.5 p g p temperature (high boost density), low charge air temperature and lower turbine power requirements. 压气机效率越高越好，效率越高压气机出气温 58.926 66 800 1.5 压气机效率越高越好 效率越高压气机出气温 度越低，发动机进气温度也越低，压气机对涡 端的功率需求也相应减小 Need to observe compressor limits of surge 10 1 0 20 40 60 80 100M(√T)/P p g flow, choke flow and maximum speed. 观测压气机的喘振流量线，阻塞流量线和最大 转速线 Turbine Map 涡轮性能图Turbine Map 涡轮性能图 The turbine needs to provide the work to drive the compressor at all conditions, at the lowest exhaustat the lowest exhaust manifold pressure possible (for good fuel consumption). 所有工况下，如果有可能尽量 t ( T ) / P 所有工况下，如果有可能尽量 使排气歧管压力最低（燃油经 济性较好），涡轮要发生足够 功驱动压气机运转 e t e r M r t A good turbine match has the operating line running through the peak efficiency islands w p a r a m e the peak efficiency islands. 一个好的涡轮匹配，运行线要 穿过最高效率点 F l o w 11 Speed Parameter N/rt(T) Wastegates旁通阀 4.5 Compressor Map For Mid-range Truck Turbocharger 1200rpm 4.5 Compressor Map For Mid-range Truck Turbocharger 1200rpm 4.5 Compressor Map For Mid-range Truck Turbocharger 1200rpm 4.5 Compressor Map For Mid-range Truck Turbocharger 1200rpm The compressor boost pressure can be increased by fitting a smaller turbine housing, but this can lead to an overspeed condition. 配用小涡壳可提升压气机的增压压力 ECU controlled 130000rpm4.0 Engine Speed 2000rpm 1600rpm 130000rpm4.0 Engine Speed 2000rpm 1600rpm 130000rpm4.0 Engine Speed 2000rpm 1600rpm 130000rpm4.0 Engine Speed 2000rpm 1600rpm 配用小涡壳可提升压气机的增压压力， 但可能导致增压超速 By fitting a turbine wastegate, the higher boost pressure can be achieved Wastegated small housing controlled modulating wastegate 110000rpm 120000rpm 3.5 T - T ) Turbo Speed 2400rpm 110000rpm 120000rpm 3.5 T - T ) Turbo Speed 2400rpm 110000rpm 120000rpm 3.5 T - T ) Turbo Speed 2400rpm 110000rpm 120000rpm 3.5 T - T ) Turbo Speed 2400rpm higher boost pressure can be achieved at low engine speeds without over speeding the turbo at higher engine speeds. 通过采用涡端旁通措施，发动机低转速 Smaller ! 100000rpm 2.5 3.0 e s s u r e R a t i o ( T 100000rpm 2.5 3.0 e s s u r e R a t i o ( T 100000rpm 2.5 3.0 e s s u r e R a t i o ( T 100000rpm 2.5 3.0 e s s u r e R a t i o ( T时就可以获得较高的增压压力，而且在 发动机高转速时，增压器也不会超速 This is a simple boost controlled wastegate housing 90000rpm 2.0 P r e 90000rpm 2.0 P r e 90000rpm 2.0 P r e 90000rpm 2.0 P r ewastegate. 上述旁通阀是单纯的压力控制式旁通阀 ECU controlled (or modulating) wastegates can give even higher Standard housing 70000rpm 1.5 70000rpm 1.5 70000rpm 1.5 70000rpm 1.5 wastegates can give even higher pressure ratios at low engine speeds without exceeding the maximum allowed turbocharger speed. ECU控制式（ 或可调节式）旁通阀可以 进 步提高发动机低转速时的压比 并 12 1.0 0 10 20 30 40 50 60 70 80 Compressor Air Flow Parameter 1.0 0 10 20 30 40 50 60 70 80 Compressor Air Flow Parameter 1.0 0 10 20 30 40 50 60 70 80 Compressor Air Flow Parameter 1.0 0 10 20 30 40 50 60 70 80 Compressor Air Flow Parameter 进一步提高发动机低转速时的压比，并 且不会使增压超过允许的最大转速限制 T b h ith W t tTurbocharger with Wastegate 带旁通阀的增压器 A t tiActuating boost capsulecapsule Wastegate 13 valve Wastegated Turbines Wastegate Swallowing Capacity 3.50 Wastegate Closed Wastegated Turbines Turbine 带旁通阀的涡端通流能力曲线 3.00 Wastegate Closed Wastegate Open Operating Points as wastegate opens 74% 56% Efficiency 2.50 n R a t i o 2.00 E x p a n s i o n 1.50 1.00 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 14 Mass Flow Parameter (kg/s.√K/MPa) Command Valve – Integral Modulating Wastegate control 指令阀—全程调节式旁通控制 15 Command Valve – Integral modulating WG - System ConceptSystem Concept 指令阀—全程调节式旁通控制的系统概念 Actuator Boost Air Signal VentValve Orifice 16 Durability for Off highway applications 非道路用增压器的耐久性非道路用增压器的耐久性 ƒ Good durability of the turbocharger is a key factor in any application 好的耐久性是增压器应用的关键所在 ƒ Repeated speed cycling of the turbocharger can lead to low c cle fatig e (LCF) fail rescycle fatigue (LCF) failures 反复的运转可能导致增压器低周疲劳失效 ƒ Some off-highway duty cycles are more severe than on-Some off-highway duty cycles are more severe than on- highway 有些非道路工作循环比道路工作循环恶劣的多 ƒ Good understanding of the duty cycle is important when matching the turbocharger 进行增压器匹配时一定要弄清楚车辆的工作循环 17 进行增压器匹配时一定要弄清楚车辆的工作循环 L C l F ti F il M d ƒ Examples of typical compressor wheel failure modes Low Cycle Fatigue Failure Modes 低周疲劳失效模式 ƒ Examples of typical compressor wheel failure modes 典型的压气机叶轮失效模式 18 T i l diff b t O Hi hTypical differences between On-Highway and Off-Highway Duty Cycles 典型的道路和非道路工作循环的比较典型的道路和非道路工作循环的比较 On-Highway (Truck)On Highway (Truck) Off-Highway (Excavator) 19 Duty cycle analysisDuty cycle analysis 工作循环分析 On-Highway (Truck) 道路工作循环（卡车 Off-Highway (Excavator) 非道路工作循环（挖掘车） ） More cycles at larger mean strain level More cycles with larger strain ranges 20 C h l t i lCompressor wheel materials 压气机叶轮的 Th d t l l i i li k d t k l d f thƒ The duty cycle analysis is linked to our knowledge of the material properties from LCF testing and a prediction of the compressor life can be made 通过分析工作循环，结合从低周疲劳试验中获知的材料属性， 就可预测压气机的寿命 ƒ For most applications cast aluminium is acceptable from anƒ For most applications cast aluminium is acceptable from an LCF standpoint 从低周疲劳失效的角度考虑大部分的叶轮可以采用铸铝 ƒ For arduous applications cast titanium can be specified giving a significant increase in life or allowing a higher sea level boost pressurepressure 对于一些条件苛刻的应用，铸钛可以显著提高叶轮的寿命，海平 面状态的增压压力也可以更高 21 Turbocharging systems for high altitude 高原状态的涡轮增压系统 ƒ Turbocharger speeds rise as altitude increases. Off highway machinery may require very high altitude capability, for example 4500m4500m 随着海拔高度的上升增压器转速增大， 非道路用机械有时会在非 常高的海拔高度工作，比如4500m ƒ Th i d i d t t b d d t ltit dƒ The maximum design speed must not be exceeded at altitude, so an altitude speed margin has to be provided at sea level 高原状态下增压器转速一定不能超过最大设计转速，所以在海平面 状态时必须保留 定的高原转速余量状态时必须保留一定的高原转速余量 ƒ It is sometimes necessary to consider two stage turbocharging in order to give acceptable sea level engine power and acceptable g p g p p altitude performance without de-rating 有时需要考虑采用二级增压技术，即可在海平面状态下保证发动机 的功率输出，在高原状态下也不用通过降低发动机功率的方式就可 22 的功率输出，在高原状态下也不用通过降低发动机功率的方式就可 维持较好的性能 Two-stage increases ltit d bilitaltitude capability 二级增压器技术提高增压器的高原能力 Cummins QSK78Cummins QSK78 mine truck applicationapplication 3500hp at 4800m 二级增压器在 Cummins QSK78 矿车发动机Cummins QSK78 矿车发动机 上的应用 海拔高度4800时 发动机的海拔高度4800时，发动机的 功率3500hp 23 Single stage compressor at altitudeSingle stage compressor at altitude 高原状态下单级增压系统压气机性能 • An altitude limit will be reached at maximum turbo speedp • This will depend on the sea level boost requirement 海平面状态不同的增压需求，决定了增压器可正常运转的最大海拔高度 3600m 2600m Sea Level boost curve 24 2 stage turbocharger compressors at altitude 高原状态下 级增压系统压气机性能高原状态下二级增压系统压气机性能 HP compressorp LP Compressor 3600 m Sea level 25 Other turbocharging systemsOther turbocharging systems 其他的增压系统 V i bl t 可变截面增压器ƒ Variable geometry 可变截面增压器 ƒGives good control of boost pressure independent of engine speed for torque and transient engine performance 不论发动机的转速多大，都可更好的控制增压压力，获得较好的扭矩 特性和发动机瞬态性能 ƒ Very good with EGR systems, gives good engine economy andVery good with EGR systems, gives good engine economy and ability to drive EGR 很好的与EGR系统匹配性能，使发动机更经济更有效的驱动废气再循 环环 ƒ Turbocompound 复合增压 ƒGives good fuel economy especially for high load factor engines 特别是对于负荷系数较高的发动机复合增压可提高发动机的燃油经 济性 ƒ Complex system needing design integration into the engine 26 p y g g g g 系统复杂，要和发动机作为一个整体设计 HOLSET VARIABLE HOLSET VARIABLE GEOMETRY TURBOCHARGER 27 Holset HE500Ve ith l t i t twith electric actuator Holset电动调节式可变截面增压器 28 Conclusion 结论 ƒ Turbocharging is a key engine technology to meet emissionƒ Turbocharging is a key engine technology to meet emission regulations for all applications 涡轮增压是一项可使发动机达到排放指标的关键技术 ƒ Understanding duty cycles is an important step for a successful application 理解工作循环是实现成功匹配的重要环节理解工作循环是实现成功匹配的重要环节 ƒ Turbocharging systems such as wastegate or two- stage allow tailoring of engine performance and altitude requirements. Other systems can be usedsystems can be used. 涡轮增压系统，例如旁通或二级增压系统，可更好的使发动机 满足性能和高原适应性要求 ƒTHANK YOU FOR YOUR ATTENTION!ƒTHANK YOU FOR YOUR ATTENTION! 感谢你的倾听！ 29