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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: To address the challenges associated with the three-dimensional flow design requirements of hydrodynamic retarders, specifically the low braking performance and limited geometric adaptability of conventional straight blade configurations. This study proposes a novel three-dimensional geometric modeling methodology for cambered blade retarders based on the class-shape-transformation (CST) approach. In the proposed method, the toroidal circulation path, blade camber line, and thickness distribution are all parameterized using CST curves, enabling a highly flexible and precise design representation of the blade geometry. To verify the reliability and accuracy of the computational approach, a comparative analysis was conducted between experimental braking performance data and numerical simulations performed using computational fluid dynamics (CFD) for a baseline straight blade retarder model. The results revealed a maximum deviation of 4.92% and a minimum deviation of 4.43% between the simulated and experimental values, both of which fall below the generally accepted threshold of 8%. These findings confirm the validity of the CFD model and establish a robust foundation for subsequent design and optimization procedures. Building upon this validated simulation framework, the study proceeds to reconstruct the original straight blade retarder using CST-based parameterization to generate an improved cambered blade retarder design. Comparative CFD analyses between the straight blade and cambered blade configurations were conducted, and the results demonstrate that the cambered blade retarder not only meets feasibility requirements from a structural standpoint but also outperforms the conventional straight blade variant in terms of braking performance. This validates both the structural viability and performance advantages of cambered blade implementations in retarder applications. In pursuit of further improvements in braking torque and reductions in idling loss power, the study employs a design of experiments (DOE) methodology to systematically explore the influence of key blade cascade parameters on 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 to identify the individual contributions of each design parameter. The analysis revealed that the peak height of the blade camber line has a significant positive impact on retarder performance, enhancing braking torque while mitigating idling loss power. Conversely, the blade deflection angle, incidence, and thickness factor were all found to exhibit negative correlations with overall retarder efficiency, indicating that these variables must be carefully managed during the design process to avoid performance degradation. To determine the optimal combination of blade parameters that can achieve a balanced improvement in both performance objectives, a multi-objective evolutionary optimization algorithm-non-dominated sorting genetic algorithm II (NSGA-II) was utilized. The NSGA-II optimization process generated a set of optimal solutions, from which a final optimized blade configuration was selected based on design priorities. A comprehensive evaluation of the optimized cambered blade retarder was conducted by comparing its external performance characteristics and internal flow field characteristics against those of the pre-optimization design. The results show that the braking performance of the optimized blade retarder is 23.5% higher than that of the cambered blade retarder, and the idling loss power is reduced by 30.9 %. In conclusion, this study presents a robust CST-based methodology for the geometric modeling and performance optimization of 3D cambered blade hydrodynamic retarders. By integrating advanced parameterization techniques, validated CFD analysis, and evolutionary multi-objective optimization algorithms, the proposed approach offers a comprehensive framework for the design of high-performance retarders. Beyond the immediate application to hydrodynamic braking systems, the modeling and optimization techniques developed herein provide a valuable reference for the broader field of turbomachinery design, offering insights and tools that can be extended to the efficiency improvement of turbines and other rotating fluid machinery.

     

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