Manufacturing Error Effects on Mechanical Properties and Dynamic Characteristics of Rotor Parts under High Acceleration

Stress, strain and vibration characteristics of rotor parts should be changed significantly under high acceleration, manufacturing error is one of the most important reason. However, current research on this prob- lem has not been carried out. A rotor with an acceleration of 150,000 g is considered as the objective, the effects of manufacturing errors on rotor mechanical properties and dynamic characteristics are executed by the selection of the key affecting factors. Through the force balance equation of the rotor infinitesimal unit establishment, a theoretical model of stress calculation based on slice method is pro- posed and established, a formula for the rotor stress at any point derives. A finite element model （FEM） of rotor with holes is established with manufacturing errors. The chan- ges of the stresses and strains of a rotor in parallelism and symmetry errors are analyzed, which verify the validity of the theoretical model. The pre-stressing modal analysis is performed based on the aforementioned static analysis. The key dynamic characteristics are analyzed. The results demonstrated that, as the parallelism and symmetry errors increase, the equivalent stresses and strains of the rotor slowly increase linearly, the highest growth rate does not exceed 4%, the maximum change rate of natural frequency is 0.1%. The rotor vibration mode is not significantlyaffected. The FEM construction method of the rotor with manufacturing errors can be utilized for the quantitative research on rotor characteristics, which will assist in the active control of rotor component reliability under high acceleration.

Rotor Strength Analysis of High-speed Permanent Magnet Synchronous Motors

为了对转子进行有效的冷却，在满足电机电磁性能的前提下，可通过减小保护套的厚度来尽可能增大定转子之间的气隙，因而必须对保护套和永磁体进行强度校核。将转子受力状况简化为平面应变问题，在此基础上推导出了两层过盈配合、三层过盈配合转子的应力场、应变场、位移场的解析公式，并利用有限元方法验证了解析公式的正确性。归纳了高速情况下热套式永磁转子强度设计准则，为转子的优化设计提供了理论依据。以一台额定转速120kr／min、10kW的高速永磁同步电机为例，给出了两种常用过盈配合高速电机转子的强度设计方法。

An High-Speed Low-Noise Rotor Topology for EV/HEV PMSM

Permanent magnet synchronous motor(PMSM)for EV/HEV pursues higher efficiency,higher power density,higher rotation speed and better NVH performance.To meet these requirements,an improved triangle rotor topology is presented.The new rotor topology is researched through comparing the performance with V shape rotor and traditional triangle shape rotor.The comparing results on air-gap flux density,key order radial forces,sound pressure,inductance,torque,anti-demagnetization capability and efficiency proved the advantage of the new rotor topology.

Highly-Efficient Aerodynamic Optimal Design of Rotor Airfoil Using Viscous Adjoint Method

In order to overcome the efficiency problem of the conventional gradient-based optimal design method,a highly-efficient viscous adjoint-based RANS equations method is applied to the aerodynamic optimal design of hovering rotor airfoil.The C-shaped body-fitted mesh is firstly automatically generated around the airfoil by solving the Poisson equations,and the Navier-Stokes(N-S)equations combined with Spalart-Allmaras(S-A)one-equation turbulence model are used as the governing equations to acquire the reliable flowfield variables.Then,according to multi-constrained characteristics of the optimization of high lift/drag ratio for hovering rotor airfoil,its corresponding adjoint equations,boundary conditions and gradient expressions are newly derived.On these bases,two representative rotor airfoils,NACA0012 airfoil and SC1095 airfoil,are selected as numerical examples to optimize their synthesized aerodynamic characteristics about lift/drag ratio in hover,and better aerodynamic performance of optimal airfoils are obtained compared with the baseline.Furthermore,the new designed rotor with the optimized rotor airfoil has better hover aerodynamic characteristics compared with the baseline rotor.In contrast to the baseline airfoils optimized by the finite difference method,it is demonstrated that the adjoint optimal algorithm itself is practical and highly-efficient for the aerodynamic optimization of hover rotor airfoil.

HIGH CYCLE FATIGUE RELIABILITY ANALYSIS ON ROTOR HUB BASED ON APPROXIMATION TECHNIQUE

A high cycle fatigue reliability analysis approach to helicopter rotor hub is proposed under working load spectrum.Automatic calculation for the approach is implemented through writing the calculating programs.In the system,the modification of geometric model of rotor hub is controlled by several parameters,and finite element method and S-N curve method are then employed to solve the fatigue life by automatically assigned parameters.A database between assigned parameters and fatigue life is obtained via Latin Hypercube Sampling(LHS) on tolerance zone of rotor hub.Different data-fitting technologies are used and compared to determine a highest-precision approximation for this database.The parameters are assumed to be independent of each other and follow normal distributions.Fatigue reliability is then computed by the Monte Carlo(MO method and the mean-value first order second moment(MFOSM) method.Results show that the approach has high efficiency and precision,and is suitable for engineering application.

High-Order Discontinuous Galerkin Method for Hovering Rotor Simulations Based on a Rotating Reference Frame

An implicit higher ? order discontinuous Galerkin(DG) spatial discretization for the compressible Euler equations in a rotating frame of reference is presented and applied to a rotor in hover using hexahedral grids. Instead of auxiliary methods like grid adaptation,higher ? order simulations(fourth ? and fifth ? order accuracy) are adopted.Rigorous numerical experiments are carefully designed,conducted and analyzed. The results show generally excellent consistence with references and vigorously demonstrate the higher?order DG method's better performance in loading distribution computations and tip vortex capturing, with much fewer degrees of freedom(DoF). Detailed investigations on the outer boundary conditions for hovering rotors are presented as well. A simple but effective speed smooth procedure is developed specially for the DG method. Further results reveal that the rarely used pressure restriction for outlet speed has a considerable advantage over the extensively adopted vertical speed restriction.

RESEARCH ON SCHEME OF HIGH-SPEED ROTOR／WING TRANSITION HELICOPTER RD15

To analyze the existing schemes of high-speed rotorcrafts and some new technologies, a new conceptual sketch of the high-speed rotor/wing transition helicopter RD15 is proposed. The overall layout of the RD15 is given out and the transition process from the helicopter mode to the airplane mode is designed. The lift system consists of a circular disk-wing with four retractable blades. The technology of individual blade control is adopted for flight control in hover and low speed flight. The tail is a vectored thrust duct propeller. It can provide the anti-torque in hover, and offer the multi-directional controls and propulsion drive for the airplane mode flight. The aerodynamic characteristics and key technologies in the transition process for this layout, including the nose up angle of disk-wing, the length of the blade, rotation speed, pitch angle and other parameters, are theoretically ana lyzed and experimentally tested. Calculation and experiments show that the shift process of the lift, the power and controls are smooth, and the designed scheme is feasible.

电动汽车用新型模块化聚磁转子永磁电机设计及其对比分析

将轮辐型内置式转子和Halbach永磁阵列结合,并取消转子铁心加强筋,减小漏磁达到高聚磁同时兼顾凸极比,实现高转矩/功率密度和宽调速范围。在保证永磁体用量相同的情况下,建立新型高凸极比聚磁转子和V型转子两种电机模型,针对两者的分段转子拓扑,开展电磁性能对比分析,包括气隙磁密、凸极比、功率以及弱磁扩速能力等。同时,考虑到无转子铁心加强筋会导致转子分段存在结构强度问题,仿真验证新型高凸极比聚磁转子结构在最高转速6000 r/min时给予碳纤维护套保护下转子结构强度的可靠性;分析温度限制下新型高凸极比转子电机的功率输出。另外,对比两种不同电机结构的振动噪声情况。最后,研制一台16极/72槽新型高凸极比转子永磁电机样机,实验验证有限元分析结果的准确性。进一步说明了新型高凸极比转子永磁电机在转矩/功率密度和宽调速运行等方面的性能优势。

Research on Rubbing-fault Diagnosis System in High-speed Rotor based on LabVIEW

The rubbing between rotors and determiners is the common mechanic vibration fault in the operation of rotation machinery. During the operation of equipment, in order to meet the demand of high speed and efficiency of machinery, the gap between the active and passive parts of the rotor system become smaller, which results in the common rubbing fault of rotors and stators. This essay studies the fault diagnosis of high speed rotors based on invented instrument and shows the measurement and research of the signals of rubbing failure of high speed rotors. The research introduces the designed software and hardware which are experimented and testified on Bentley rotor experiment platform. The system has theoretical and applicative meaning in practical projects.

车用柴油机高压比宽流量增压器研制

目的 对于单级高压比宽流量增压器,为适应发动机强化指标,进行一系列的改进设计。方法 利用仿真设计与试验相结合的方法,对高海拔环境应用增压器进行改进设计。通过理论推导,确定压气机及涡轮的气动性能优化设计方法,开展高稳定裕度转子轴承系统设计方法研究与验证。结果 匹配高压比宽流量增压器的发动机与原机相比,高原功率恢复了17%,发动机排气温度降低了7%,增压器转速降低了13%。结论 在原机的基础上设计了压比为4.6的宽流量高性能涡轮增压器,成功实现了高压比宽流量增压器的设计,满足了发动机平原、高原不同环境的运行需求。

轴承转子系统快变过程振动响应的高精度频谱分析

针对高速轴承转子系统的启停过程,研究平稳和非平稳信号的高精度频谱分析方法,利用比例校正法对平稳信号频谱分析后的频率、幅值、相位进行了校正,建立一种将t时空域非平稳信号转变为t~2时空域平稳信号的方法,并基于平稳信号的比例校正法对其进行频谱分析,最后返回到t时空域获得某时刻的频域参数。仿真分析结果表明:该方法可以准确提取平稳信号的谱特征,也能较精确地提取非平稳信号特定时刻的频率、幅值和相位,提取结果精度较好,有效解决轴承转子系统快变过程的谱分析特征提取问题,为动力学特性分析提供了新思路。

1.1 MW高速内置式永磁同步电机新型转子拓扑设计与强度优化

大功率高速永磁电机中通常采用绑扎碳纤维护套的方式来降低转子应力,然而护套厚度过大会导致等效气隙增加,电机性能随之降低。针对这一问题,设计了一种具有新型转子拓扑结构的1.1 MW、18 000 r/min的内置式高速永磁同步电机。该结构采用永磁体分段设计,并增设加强筋,分担转子隔磁桥处的应力,使护套厚度得到有效降低。同时,将转子外部隔磁桥处替换为非导磁填充块,阻断漏磁路径,提升永磁体利用率。最后,有限元分析结果表明,相较于初始模型,新型结构电机在等效气隙增大1.5 mm的情况下,输出转矩达到600.44 N·m,增加了16.86 N·m,并且新型转子铁心最大应力降低了496.82 MPa,转子结构的机械强度得到显著提高,可为大功率高速永磁电机转子拓扑设计提供参考。

基于桨距角控制的永磁风电机组高电压穿越控制策略

为解决传统永磁风电机组高电压穿越控制策略存在超速脱网风险问题,提出一种基于桨距角控制的高电压穿越控制策略。高电压穿越期间,首先,按照并网要求向电网提供无功支撑;其次,考虑转子转速限制,当转子转速达到参考值时启动桨距角控制,抑制转子转速上升;最后,通过仿真试验,验证了所提控制策略的有效性。基于桨距角控制的永磁风电机组高电压穿越控制策略,既能向电网提供无功支撑,又能避免超速脱网。

高压煤油恒速液动机转子倾覆现象的理论研究

介绍了高压煤油恒速液动机(简称“液动机”)的转子倾覆现象,分析了机理,并按照发生的原因将倾覆现象分为主动倾覆和被动倾覆。重点研究了主动倾覆,基于对转子柱塞组件的受力分析,提出了倾覆条件的数学表达,引入了无量纲的倾覆安全系数,以定量表达倾覆风险。分析了被动倾覆的原因,并提出了解决被动倾覆的方法。在产品设计中应避免出现主动倾覆和被动倾覆。

聚磁式永磁轮毂电机多目标优化设计

集成二级行星减速器轮毂驱动系统对电机电磁和力学性能提出了更苛刻需求。为进一步提升永磁轮毂电机转矩密度和弱磁范围,提出一种聚磁式永磁轮毂电机拓扑结构,分析转子关键参数对转矩密度、弱磁能力和转子强度的影响规律,确定电机初始优化目标;进一步利用有限元及响应面法构建输出转矩、特征电流及转子应力的代理优化模型,并利用改进布谷鸟算法进行多目标优化设计;对比分析优化前后电机电磁和机械性能。最后,试制75 kW聚磁式永磁轮毂电机,试验结果验证所提多目标优化算法的可行性和有效性。

基于SAMCEF Rotor的高速泵转子临界转速分析

为了提高高速泵的可靠性,利用专业的转子动力学特性分析软件SAMCEF Rotor对高速矿用抢险泵转子系统进行分析,研究转子的动力特性--临界转速及其振型,根据径向轴承参数建模,分别采用一维梁模型,二维傅里叶模型和三维实体模型进行计算比对,得到了各自的坎贝尔图和临界转速及振型。研究表明,三种模型吻合的状态基本一致,设计方案避免了工作转速达到临界转速产生共振现象。根据转子动力学分析软件SAMCEF Rotor分析研究,临界转速的计算方法比较完善,分析结果较为精确,且一维及二维模型求解法对计算机配置要求低,求解耗时短。

直升机尾桨参数对RCS影响分析

在执行战时任务时,对武装直升机的隐身性能提出了较高要求,为降低直升机在执行任务时被发现的概率,基于几何光学法和一致性绕射理论,研究直升机尾桨翼型厚度、弯度、剪刀角角度对RCS的影响。选用两种雷达照射方位,通过对尾桨不同参数和涂敷吸波材料的RCS峰值、均值对比,判断更有利于直升机尾桨隐身的条件。结果表明:雷达从地面照射时,尾桨厚度小、弯度小的RCS会适当减小,剪刀角角度的变化会导致RCS峰值相位变化;雷达平行照射时,厚度小的尾桨RCS小,弯度小的RCS峰值更小;在桨叶前缘与桨尖端面涂敷吸波材料可以有效降低桨叶整体RCS。因此,选择尾桨的厚度越小、弯度越小,有利于降低直升机尾桨的RCS,对桨尖端面和桨叶前缘进行吸波材料涂敷可以有效降低整体RCS。

基于非线性建模与拟合的永磁同步电机转子初始位置精确估计方法

针对永磁同步电机转子初始位置估计的精度与收敛速度受限问题,提出一种基于高频信号注入的非线性建模与拟合实现的初始位置估计方法。首先,建立初始位置与高频信号响应的关联模型,表明高频响应可用于直接计算初始位置,但直接计算结果在大部分转子位置易受测量噪声的影响。为此,提出基于多项式模型建立位置估计非线性模型,选取合适的模型参数,利用少量测试点拟合该模型,即可实现初始位置的快速精确估计,有效提高了估计精度与系统抗干扰能力。实验与仿真结果表明,相比现有方法,提出的方法易于实现,无需复杂滤波器与观测器设计,仅需要选取少量测试点即可快速估计精确转子初始位置,在保证估计精度的同时改进了传统估计方法收敛速度慢问题。

共轴高速直升机/发动机交联控制方法研究

针对常规的旋翼总距前馈方法难以有效实现共轴高速直升机/发动机快速交联控制的问题,本文提出并设计了适用于共轴高速直升机/发动机的新型交联控制方法。首先,基于共轴高速直升机/发动机综合仿真平台,揭示不同运行工况下,共轴双旋翼、推力桨操纵输入、发动机燃油输入变化规律;其次,在此基础上,提出了综合考虑共轴双旋翼、推力桨桨距的增益自调节交联控制方法,并针对不同的运行工况,开展了数值仿真验证。结果表明,在中等、高速度飞行时,相比于常规的旋翼总距前馈,新型交联控制方法可使动力涡轮转速的超调与下垂量减小36%与70%,可使直升机/发动机快速交联控制品质更优,进一步提升直升机/发动机综合系统的控制品质。