Effects of process parameters on semi-solid squeeze casting performance of aluminum alloy scrolls for scroll compressors

The aluminum alloy scroll is one of the key parts of the scroll compressors widely used in the air-conditioning,refrigeration,and heat pump systems.In this work,the semi-solid squeeze casting(SSSC)process was used to fabricate the aluminum alloy scroll.The effects of process parameters including the pouring temperature,mold temperature,and squeezing velocity on the filling and solidification behaviors of the alloys were investigated through simulations based on the power law cut-off(PLCO)material model.Results show that there is a significant increase in the flow velocity of the slurry,and the area of the high-speed region enlarges with the increase of the pouring temperature.The homogeneity of the temperature and velocity fields in the slurry is improved with an increase in mold temperature.Both the filling time and its variation rate decrease with an increase in squeezing velocity.The maximum solidification time exhibits a linear variation with the increase in pouring temperature.The shrinkage area is decreased by increasing the mold temperature.The optimal process parameters of the SSSC process were obtained from simulation analysis,which are the pouring temperature of 595°C,mold temperature of 350°C,and squeezing velocity of 0.3 m·s-1.Moreover,the qualified scroll casting was fabricated using the SSSC process under the optimal process parameters.

Flow characteristics of tangential leakage in a scroll compressor for automobile heat pump with CO_(2)

Tangential leakage loss reduction has great significance on improving the performance of scroll compressors.In this study,the flow field of a scroll compressor working with CO_(2) was numerically investigated.The development characteristics of the tangential leakage flow in different working chambers were carried out,which was obtained by analyzing the field quantities distributions.The impacts of the radial clearances and sidewall roughness on the tangential leakage were also taken into consideration,in order to explore the feasible method of the flow control for the tangential leakage in scroll compressors.Results showed that the tangential leakage flow had various characteristics in the suction and compression chambers due to the different interactions between the tangential leakage flow and mainstream.Owing to little reverse pressure gradient,the tangential leakage flow maintained the typical jet form in the suction chambers.By contrast,the mixing of the tangential leakage flow and mainstream induced the passage vortex and secondary flows in the compression chamber.The secondary flow was the primary factor that results in the occurrence of localized high temperature region rather than the tangential leakage.With the increase of the radial clearance,the volumetric efficiency declined and the discharge temperature increased rapidly.In terms of flow control of the tangential leakage,the increase of sidewall roughness by 2μm could achieve the same effect as the decrease of the radial clearance by 4μm,while the volumetric efficiency increased by almost 5%and average discharge temperature decreased by 5K.

Performance analysis of a single-stage scroll compressor used in a drying heat pump over a wide condensing temperature range(30–80°C)

This study presents the performance of a new single-stage scroll compressor used for the heat pump drying of thermally sensitive materials over a wide temperature range. The performance of the new compressor was predicted by an ARI standard 540 map-based compressor model and verified by a semi-open drying heat pump system constructed for this purpose. A comparison of the experimental data with the predicted data proved that the new scroll compressor used in the drying heat pump works well, can supply a wide range of condensing temperatures （30--80℃） （without auxiliary heating）, and has a minimum coeffi- cient of performance （COP） above 2.0, even in the worst condition.

Structural dynamic analysis of the orbiting scroll wrap in the scroll compressor

A deep analysis of orbiting scroll wraps was conducted in this paper by using ANSYS and SolidWorks. Through the modal analysis, the involute of the circle profile orbiting scroll wrap demonstrated a large span in natural frequencies, which led to more superiority in avoiding structural resonances. Based on the dynamic harmonic analysis, loads of frequency changes were gained and the stress and strain distribution of the orbiting scroll wrap in the most dangerous working conditions were obtained, which determined the segments with maximum stress and strain-displacement properties. Two paths defined to elucidate further the structural characteristics of the exhaust chamber provided evidence for the initial correction of orbiting wraps. The results of the present study offer a theoretical basis for the design and manufacture of scroll wraps, and providing a new way to evaluate different scroll wraps.

Leakage Model of Axial Clearance and Test of Scroll Compressors

Leakage clearance plays an important role in guaranteeing high efficiency of scroll compressors.In view of the shortcomings of the existing leakage models of axial clearance of scroll compressors,a modified Fano flow model and a turbulence model are presented based on the flow characteristics of fluid in the leakage passage under actual working conditions.Firstly,according to the Fano flow energy equation and the turbulence theory,two kinds of leakage models,Fano flow model and turbulence model,of axial clearance are established.Then,the established models are verified through an experimental platform established to measure the axial clearance leakage in the working process of a scroll compressor,and the measured values are compared with the values obtained from the two theoretical models.Finally,the effect of such factors as pressure difference,clearance amount,spindle speed on the axial clearance leakage is analyzed.Results show that the two established models can precisely reflect the variation law of axial clearance leakage of scroll compressor under different working conditions.In particular,the Fano flow model is more suitable for predicting the clearance leakage when the spindle speed is low(less than 3500 r/min)and the clearance is small(less than 0.025 mm),whereas the turbulence model is suitable for high spindle speed(more than 3500 r/min)and large clearance(more than 0.025 mm).

Research on the natural meshing mechanism and testing analysis of scroll profiles for refrigeration scroll compressor

In the design theory of scroll profiles for refrigeration scroll compressor,a mechanism principle of scroll profiles based on the center of natural temporal involutes and meshing region is presented,by which the performance characteristics of the various involutes are studied. Profiles type selection is very important for scroll compressor. Through analyzing the characteristic geometry,natural meshing mechanism is discovered in the study of scrolls. And a novel method for scroll profiles based on natural meshing mechanism is proposed. The result shows that the meshing region angle of odd regular polygon involutes is half of the characteristic-geometry exterior angle,and that of even regular polygon involutes is equal to the exterior angle to the moment. The corresponding meshing region angle is reduced increasingly with the increase of the edge number of characteristic geometry. The performance characteristics of scroll compressor tend towards the best correspondingly. Aiming at the existing problems of profile design for scrolls,we developed a novel methodology to study scroll profile. Originality research was done for the further study of scroll profile. It is the fundamentality factor representing essence character of scroll profiles function itself.

Air-source heat pump coupled with economized vapor injection scroll compressor and ejector:Design and experimental research

Ejector can utilize high pressure energy from liquid mechanism,it can be used in heat pump system coupled with economized vapor injection(EVI)scroll compressor.When running under low temperature conditions,the performance of the EVI system with ejector can be improved further.In this paper,the design method of the heat pump system with ejector is presented,and the process for designing the heat pump with ejector(EVIe)was summarized.One prototype heat pump was designed under the condition of the evaporation temperature of -20oC,and an experimental setup was established to test the prototype.The measured results demonstrated that the heating EER(energy efficiency ratio)of the EVIe could reach about 4%higher than that of the system without the ejector when the heating capacity remained nearly constant.The design method is helpful to development of a heat pump system coupled with scroll compressor and ejector.

基于功率流有限元法的涡旋压缩机振动特性研究

针对涡旋压缩机内部振动传递路径复杂,采用传统的传递函数法往往不能真实地描述振动产生与传递的本质问题,引入功率流有限元法从能量角度分析振动传递特性,进行涡旋压缩机内部振动产生、传递与空间分布的可视化研究。在分析涡旋压缩机的动力拓扑关系基础上建立激励源,提取与振动响应模型并进行仿真分析;利用实体试验和响应分析结果对比进行模型有效性分析;在验证后的模型上定义8个能量输出面,分析谐波与激励作用下上支撑和下支撑的振动能量传递特性,并且计算节点的功率流矢量确定振源的空间分布。结果表明,涡旋压缩机曲轴在运转到280°时,振动频率在1 000 Hz与1 890 Hz时振动能量传递率较高,上支撑能量分布均匀并集于自身,下支撑能量集中于支脚并向外传递。研究方法和研究成果对于涡旋压缩机振动分布及传递、振动控制和优化设计等方面具有一定借鉴意义。

涡旋膨胀机研究进展及展望

随着“双碳”目标的提出,涡旋膨胀机作为回收低品位能量的机械装置备受关注。首先,对近年来涡旋膨胀机的理论研究成果进行了综述,主要包括型线理论、热动力学和计算流体力学(CFD)仿真。然后,对涡旋膨胀机在有机朗肯循环(ORC)中的应用进行了总结,梳理了涡旋膨胀机在跨临界CO_(2)制冷循环中的应用研究成果。最后,对涡旋膨胀机未来的研究方向进行了展望。结果表明:变壁厚涡旋膨胀机因其可以在不增加泄漏线长度的情况下增加内容积比,因此将成为未来型线优化的主要方向;CFD仿真已成为重要的研究工具;润滑油是影响涡旋膨胀机性能的关键因素,提高润滑油的黏度有利于提升效率,而过量的润滑油则会使其性能下降;工作压力是影响涡旋膨胀机性能的最主要的因素,过膨胀、欠膨胀以及泄漏现象都会使其性能下降。此外,涡旋膨胀压缩一体机集成了膨胀机和压缩机两个功能单元于一个机壳中,显著简化了系统结构并提高了能量回收效率,是提升新能源车用CO_(2)热泵空调系统性能的有效途径。基于当前的研究成果和行业需求,提出涡旋膨胀机未来应继续深入研究和优化型线设计、减少泄漏、优化工作压力等,以满足日益增长的能量回收和环境保护需求。

背压扰动平衡盘对涡旋压缩机黏性内流压力影响研究

在变转速工况下,电动涡旋压缩机背压腔中润滑油产生的背压力无法准确平衡轴向气体力。针对这一问题,提出了一种带有扰动片的背压扰动平衡盘,研究了背压扰动平衡盘对涡旋压缩机黏性内流压力的影响。首先,对背压扰动平衡盘作用原理进行了分析,使用贝塞尔曲线构建了扰动片型线,对润滑油被扰动后的静压增量进行了公式推导,计算了扰动片出口安装角和扰动片数对润滑油静压的影响;然后,建立了含背压扰动平衡盘的背压腔模型,将流体域分为旋转域和静止域,采用旋转坐标系的方法进行了数值模拟,研究了背压腔内润滑油的压力场;最后,根据理论计算,模拟了润滑油在不同出口安装角和扰动片数下的润滑油静压,对润滑油静压与压缩机所需最佳背压进行了对比分析。研究结果表明:采用背压扰动平衡盘可以使润滑油静压增加21%,且静压增量随主轴转速的增加而增大,适当增大扰动片出口安装角可使润滑油静压增加0.032 MPa;对比最佳背压可知,扰动前润滑油静压与最佳背压相差26%,而合理设计扰动片后的润滑油静压与最佳背压相差仅为9%,极大改善了电动涡旋压缩机在变转速下的轴向平衡。

基于CBAM-CNN的涡旋压缩机故障诊断

针对涡旋压缩机振动信号不平稳和噪声情况下故障振动信号弱、需要人为提取故障特征以及准确率有待进一步提高的问题,提出基于多尺度注意力机制(convolutional block attention mechanism,简称CBAM)-卷积神经网络(convolutional neural network,简称CNN)涡旋压缩机故障诊断方法。首先,通过多个不同尺度的卷积核对振动信号转化为灰度图的故障特征进行全面提取,并引入注意力机制,通过调整权重值的方式提取重要的故障特征;其次,利用降维卷积模块、深度可分离卷积模块和残差模块提取更高维度的深层次故障特征,提升网络计算效率;最后,设置舍弃率为0.5的Dropout层防止过拟合,提升了网络的鲁棒性、抗干扰能力和泛化能力。实验结果证明,该方法在无噪声和添加不同信噪比噪声的情况下,均能有效地对涡旋压缩机故障进行分类,具有更高的识别准确性和更快的收敛能力。

基于湍流理论的涡旋压缩机轴向间隙泄漏研究

针对涡旋压缩机轴向间隙泄漏控制问题,定量计算轴向间隙泄漏,为了更加接近工程实际,在考虑转速、温度、气体粘度等因素基础上,基于湍流理论,建立了完整的涡旋压缩机间隙泄漏量理论计算模型。分析了影响轴向间隙泄漏的关键参数,便于通过优化参数以达到控制间隙泄漏的目的,同时为了验证理论计算模型的可靠性,搭建模拟涡旋压缩机试验测试平台,测试了定转速不同间隙和定间隙不同转速下的泄漏量值,并与理论计算结果相比较。结果表明:涡旋压缩机高低压腔压力差与泄漏量成正比,当主轴转速不变,间隙为0.020 mm时,测试值与计算结果拟合较好,并且随着压差增大,泄漏量逐渐减小,说明通过增大压差可以降低间隙泄漏量;当间隙不变时,主轴转速越高,间隙泄漏量越小,当转速大于3500 r/min时,实测值与计算值开始啮合,并且转速越高,啮合度越高。说明基于湍流模型所建立的泄漏量计算模型可靠。通过定量准确计算轴向间隙泄漏量,为降低涡旋压缩机泄漏提供理论依据,也为涡旋压缩机推广应用提供帮助。

基于范诺流理论的变截面涡旋压缩机轴向间隙泄漏研究

为了定量研究变截面涡旋压缩机轴向间隙泄漏,基于范诺流理论,考虑其主轴转速、介质粘度和摩擦等因素,探索建立变截面涡旋压缩机轴向间隙泄漏量计算模型,根据模型分析影响泄漏的主要参数,以便利用控制关键参数来降低轴向间隙泄漏。通过搭建涡旋压缩机试验平台,测定涡旋压缩机工作腔在实际工况下,不同间隙同一主轴转速和同一间隙不同主轴转速下泄漏量的实测值。结果分析表明:压差大小与泄漏量成正比,当主轴转速一定,间隙为0.02 mm时,实测值与理论值拟合较好,并且随着压差增大,泄漏变化较小;主轴转速越高,间隙泄漏量越小,当间隙一定,转速为3000 r/min时,实测值与理论值拟合较好,并且转速越高,泄漏量越大。通过理论计算与实际测量结果对比分析,所建立的泄漏量计算模型准确可靠。此模型的建立为深入研究和控制轴向间隙泄漏奠定基础,也为推广涡旋压缩机在大功率领域的应用提供理论基础。

基于WP-ICA分析的涡旋压缩机故障特征提取方法研究

针对涡旋压缩机故障特征难以提取以及在小样本下故障类别难以区分的问题,提出了一种基于小波包能量谱与独立成分分析相结合的故障特征提取方法,结合支持向量机建立故障分类模型,实现非平稳信号的准确识别。首先对信号进行小波包分解与重构,通过重构系数获取分解后不同频带所对应的小波包能量作为故障特征值;再利用独立成分分析法对故障特征值进行优化得到特征向量值;最后构造支持向量机,输入故障特征向量进行训练和测试,可得出涡旋压缩机故障诊断的准确率。实验和仿真分析结果验证了该方法的有效性,其诊断准确率可达94.5%。

涡旋压缩机径向柔性机构动力学仿真分析

以偏心滑块式径向柔性机构为研究对象,从机构学角度对机构的避让功能进行分析,确定了机构限位范围;利用ADAMS软件对柔性机构转子系统的动态特性进行了仿真分析,得到动涡旋质心的运动轨迹,确定机构限位参数对动涡盘质心运动规律之间的关系,优化主轴承受力,为空调涡旋压缩机的振动分析和性能提升奠定基础。

涡旋压缩机平衡铁结构对阻力矩的影响研究

针对涡旋压缩机平衡铁随主轴旋转时产生的阻力损失问题,提出了圆角结构及机翼型结构平衡铁。运用Fluent有限元分析软件,结合滑移网格技术对平衡铁工作区域模拟,研究了3种不同结构平衡铁所受的压差阻力矩和摩擦阻力矩,对比分析了不同结构产生的阻力矩大小。结果表明:压差阻力矩占总阻力矩的90%以上,总阻力矩随转速的增大而增大;相对于样机平衡铁,前后端面为圆角的平衡铁总阻力矩减小了30%~50%之间;机翼型平衡铁总阻力矩减小了55%~65%之间。

汽车空调涡旋压缩机排气孔优化研究

针对汽车空调涡旋压缩机排气孔处气体流动变化产生的流动损失问题,对排气孔结构进行优化,以期降低流动损失并提高排气压力。通过三维动网格模型对不同排气孔结构的涡旋压缩机排气过程进行瞬态仿真,发现腰果形排气孔更大的截面积使其拥有更好的开启特性,可有效降低排气损失,提高排气稳定性。在对腰果形排气孔采取进一步扩压式优化后,发现其可以更加有效地降低排气速度并提高排气压力。

微小型压缩空气储能系统用涡旋压缩机流动特性研究

以空气为工质,基于计算流体动力学方法,对无油空气涡旋压缩机在变工况运行条件下进行了三维非稳态数值模拟。研究发现:动静涡旋齿之间存在的径向间隙,会使得压缩机工作腔内温度、流速和压力的分布不规律;增大转速,不但可以增加涡旋压缩机的质量流量,而且还可以减小切向泄漏量,进而提高压缩机的工作效率;排气压力过大,会降低涡旋压缩机的基本输出性能;在低转速下,过高的排气压力会使得压缩机排气口出现“净回流”现象。

电动汽车补气式涡旋压缩机考虑内漏和传热的热力学研究

针对采用简化的等熵过程来计算压缩机的热力学工作过程与实际工作过程有差别的问题,提出了一种加入内漏和传热过程的一维模型,在低温工况下用短型线补气式涡旋压缩机进行验证。对比压缩机在不同转速下(5 000,6 000 r/min)的功率、制热COP、制热量及排气温度的仿真结果与试验结果,其间最大误差均在8%以内;对比在吸气、排气压力分别为0.16,0.90 MPa时,采用等熵模型和本文提出的仿真模型计算压缩机的工作过程的结果,发现考虑内漏和传热后,制热量和排气温度的计算值与试验值之间的差距从20%最低下降到4%;采用本文仿真模型的计算结果能更准确地反映压缩机的实际工作过程。研究结果可为补气式涡旋压缩机的设计和应用提供参考。

径向间隙与转速对滚动转子压缩机油膜密封角的影响

针对计算滚动转子压缩机内径向间隙泄漏时,将油膜长度视为恒定值而导致误差较大的问题,同时深入探讨油膜长度对压缩机性能的影响,基于实际微型滚动转子压缩机参数,采用VOF多相流模型模拟了压缩腔内制冷剂R290和润滑油PAG32的混合流动过程,重点揭示了油膜在径向间隙通道中动态变化的特性,研究分析了不同径向间隙和转速对油膜密封角的具体影响。结果表明,径向间隙从35μm减小至10μm时,油膜的最大密封角从14°增加至42°,较小的径向间隙有利于形成更大的油膜密封角,并且油膜能够保持较长时间,显著减少了气体泄漏量;转速从2000 r/min提升至4000 r/min时,油膜的最大密封角从31°增加至43°,较高的转速有助于压缩机在排气阶段形成更大的油膜密封角,但转子壁面速度的增加,显著加剧了由壁面剪切力引起的径向泄漏,导致总泄漏质量流量增大。研究结果可为滚动转子压缩机的设计开发提供参考。