This application claims priority to Chinese Patent Application Ser. No. CN201810009782.3 filed on 5 Jan. 2018.
The invention belongs to the technical field of reliability and durability of power mechanical equipment, relates to a method for optimizing a blade axis position of a full-adjustable water pump under all operating conditions, and particularly relates to a blade axis position optimizing method for minimizing the maximum blade hydraulic torque of a water pump under all the operating conditions at different heads and different blade angles.
Axial-flow pumps and guide vane mixed-flow pumps are mainly used in fields like agricultural irrigation and drainage, water diversion, sewage treatment, thermal power generation, ship industry and nuclear power, but their high-efficiency areas are narrow, when the water level or head of a pump station changes and deviates from the rated condition, operation efficiency is low, and vibration and overload tend to occur, affecting efficient and safe operation. By arranging a blade full-adjustment mechanism, blade angle adjustment of large and medium-sized axial-flow pumps and guide vane mixed-flow pumps is achieved, so as to realize variable-angle optimized operation, adjust the flow rate, save the operation cost and improve the reliability and durability of the pump unit. There are two types of blade full-adjustment mechanisms, a mechanical type and a hydraulic type, but at present, the blade adjustment force of a axial-flow pump is generally large, especially the blade adjustment force which fails to take into account of all operating conditions of the axial-flow pump, resulting in large stress, serious deformation, large angle adjustment error and easy damage to a release bearing for mechanical blade full-adjustment mechanisms, and high adjustment-required oil pressure and high possibility of seal failure for hydraulic blade full-adjustment mechanisms, leading to oil leakage and angle adjustment failure. Calculation and research show that the blade adjustment force of a axial-flow pump is mainly composed of a hydraulic torque on the blade axis caused by the action of axial-flow flow on a blade during operation. Therefore, it is necessary to design a blade with the smallest blade hydraulic torque under all the operating conditions on the premise of ensuring or not changing the hydraulic performance of an impeller, so as to reduce the blade adjustment force and improve the angle adjustment accuracy as well as reliability and durability of an adjustment mechanism.
The purpose of the invention is to solve the problem that the blade hydraulic torque of large and medium-sized full-adjustable axial-flow pumps and guide vane mixed-flow pumps is too large, and to provide a method for optimizing a blade axis position of an axial-flow pump under all operating conditions, the surface pressure distribution and the hydraulic torque of an impeller blade are calculated by using computational fluid dynamics-CFD flow field calculation software, and the position of a blade axis in the water flow inlet and outlet direction of the blade is adjusted and optimized through analysis, so that the blade hydraulic torque of the axial-flow pump under all operating conditions is reduced, and the purpose of reducing the adjustment force is achieved.
According to the technical scheme of the invention, a method for optimizing the blade axis position of a axial-flow pump under all operating conditions is characterized by including the following operation steps:
A. determination of calculation conditions within the range of all the operating conditions of the axial-flow pump;
B. three-dimensional modeling and mesh generation of the calculation area of the flow field of the axial-flow pump;
C. numerical simulation of the flow field of the axial-flow pump and calculation and determination of the blade hydraulic torque;
D. determination of the range of the position of the blade resultant hydraulic pressure action line of the axial-flow pump and the optimal blade axis position under all the operating conditions;
E. determination of the small region of the optimal blade axis position of the axial-flow pump under all the operating conditions;
F. determination of the optimal blade axis position of the axial-flow pump under all the operating conditions; and
G. comparison of blade hydraulic torques before and after optimization of the blade axis position of the axial-flow pump.
The method of determination of the calculation conditions within the range of all the operating conditions of the axial-flow pump as described in step A is as follows: within the range of the operating head of the axial-flow pump, m equally spaced heads are selected, m=5˜10, the minimum operating head Hmin and the maximum operating head Hmax are included, a head interval is
i.e., m operating heads are H1=Hmin, H2=Hmin+ΔH, . . . Hm-1=Hmax−ΔH, Hm=Hmax; for each of the m heads, n blade angles are selected at certain intervals within the range of operating blade angles of the axial-flow pump, n=5˜10, the minimum operating blade angle αmin and the maximum operating blade angle αmax are included, i.e., α1=αmin, α2, . . . , αn-1, αn=αmax, thus determining m×n calculation conditions.
The method of determination of the calculation area of the flow field of the axial-flow pump as described in step B is as follows: as shown in
The method of numerical simulation of the flow field of the axial-flow pump and calculation and determination of the blade hydraulic torque as described in step C is as follows:
the flow control equations, the continuity equation is:
the momentum equation is:
wherein ρ-density of water body; t-time; U-velocity vector; B-sum of volume forces; μeff-effective viscosity; p-correction pressure; ∇-divergence; ⊚-vector product; ⊗-multiplication cross, and T-transposition; wherein
wherein μ-viscosity of water body; μt-turbulent viscosity; p-pressure; k-turbulent kinetic energy; a k-ε turbulence model assumes that turbulence viscosity is related to turbulent kinetic energy and turbulent kinetic energy dissipation, i.e.,
wherein ε-turbulent kinetic energy dissipation rate; and Cμ-k-ε turbulence model constant.
The following k-ε turbulence models are adopted:
wherein Cε
Boundary conditions: pressure inlet boundary conditions and mass flow outlet boundary conditions are adopted in the calculation area of the flow field of the axial-flow pump.
CFX fluid calculation software is used for numerical simulation of the calculation area of the flow field of the axial-flow pump under m×n calculation conditions in step A, so as to obtain the blade hydraulic torque under each calculation condition at different heads and different blade angles, which is listed in table 1.
The method of determination of the range of the position of the blade resultant hydraulic pressure action line of the axial-flow pump and the optimal blade axis position under all the operating conditions as described in step D is as follows: according to the blade hydraulic torque (the torque of hydraulic pressure to a blade axis) and the resultant hydraulic pressure of the axial-flow pump under m×n calculation conditions calculated with CFX fluid calculation software, the distance between the blade resultant hydraulic pressure action line and the current blade axis approximately on a calculation cylindrical surface under m×n calculation conditions of the axial-flow pump is calculated and determined by a formula (8)
wherein L—the distance from the blade resultant hydraulic pressure action line to the current blade axis approximately on a calculation cylindrical surface; M—the hydraulic torque of the blade hydraulic pressure to the current blade axis, calculated with CFD software; FW—the blade resultant hydraulic pressure obtained by combining the axial, circumferential and radial pressures on the blade, calculated with the CFD software (for an axial-flow pump, the radial component of the blade hydraulic pressure is small), and then the optimal blade axis position is located between the two blade resultant hydraulic pressure action lines farthest from each other under all operating conditions, i.e., between the two outermost blade hydraulic pressure action lines in the circumferential direction from inlet to outlet of the blade, as shown in
According to the determination of the small region of the optimal blade axis position of the axial-flow pump under all the operating conditions as described in step E, the range width between the two blade resultant hydraulic pressure action lines farthest from each other on the calculation cylindrical surface of the blade is s, the range width s is divided into k equal parts, starting from the action line, closer to the current blade axis, in the two outermost blade resultant hydraulic pressure action lines, blade axes 1, 2, . . . , k−1, k are set at the equal parts to the other end of the range with the width s, and distances between the k blade axes and the resultant action line closest to the current blade axis are set as slk, 2slk, . . . (k−1)slk, s; a coordinate system as shown in
According to the determination of the optimal blade axis position of the axial-flow pump under all the operating conditions as described in step F, as shown in
If the maximum hydraulic torque of the blade of the axial-flow pump under all the operating conditions for the blade axis O3-O3 is positive, it is indicated that the optimal blade axis is located between the axis O3-O3 and the axis O2-O2, then a blade axis O4-O4 is set at a distance of 0.618×(1˜0.618)slk from the axis O3-O3 to the axis O2-O2, and the maximum hydraulic torque of the blade of the axial-flow pump under all the operating conditions for the blade axis O4-O4 is calculated and determined; if the maximum hydraulic torque of the blade of the axial-flow pump under all the operating conditions for the blade axis O3-O3 is negative, a blade axis O4-O4 is set at a distance of 0.618×0.618slk from the axis O1-O1 to the axis O3-O3, and the maximum hydraulic torque of the blade of the axial-flow pump under all the operating conditions for the blade axis O4-O4 is calculated and determined; . . . , continue this way until the distance between the last approaching two adjacent blade axes is small enough to satisfy a formula (9),
Δs≤0.001m (9),
the blade axis at this position is the optimal blade axis, which can ensure the minimization of the maximum hydraulic torque of the blade of the axial-flow pump under all the operating conditions.
According to comparison of blade hydraulic torques before and after optimization of the blade axis position of the axial-flow pump as described in step G, the blade hydraulic torque after optimization of the blade axis position is calculated and listed in a Table 2. Taking the blade angle as an abscissa and the blade hydraulic torque as an ordinate, the blade hydraulic torques of the axial-flow pump under m×n calculation conditions before and after the optimization of the blade axis position are plotted on a graph, and blade hydraulic torque points at the same head but different angles are connected to compare the blade hydraulic torque before and after the optimization of the blade axis position.
Results show that after the optimization of the blade axis position of the axial-flow pump, the maximum absolute hydraulic torque of the blade under all the operating conditions is reduced by about ½, an average absolute hydraulic torque of the blade is reduced by about ¾, and the blade hydraulic torque is greatly reduced.
The invention has the beneficial effects that the method for optimizing the blade axis position of the axial-flow pump under all the operating conditions is a blade axis position optimization determination method capable of minimizing the maximum blade hydraulic torque of the axial-flow pump under all the operating conditions at different heads and different blade angles, and can reduce the blade hydraulic torque and adjustment force on the premise of not changing the hydraulic performance of the impeller. Through the calculation and analysis of the blade hydraulic torque and the adjustment force of the full-adjustable axial-flow pumps and guide vane mixed-flow pumps under all the operating conditions, the blade axis position of the axial-flow pump is optimized, and the blade hydraulic torque of the axial-flow pump under all the operating conditions is greatly reduced, thus reducing the adjustment force. The invention has been put into use and can greatly reduce the adjustment force of a blade adjustment mechanism of the axial-flow pump under all the operating conditions, reduce a blade angle adjustment error, improve the accuracy of operating parameters of the axial-flow pump and the reliability and durability of the adjustment mechanism, and prolong the service life, and can be widely applied to large and medium-sized full-adjustable axial-flow pumps and guide vane mixed-flow pumps which are extensively used, so as to promote the industry progress, thus having important significance.
1—blade cross section on a calculation cylindrical surface; 2—current blade axis position; 3—resultant force action line closest to an outlet edge of the blade; 4—resultant force action line closest to an inlet edge of the blade; s—the range which the optimal blade axis position locates in
The present invention will be further described with reference to the following embodiments.
For a large vertical axial-flow pump in a pumping station, impeller diameter D=1640 mm, impeller hub diameter dh=820 mm, blade design angle is 0°, rotation speed is 250 r/min, design head of a pump device is 6 m, design flow is 10.6 m3/s, and blade angle adjustment range is −4°˜+6°. The blade is made of stainless steel, and an impeller and a guide vane structure of the axial-flow pump are known. Performance curves of the pump device are shown in
A. Determination of calculation conditions within the range of all operating conditions of the axial-flow pump
According to the actual operating range of the axial-flow pump, five heads of the pump device: 3.5 m, 4.75 m, 6 m, 7.25 m and 8.5 m, and five blade angles: −4°, −2°, 0°, 3° and 6° are determined, a total of 25 calculation conditions. Through the calculation and analysis of the blade hydraulic torque under the 25 conditions, the blade axis position is optimized to achieve the purpose of reducing the blade hydraulic torque.
B. Three-dimensional modeling and mesh generation of the calculation area of the flow field of the axial-flow pump
This embodiment carries out three-dimensional modeling on the calculation area of the flow field of the axial-flow pump composed of four sections: a section before an impeller inlet, an impeller section, a guide vane body section and a section after the guide vane outlet as shown in
C. Numerical simulation of the flow field of the axial-flow pump and calculation and determination of the blade hydraulic torque
By using CFX fluid calculation software and a k-c turbulence model, the flow field of the 25 calculation conditions in A is numerically simulated, and the internal flow field of the axial-flow pump, the surface pressure distribution of a blade and the blade hydraulic torque are obtained. The hydraulic torques of the 25 calculation conditions are shown in Table 3.
D. Determination of the range of the position of the blade resultant hydraulic pressure action line of the axial-flow pump and the optimal blade axis position under all the operating conditions
Taking the operating point where head H=6 m and blade angle α=0° as an example, forces on the blade in axial, circumferential and radial directions is calculated with CFX: the circumferential resultant force on two sides of the blade is 13642.8 N, the radial resultant force on the two sides is 421.185 N, the axial resultant force on the two sides is 29495.1 N, and the blade hydraulic torque is 2974.868 N·m. A force arm L in the blade cross section is calculated to be 0.0915 m according to a formula (8). As shown in
E. Determination of the small region of the optimal blade axis position of the axial-flow pump under all the operating conditions
As shown in
F. Determination of the optimal blade axis position of the axial-flow pump under all the operating conditions
As shown in
G. Comparison of blade hydraulic torques before and after optimization of the blade axis position of the axial-flow pump
The blade hydraulic torques under 25 calculation conditions after optimization of the blade axis position are shown in Table 5. As shown in Table 3, Table 5 and
Number | Date | Country | Kind |
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201810009782.3 | Jan 2018 | CN | national |
Number | Name | Date | Kind |
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20120082543 | Choudhuri | Apr 2012 | A1 |
Number | Date | Country | |
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20190154040 A1 | May 2019 | US |