基于热弹性流体动力学理论的液压变压器组合式配流盘摩擦副润滑特性研究

Hydraulic transformer is the core component of secondary regulated system of constant pressure network. To solve bad working characteristics, vibration and noise of the hydraulic transformer, the new combined valve plate with good development was invented. However, the structure of combined valve plate with several interaction friction pairs is complex. The lubrication characteristics of the friction pairs are affected by heat, surface roughness, mixed friction, micro motion and thermal elastic deformation of solid element. And, oil film stability is bad and there are more friction energy loss and leakage. The correlation and effect law of the factors is complex, and lack of a set of systems theory and model. Based on the thermal elastohydrodynamic theory, theoretical modeling, numerical simulation and experimentation of the lubrication characteristics of combined valve plate in high pressure are researched in the project. The heat-force-flow fields of the combined valve plate in high pressure would be revealed. The influencing factors of lubrication characteristics of the combined valve plate would be clarified, the relationships among the influencing factors mastered, and the law of the effect factors grasped. A set of lubrication theoretical model and solving algorithm of high pressure valve plate would be established. Theoretical and technical support would be provided for hydraulic transformer in high pressure with the combined valve plate, and the secondary regulated technology of constant pressure network. It is good for the national energy-saving and emission-reduction.

液压变压器是恒压网络二次调节系统的核心元件。针对液压变压器面临的工作特性差、振动和噪声难题，申请人发明了组合式配流盘新技术，发展前景良好。然而，组合式配流盘结构较复杂，摩擦副多且相互干扰，其摩擦副润滑特性受表面粗糙度、混合摩擦、固体单元微运动等多因素影响，导致油膜稳定性差，热效应、摩擦和泄漏严重；并且这些影响因素的相互关系和作用规律复杂，目前仍缺乏一套系统理论。本项目以组合式配流盘摩擦副润滑特性为研究对象，以热弹性流体动力学理论为基础，从摩擦副润滑特性理论建模、数值模拟和实验三方面展开研究，旨在揭示组合式配流盘摩擦副的热-力-流场分布规律，厘清组合式配流盘摩擦副润滑特性影响因素，探明润滑特性影响因素的相互关系，掌握润滑特性影响因素的作用规律，建立一套组合式配流盘摩擦副润滑特性理论模型和求解算法，为组合配流盘式液压变压器研发，为二次调节节能技术推广应用，为国家节能减排提供理论与技术支撑。

静压式柱塞泵、马达和液压变压器是高能量密度静液传动系统的核心。该类元件的配流副润滑油膜工作特性对于元件性能、效率和可靠性等十分重要，由于受多自由度力与力矩、静动压力场、接触面轮廓、配流副油膜几何形状等多因素影响，理论建模和研究难度很大。本项目针对配流副润滑油膜工作特性，改进了配流副多自由度力与力矩模型，采用雷诺方式导出油膜动压力场和速度场模型，采用G-W粗糙接触面模型导出接触应力场模型；建立了配流副润滑油膜几何形状理论新模型，考虑了主轴与柱塞缸同轴度、配流盘偏磨等因素，定义了多个新变量：X楔形角、Y楔形角、Z楔形角、磨损楔形角、总楔形角及对应方位角；结合力学和几何模型，建立了配流副润滑油膜的力-流-热多领域耦合理论模型；搭建了配流副润滑油膜厚度测量试验平台；结合理论与试验结果，系统研究了配流副的多自由度力与力矩的动态特性、配流副油膜的楔形角、方位角、最小油膜厚度的稳态和动态特性、多矢量场（接触应力场、油膜压力场、速度场和温度场）的影响因素与影响规律。研究结果表明，Z轴向力和绕X、Y轴力矩在周期[0,2π/Z]内明显包含四个阶段；同轴度误差和配流盘偏磨是形成油膜总楔形角的主要因素；油膜总楔形角、总方位角、最小油膜厚度曲线均是在周期[0,2π]内存在7次微波动的三角函数曲线；最小油膜厚度附近区域的接触应力最高、动压力变化最大、泄漏速度最小、流固体温度最高。通过研究，厘清了配流副润滑油膜工作特性的影响因素及其影响规律，建立了配流副油膜力-流-热多领域耦合理论模型与试验方法，揭示了油膜温度场-压力场-速度场变化规律，为轴向柱塞泵、马达、液压变压器正向研发与再优化，为二次调节节能技术和压力耦合性混合动力技术推广应用，为国家节能减排提供理论与技术支撑。

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