CN101893536A - Heated structural member thermal shock and thermal fatigue test stand - Google Patents
Heated structural member thermal shock and thermal fatigue test stand Download PDFInfo
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- CN101893536A CN101893536A CN 201010226496 CN201010226496A CN101893536A CN 101893536 A CN101893536 A CN 101893536A CN 201010226496 CN201010226496 CN 201010226496 CN 201010226496 A CN201010226496 A CN 201010226496A CN 101893536 A CN101893536 A CN 101893536A
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Abstract
The invention relates to a structural member test unit, aiming at providing a heated structural member thermal shock and thermal fatigue test stand which comprises a movable test bench for a test piece erecting stage, wherein a travelling mechanism is arranged below the test piece erecting stage and comprises a sliding sleeve, a guide rail, a rack, a gear, a transmission shaft and a servo motor; the sliding sleeve and the rack are fixed below the test piece erecting stage, and the guide rail is sleeved in the sliding sleeve; a heating station is arranged on the test bench, and the two sides of the heating station are respectively and symmetrically provided with a cooling station; and a burner of a fuel gas heating system is arranged at the heating station, and each cooling station is provided with a compressed air or cooling water outlet. The invention provides a real machine assessment system which can replace the existing thermal fatigue/thermal shock tests of heated parts such as pistons, cylinder covers and the like; and under the condition of no engine model machine, the heated structural member thermal shock and thermal fatigue test stand can carry out hot strength assessment operation on the heated parts such as pistons, cylinder covers and the like, thus not only saving test expenses but also shortening development period.
Description
Technical field
The present invention relates to a kind of component test device, the particularly a kind of heat fatigue of heated components such as engine piston, cylinder cover, testing table of thermal shock strength examination of being applied to.
Background technology
Along with popularizing and development of technology such as improving constantly of engine reinforcing degree, particularly supercharging, the thermal load of heated components such as engine piston, cylinder cover and hot strength problem become increasingly conspicuous, and directly have influence on the functional reliability and the serviceable life of complete machine.In engine working process, heating part bears the effect of alternation thermal load mostly, than being easier to occur hot tearing, burning phenomenon.Meanwhile, outside engine, also exist and much bear the member and the material of the effect of alternation thermal load, therefore studying heated component such as engine piston, cylinder cover and other, to bear heat fatigue, the thermal shock resistance properties of the member of alternation thermal load effect and material significant for improving engine and other member functional reliabilities and overall performance.
At present, in the research field of thermal load, hot strength, main research means has: finite element analysis, real machine torture test and simulated experiment.
Finite element analysis is a kind of computer analysis method that produces along with the computing machine develop rapidly, and is convenient, fast, can carry out computer simulation analysis under the test condition condition of limited.But, whether its accuracy depends on boundary condition and tallies with the actual situation, and boundary condition determine to be fixed against test.
The real machine torture test is near the test method of actual conditions, can truly reflect corresponding performance.But, experimentation cost expends too big, and the test period is oversize, has significant limitation.
Simulation test is a kind of method of testing of design experiment method simulating actual conditions voluntarily, and applicability is very wide, and the cycle is shorter relatively, also has suitable accuracy, is a kind of effective research means.
Summary of the invention
The technical problem to be solved in the present invention is, overcomes deficiency of the prior art, and a kind of heat fatigue of heated components such as engine piston, cylinder cover, testing table of thermal shock strength examination of being applied to is provided.
For solving this technical problem, technical scheme of the present invention is:
A kind of heated structural member thermal shock and thermal fatigue test stand are provided, comprise test-bed; Described test-bed has a movably test specimen mounting platform, and test specimen mounting platform below is provided with travel mechanism; Described travel mechanism comprises sliding sleeve, guide rail, tooth bar, gear, transmission shaft and servomotor, and sliding sleeve and tooth bar are fixed in test specimen mounting platform below, and guide rail sleeve is located among the sliding sleeve, and the installation direction of guide rail and tooth bar is consistent with the moving direction of test specimen mounting platform; Rack and pinion is complementary, and the axle center of gear joins by transmission shaft and servomotor; Described test-bed is provided with heating station, and the symmetria bilateralis of heating station is provided with each one cooling station; The heating station place establishes the burner of gas heating system, the outlet that cooling station place establishes pressurized air or chilled water.
As a kind of improvement, described test specimen mounting platform has the structure of hollow out, and the outlet of chilled water is set below described cooling station.
As a kind of improvement, be provided for the photoelectric sensor and the limit switch of travel distance location on the described test specimen mounting platform.
As a kind of improvement, this testing table also comprises test specimen system for detecting temperature and testing table control system; Described test specimen system for detecting temperature comprises the thermopair of installing on test specimen, and thermopair is connected to temperature transmitter, A/D signal conversion module and the Programmable Logic Controller of testing table control system successively by signal wire; Described Programmable Logic Controller also joins with servomotor, photoelectric sensor and the limit switch be located on the test specimen mounting platform respectively by signal wire.
As a kind of improvement, described testing table has a cooling system, comprises the water tank of establishing electric heater in one, and electric heater links to each other with described Programmable Logic Controller through temperature controller; Gap and cold water water intaking valve also are set on the water tank, and the outlet of water tank links to each other with the outlet of chilled water through water pump.
As a kind of improvement, described testing table has a flame temperature monitoring system, and the flame temperature monitoring system comprises a camera that is used to monitor described burner flame intensity.
As a kind of improvement, described testing table has a data-storage system, and data-storage system comprises a host computer, is connected to described Programmable Logic Controller by signal wire.
As a kind of improvement, described testing table has safety and warning system, safety and warning system comprise be used to detect gas leakage, test specimen is overheated, chilled water hydraulic pressure is low excessively, the overshoot of testing table travel mechanism, test specimen heat time heating time is overtime and the test platform walking is overtime alarm detecting unit; Described Programmable Logic Controller is connected to each alarm detecting unit by signal wire, and Programmable Logic Controller is connected to the total control switch of control gas source and power supply simultaneously by signal wire.
As a kind of improvement, described burner has the shower nozzle of five circle concentric flames; But each circle independent regulation vertical height of burner, its height control amplitude is 10mm; The fuel gas supply of five circles between the shower nozzles be separate, freely select for use; Distance adjustment is between 35～45mm between burner and the test specimen end face.
The invention has the beneficial effects as follows:
The present invention proposes the real machine checking system of the heat fatigue/thermal shock test of heated components such as can substituting present piston, cylinder cover.Current stage particularly, the mode of exploitation is synchronously adopted in the new architecture development usually, and this simulation test can be carried out the hot strength examination work of heated components such as piston, cylinder cover under the situation that does not possess engine specimen, not only saved testing expenses, and the construction cycle that shortens.Thermal shock/the thermal fatigue test stand that can certainly be used for the thermal shock resistance simulation test of other member that bears the effect of alternation thermal load and material.
Description of drawings
Fig. 1 is the side profile view of testing table among the present invention;
Fig. 2 is travel mechanism structural representation (perpendicular to a direction of travel);
Fig. 3 is the result schematic diagram of burner;
Fig. 4 is travel mechanism and heating and cooling system principle of work synoptic diagram;
Fig. 5 is the cooling system synoptic diagram;
Fig. 6 is the control system functional block diagram.
Reference numeral among the figure:
1 guide rail, 2 tooth bars, 3 test specimens to be measured, 4 test specimen mounting platforms, 5 sliding sleeves, 6 transmission shafts, 7 gears, 8 servomotors; The inner ring nozzle of the 4th circle nozzle of the 3rd circle nozzle, 11 burners of 9 heat exchange fins, 10 burners, 12 burners, 13 retaining valves, 14 tensimeters, 15 flow control valves, 16 back fire arresters, 17 mixing chambers, 18 needle valves; 19 cooling air valve B, 20 combustion gas control electromagnetic valve, 21 cooling air valve A, 22 test specimen B, 23 burners, 24 test specimen A, 25 limit switches, 26 cooling water valve B, 27 cooling water valve A, 28 water pumps, 29 water tanks, 30 photoelectric sensors, 31 limit switches, 32 cooling water valve C, 33 cooling water valve D, 34 well heaters; 35 bat-handle switchs, 36 bat-handle switchs, 37 entering water electromagnetic valves, 38 rotary switches, 39 rotary switches, 40 temperature controllers.
Embodiment
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is carried out detailed presentations.
One, the overall formation of heated structural member thermal shock and thermal fatigue test stand
Testing table is made up of test-bed and control system two big parts, and its profile as shown in Figure 1.According to the function branch, it comprises: test specimen mounting platform and travel mechanism thereof, test specimen system for detecting temperature, gas heating system, cooling system, safety and warning system, control system, monitoring and data-storage system etc.
Two, the testing table each several part is introduced
Test specimen mounting platform and travel mechanism
As shown in Figure 2, movably test specimen mounting platform 4 is located on the test-bed, and its below is provided with travel mechanism; Travel mechanism comprises sliding sleeve 5, guide rail 1, tooth bar 2, gear 7, transmission shaft 6 and servomotor 8, sliding sleeve 5 and tooth bar 2 are fixed in test specimen mounting platform 4 belows, guide rail 1 is sheathed among the sliding sleeve 5, and the installation direction of guide rail 1 and tooth bar 2 is consistent with the moving direction of test specimen mounting platform 4; Tooth bar 2 is complementary with gear 7, and the axle center of gear 7 joins by transmission shaft 6 and servomotor 8; Described test-bed is provided with heating station, and the symmetria bilateralis of heating station is provided with each one cooling station; The heating station place establishes the burner 23 of gas heating system, the outlet that cooling station place establishes pressurized air or chilled water.
During the mentality of designing of testing table, two test specimens carry out simultaneously when operation, to improve the operational efficiency of testing table.Test specimen mounting platform 4 is used to install the installation and the location of test specimen, and it passes through gear 7 and tooth bar 2 transmissions by servomotor 8, can be along guide rail 1 to-and-fro movement.The design of travel mechanism is in order to guarantee that two test specimens 3 to be measured move into or shift out heating station or cooling station like clockwork according to the heating cooling cycle of setting.
The burner 23 of testing table is arranged in heating station between two parties, and the shower nozzle of cooling air and chilled water is symmetrically arranged in the cooling station in its left and right sides.As test specimen 3 to be measured are cylinder covers, then are to insert chilled water by flexible pipe.Heating station immobilizes with the cooling station, and the constant distance between them is 440mm, and the spacing that is installed in two test specimens on the mounting platform 4 also is 440mm.In order to ensure the accurate location of test specimen mounting platform 4 in test specimen installation and motion process, two photoelectric sensors 30 have been installed on the corresponding position of travel mechanism.In addition, cause the travel mechanism overshoot, two limit switches 25,31 also have been installed on it for preventing accidental cause.
The working method introduction of travel mechanism:
When non-test, can move test specimen mounting platform 4 by handle, carry out the installation of test specimen and debugging etc.
When on-test, system locatees test specimen mounting platform 4 in the mode of self check automatically, makes test specimen A24 aim at heating station, and it is heated.When the temperature that detects test specimen A24 when thermopair reaches set the highest control temperature (temperature model), or heat time heating time is to (temporal mode), then control system is sent signal, drive servomotor 8 actions, test specimen mounting platform 4 is moved right, make test specimen A24 arrive the cooling station, at this moment test specimen B22 correspondingly enters heating station.After putting in place, the motor stall, control system is sent signal and is opened cooling air valve A21 and cooling water valve A27 simultaneously, and A cools off to test specimen, and test specimen B22 is in heated condition immediately.When test specimen A24 was cooled to set minimum control temperature, control system was sent signal and is closed cooling air valve A21 and cooling water valve A27 (for cylinder cover, cooling water valve is in opening always in process of the test) immediately.Because cooling velocity is faster than firing rate, so this moment, test specimen B22 still was in heated condition, reach the highest set control temperature up to temperature, control system is just sent signal and is driven servomotor 8 counter-rotatings, and test specimen mounting platform 4 is moved to the left.Ensuing action is that test specimen B22 arrives the cooling station, opens cooling air valve B19 and cooling water valve B26 simultaneously, and B22 cools off to test specimen, and meanwhile test specimen A24 is heated once more.So repeat above-mentioned do action, until setting cycle index.
Annotate: cooling water valve B26, A27 are at the piston type member among Fig. 4, and cooling water valve C32, D33 be at cylinder cap class test specimen, different tests opening difference.
The test specimen system for detecting temperature
Testing table can adopt K type thermopair to detect the test specimen temperature, at most 8 measuring points can be installed respectively on two test specimens.Thermopair is welded on the test specimen by thermopair welding instrument.
The thermocouple lead of each measuring point directly is connected on the temperature transmitter in the temperature transmitter case.Temperature transmitter is converted to the standard two-wire system signal of 4～20mA with the electromotive force of the thermopair on two test specimens, imports on 4 general-purpose simulation amount load modules of PLC by twisted-pair feeder then.These load modules carry out the A/D conversion to the signal that imports into, give PLC with test bit then, with the major control signal as thermal load test platform under the temperature model, all data are uploaded in the monitoring PC computing machine by the RS232 communication port and count database simultaneously, in order to post-processed.
This system mainly comprises the temperature transmitter case, AD module, Switching Power Supply etc.
Gas heating system
For the combustion case in the simulated engine cylinder, heating system adopts the mode of combustion gas heating.For improving its programming rate, adopt oxygen-LPG fuel.Its temperature of combustion can reach about 2800 ℃, and operating cost is about about 3/5 of electricity cost.Show that according to preliminary analog reslt its programming rate can meet design requirement fully.Consider the Temperature Distribution of test specimen under actual working state such as piston, cylinder cap, and the adjusting of heated perimeter and intensity during convenient test, designed and produced burner 23 with five circle concentric flame shower nozzles.Fuel gas supply between the five circle shower nozzles is separate, can freely select for use.Distance should be adjusted in 35～45mm between burner 23 and the test specimen end face.But burner 23 each circle independent regulation vertical height, its height control amplitude is about 10mm.Burner 23 is a fuel with the liquefied petroleum gas (LPG), and oxygen is combustion-supporting, can change flame intensity by regulating flow and air-fuel ratio.Burner 23 mission lives can reach more than 5000 hours.Structural representation has shown the structural representation of three circles in the burner 23 as shown in Figure 3 among the figure, the outside two circle structure of nozzle are identical therewith.
The characteristics of burner 23 are:
1). between each nozzle for movingly.By screw thread, can realize coaxial adjusting.Amplitude modulation is about 10mm.Can adopt different heating locations to different test specimens.
2). be provided with cooling water chamber between each nozzle for chilled water usefulness, to guarantee the burner life-span.
3). nozzle-end is provided with 1-2 row φ 1.5-φ 2 apertures that are uniformly distributed along the circumference, to guarantee homogeneous heating and heating intensity.
4). by variable valve, adjustable O
2With the LPG mixing ratio, guarantee combustion gas mixing quality and stability.
5). nozzle top is provided with mixing chamber, guarantees to stablize air feed.
6). nozzle material is a red copper.
7). the tracheae of well heater and water pipe all concentrate in the special-purpose pipe box, guarantee but usefulness of enough water cavity coolings simultaneously, improve the well heater life-span.
8). well heater is provided with and prevents the tempering functional device, guarantees safety.
9) .LPG belongs to inflammable dangerous material, must ensure safety in production in the production run.Well heater is provided with back fire arrester, tensimeter and unidirectional stop valve for this reason, and devices such as LPG gas leakage alarms device are housed in the operating room.
Left side, the testing table back side is pressurized air, oxygen and fuel gas pipeline interface from top to bottom; And five groups of adjusting knobs are arranged in the testing table front, and every group comprises oxygen and two adjusting knobs of combustion gas, the inflammable gas flow and the air-fuel ratio of the every circle nozzle of scalable.
Cooling system
The thermal load test platform adopts two kinds of heat eliminating mediums that test specimen is cooled off.To adopting the pressurized air cooling with the test specimen surface that flame directly contacts, the countercylinder lid is introduced chilled water in its cooling chamber by flexible pipe, with recirculated water cooling under the simulation actual condition; For piston, then to its bottom cooling of spraying water.Cooling water temperature can be provided with on temperature controller 40 before test voluntarily.Duration of test, temperature control system will remain cooling water temperature and be stabilized in and be provided with within ℃ scope of temperature ± 5.Constant for guaranteeing coolant water temperature, well heater 34, hot water gap and cold water water intaking valve have been installed in the water tank 29.Temperature controller 40 is according to thermal resistance signal, the action of control heater 34 and water intaking valve.Promptly, drive relay closes, make cooling water heater 34 energisings, the heating of the chilled waters in the water tank 29 when water temperature during than low 5 ℃ of set cooling water temperature; When water temperature during than high 5 ℃ of set cooling water temperature, drive the cold water water intaking valve and open, along with the adding of cold water, the hot water that is positioned at water tank 29 tops then automatically overflows along gap, thereby the cooling water temperatures in the water tank 29 are descended.Temperature control self-organizing system in the water tank 29 is by temperature controller 40 controls.The synoptic diagram that cooperates of cooling system and heating system and travel mechanism, cooling system synoptic diagram such as Fig. 4, shown in Figure 5.
(1) bat-handle switch 36, and the manual water intaking valve of cooling water tank 29 is used to test forward direction cooling water tank 29 and adds water, when gap has water to overflow, please close this valve.
(2) bat-handle switch 35, cooling water tank 29 draining valves.When the time interval of twice test is longer, in order to prevent to produce scale, perhaps please after off-test, open this valve for antifreeze winter, drain the water in the water tank 29.
(3) rotary switch 38, and burner 23 cooling water flow adjustable valves are used to regulate burner 23 cooling water flows.To guarantee that burner 23 fully cools off.
(4) rotary switch 39, and test specimen cooling water flow adjustable valve is used to regulate the test specimen cooling water flow, to regulate cooldown rate.
(5) entering water electromagnetic valve 37, when water temperature exceeds design temperature in the water tank 29, opened by temperature controller 40 controls, charge into cold water in water tank 29, to keep water tank 29 temperature constant.
(6) well heater 34, and when water temperature was lower than design temperature in the water tank 29, well heater 34 was by temperature controller 40 control heating.
Safety and warning system
Carry out for the safety of warranty test, testing table is provided with multiple warning device.Mainly contain: gas leakage, alarm detecting unit such as test specimen is overheated, chilled water hydraulic pressure is low excessively, the overshoot of testing table travel mechanism, test specimen heat time heating time is overtime, the test platform walking is overtime.Occur above-mentioned any situation in the test, warning system all will be cut off source of the gas, the power supply of testing table automatically, stop all actions of whole all systems, and show fault category on PC.
The testing table control system
This system schematic as shown in Figure 6.The control of testing table and surveillance are used to realize automatic control and the supervision to process of the test.Its main components and parts comprise that PLC installs concentratedly in electrical control cabinet, and one of exterior arrangement is used for the PC of process monitoring and test figure recording processing.PLC is the MELSEC FX of a MIT series Programmable logic Controller (PLC), is used for signals collecting and to the control of testing table various piece.Relation between PC and the PLC is: in the process of the test, even close PC, but PLC operate as normal still, test is carried out as usual, and just data recording is interrupted.Control system adopts the upper and lower computer structure, and the PLC that higher reliability is arranged has complementary advantages as the control core, makes the simple easy operating of whole test and have high stability and security.
The flame temperature monitoring system
This system is used for the monitoring of flame temperature, and fundamental purpose is in the warranty test process, and it is constant that flame intensity keeps.Principle of work is: keep oxygen, gaseous-pressure constant, regulate the two flow by combustion gas, oxygen knob, keep certain air-fuel ratio.The intensity of flame is then taken pictures by camera, reads the gray-scale value of flame image, controls the flame gray-scale value by the adjusting air-fuel ratio and only has fluctuation within a narrow range.
Data-storage system
All measurement result in the test comprises final test findings, all is stored in the host computer appointed positions.The management of data is all carried out in database in the upper computer software, both has been convenient to operation, has also guaranteed safety of data.Each test specimen is all set up corresponding with it data, data attribute is except comprising test specimen parameter and detected parameters, the key word that also has a test group number, this key word has illustrated the test group under this test, after sample Total Tests all in the battery of tests is finished, just can derive whole data and allow computer self handle like this according to this key word.
After statistics was finished, host computer generated the statistical study form automatically, and all simultaneously test figures and result can print output as requested or be converted to the word document.
Three: pilot system is implemented
1. test preliminary work
At first, after test specimen determined, carry out making and installation that temperature sensor is a thermopair.Determine the thermopair model according to the test temperature scope, determine the number of thermopair, determine the thermopair pad, finish the preparation of test specimen according to the collection point according to sampled point.
Secondly, determine that system such as mobile platform, cooling system, heating system, temperature acquisition system and pipeline, circuit are in normal condition.
At last, finish upper computer software and install, the The whole control system self check is normal.
2. process of the test
After set-up procedure finishes, will carry out process of the test.
At first, test parameters is provided with test specimen type, control model, test number, test specimen parameter, cycle index, chilling temperature and cool time, data storage interval etc.
Secondly, after setting completed, system carries out self check, judges whether normal.
At last; manual ignition is tested, and system carries out system monitoring in real time, finds after the fault failure judgement reason and carries out corresponding failure and handle (warning, emergency stop etc.); after finishing test at last, close various switches (burnt gas switch, oxygen switch, water source switch) and power supply.
What more than announce at last, only is specific embodiments of the invention.All distortion that those of ordinary skill in the art can directly derive or associate from content disclosed by the invention all should be thought protection scope of the present invention.
Claims (9)
1. heated structural member thermal shock and thermal fatigue test stand comprise experimental stand, it is characterized in that described test-bed has a movably test specimen mounting platform, and test specimen mounting platform below is provided with travel mechanism; Described travel mechanism comprises sliding sleeve, guide rail, tooth bar, gear, transmission shaft and servomotor, and sliding sleeve and tooth bar are fixed in test specimen mounting platform below, and guide rail sleeve is located among the sliding sleeve, and the installation direction of guide rail and tooth bar is consistent with the moving direction of test specimen mounting platform; Rack and pinion is complementary, and the axle center of gear joins by transmission shaft and servomotor; Described test-bed is provided with heating station, and the symmetria bilateralis of heating station is provided with each one cooling station; The heating station place establishes the burner of gas heating system, the outlet that cooling station place establishes pressurized air or chilled water.
2. testing table according to claim 1 is characterized in that described test specimen mounting platform has the structure of hollow out, and the outlet of chilled water is set below described cooling station.
3. testing table according to claim 1 is characterized in that, is provided for the photoelectric sensor and the limit switch of travel distance location on the described test specimen mounting platform.
4. according to any described testing table in the claim 1 to 3, it is characterized in that this testing table also comprises test specimen system for detecting temperature and testing table control system; Described test specimen system for detecting temperature comprises the thermopair of installing on test specimen, and thermopair is connected to temperature transmitter, A/D signal conversion module and the Programmable Logic Controller of testing table control system successively by signal wire; Described Programmable Logic Controller also joins with servomotor, photoelectric sensor and the limit switch be located on the test specimen mounting platform respectively by signal wire.
5. testing table according to claim 4 is characterized in that described testing table has a cooling system, comprises the water tank of establishing electric heater in one, and electric heater links to each other with described Programmable Logic Controller through temperature controller; Gap and cold water water intaking valve also are set on the water tank, and the outlet of water tank links to each other with the outlet of chilled water through water pump.
6. testing table according to claim 4 is characterized in that, described testing table has a flame temperature monitoring system, and the flame temperature monitoring system comprises a camera that is used to monitor described burner flame intensity.
7. testing table according to claim 4 is characterized in that described testing table has a data-storage system, and data-storage system comprises a host computer, is connected to described Programmable Logic Controller by signal wire.
8. testing table according to claim 4, it is characterized in that, described testing table has safety and warning system, safety and warning system comprise be used to detect gas leakage, test specimen is overheated, chilled water hydraulic pressure is low excessively, the overshoot of testing table travel mechanism, test specimen heat time heating time is overtime and the test platform walking is overtime alarm detecting unit; Described Programmable Logic Controller is connected to each alarm detecting unit by signal wire, and Programmable Logic Controller is connected to the total control switch of control gas source and power supply simultaneously by signal wire.
9. testing table according to claim 4 is characterized in that, described burner has the shower nozzle of five circle concentric flames; But each circle independent regulation vertical height of burner, its height control amplitude is 10mm; The fuel gas supply of five circles between the shower nozzles be separate, freely select for use; Distance adjustment is between 35～45mm between burner and the test specimen end face.
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