CN102735561B - Cylinder head thermal shock test bench based on pre-tightening force, and method thereof - Google Patents
Cylinder head thermal shock test bench based on pre-tightening force, and method thereof Download PDFInfo
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Abstract
The present invention discloses a cylinder head thermal shock test bench based on pre-tightening force, and a method thereof. The test bench comprises a test apparatus and a control system, wherein the test apparatus comprises a cylinder head requiring detection, bolts, a valve mechanism, infrared heaters, an insulation pad, a cylinder gasket, a sense heating coil, a pseudo body, a fixing table stand, a sense heater control system, an infrared heater control system, a water pump, a water tank, a heater, a thermostat, and the like. The cylinder head requiring detection is additionally provided with the valve mechanism. The cylinder head requiring detection, the insulation pad, the cylinder gasket and the pseudo body are sequentially connected, and are fixed with the bolts. The front side and the rear side of the cylinder head requiring detection are provided with the infrared heaters. The sense heating coil is arranged inside the pseudo body. The cylinder head requiring detection is connected with the water tank through a water pipe and is driven by the water pump. Forced water cooling is performed on the cylinder head requiring detection. The test apparatus is controlled by the control system. With the present invention, the pre-tightening force is considered as the mechanical constraint, such that the actual working conditions can be simulated realistically, and the thermal fatigue state and the thermal shock state of the cylinder head can be accurately analyzed so as to improve the credibility of the test results.
Description
Technical field
The present invention relates to consider pretightning force Heat Shock Test Bench, relate in particular to a kind of cylinder cap Heat Shock Test Bench and method thereof of considering pretightning force.
Background technology
Along with the universal and development of the technology such as improving constantly of engine reinforcing degree, particularly supercharging, the thermal load of engine cylinder cover and mechanical load problem become increasingly conspicuous, and directly have influence on functional reliability and the serviceable life of complete machine.In engine working process, the heating parts such as cylinder cap mostly bear alternation thermal load simultaneously and are subject to pretightning force to retrain the dual test of the mechanical load causing, than being easier to occur hot tearing, burning phenomenon.Combined action and the impact of the factors such as the main heat fatigue of reliability, thermal shock, high-temerature creep and the mechanical fatigue of cylinder cap, the inevitable fine crack that cylinder cap exists in casting process can be in alternating thermal stress and Machine Movement Process, generation stress is concentrated, and then crack near fire power face side or firepower surface, and progressively expansion so that fracture, the reliability of serious threat internal combustion engine and security.How to consider various factors impact, the coupling effect that considers various mechanical stresses on the basis of temperature field and thermal stress has become the focus of current engine design.
The main stress that pretightning force is subject under nominal situation as cylinder cap, its large young pathbreaker produces the impact of can not ignore on the mission life of cylinder cap.In the time that engine cylinder cover bolt pretightening is too small, can make cylinder cap cause because not pressing tightly cylinder pad from the gas leakage of cylinder pad, leakage of oil, and reduce the ratio of compression of engine, dynamic property, economy, the functional reliability of engine are declined.In the time that pretightning force is excessive, easily make bolt produce permanent stretcher strain, pretightning force declines on the contrary, even causes slide fastener or the phenomenon that fractures, and cylinder body screw thread subject to damage, thereby affects the sealing of cylinder body and body.
The experimental study in advance of gas engine part is the basic of internal combustion engine product development.Thermal shock simulation test is the temperature field of simulation heated part, analyzes one of effective means of its maximum thermal stress can bear, thermal strain and thermal fatigue life.And the thermal load that the more performance of the damage problem of cylinder cap is born due to parts produces, so thermal shock simulation test is the important method of research cylinder cap reliability, only have simulation cylinder head temperature field truly, could its heat resistanceheat resistant load performance of accurate evaluation.Therefore the ripe complete thermal shock test system of design, draws cylinder cap heat fatigue, thermal shock process under realistic operating mode, has become the another large important topic of Hyundai Motor industry.But, component structural strength study aspect at present, pretightning force is only applied to detecting in the mechanical fatigue of gas engine part, do not relate to, and engine cylinder head system is inevitable bearing pretightening force under nominal situation in thermal modeling test.This ignoring pretightning force impact, can cause the error between actual condition, thermal deformation exerts an influence to parts in finite element simulation calculates, also to have found the constraint of pretightning force, therefore the constraint of, ignoring pretightning force in cylinder cap thermal shock simulation test procedure can reduce the confidence level of test findings greatly.
Based on above reason, the cylinder cap heat fatigue of consideration pretightning force, the development of thermal shock test system are for simulating more realistically actual condition, accurately research and analyse the hot state of cylinder cap, fill up the scientific research blind spot of current heat fatigue, thermal shock test system, to improving the design of cylinder cap, improve internal combustion engine and other member functional reliability and overall performance, increase economic efficiency etc. all significant.
Summary of the invention
In order to solve deficiency of the prior art, the object of the present invention is to provide a kind of cylinder cap Heat Shock Test Bench and method thereof of considering pretightning force.
For solving this technical problem, technical scheme of the present invention is:
Consider the cylinder cap Heat Shock Test Bench of pretightning force, comprise test unit and control system, wherein test unit comprises the first rotary switch, cylinder cap to be measured, bolt, valve mechanism, infrared heater, heat insulating mattress, cylinder pad, load coil, false body, fixing with stand, induction heater control system, infrared heater control system, water pump, rising pipe, water tank, well heater, the second rotary switch, electric wire, water inlet pipe, recirculatory pipe, first handle switch, entering water electromagnetic valve, second handle switch, temperature controller and thermopair, on cylinder cap to be measured, install valve mechanism additional, cylinder cap to be measured, heat insulating mattress, cylinder pad, false body is connected in turn, and be bolted, before and after cylinder cap to be measured, both sides arrange infrared heater, in false body, be provided with load coil, false body is placed on fixing with on stand, infrared heater is connected with infrared heater control system, in water tank, be provided with well heater, temperature controller, well heater is connected with Programmable Logic Controller through temperature controller, water outlet of water tank is connected with cylinder cap water inlet to be measured through rising pipe, rising pipe is provided with water pump, the first rotary switch, water tank recirculatory pipe is connected with cylinder cap water delivering orifice to be measured, be two-way from the moisture of water inlet pipe, a-road-through is toward load coil, another road is through first handle switch, entering water electromagnetic valve control, flow into water tank, overflow pipe is divided into two-way, a-road-through is toward the gap of water tank upper end, another road is connected to water tank lower end through second handle switch, load coil is connected with induction heater control system through electric wire, load coil is connected with water tank refluxing opening through recirculatory pipe, on water inlet pipe, be provided with the second rotary switch, the thermopair that cylinder cap to be measured is provided with, thermopair is connected to testing table control system successively by signal wire, induction heater control system is connected with Programmable Logic Controller respectively with infrared heater control system, test unit is by control system control.
Described control system comprises temperature transmitter, an AD module, the 2nd AD module, the 3rd AD module, relay, Programmable Logic Controller, communication module, PC, printer, display; Programmable Logic Controller is connected with an AD module, the 2nd AD module, the 3rd AD module, relay, communication module respectively, temperature transmitter is connected with an AD module, the 2nd AD module, the 3rd AD module respectively, communication module is connected with PC, and PC is connected with printer, display.
The cylinder cap thermal shock test method of the consideration pretightning force of described testing table, comprises the steps:
1) 4 thermopairs are welded on respectively near cylinder cap intake and exhaust to be measured doorway near near two sides place, front and back, atomizer, centre position, ridge area place;
2) choose a block length and width dimensions respectively the rectangular parallelepiped cast iron identical with width dimensions with the length of cylinder cap to be measured make false body, be cast with threaded hole carrying out bolt junction with cylinder cap to be measured, by false body middle part just to cylinder cap fire power face to be measured place, the circle take fire power face the end of as, false body is punched with right cylinder form, install additional after heat insulating mattress, cylinder pad, use bolt to be connected with cylinder cap to be measured;
3) on bolt, apply and the pretightning force of cylinder cap equal sizes to be measured;
4) select plane thread formula induction heating head, make two independently inductive coils of semi-circular canoe;
5) control model, test number, cylinder cap parameter to be measured, cycle index, basal temperature, cylinder cap heating-up temperature to be measured or heat time, Cooling of Cylinder Head temperature to be measured or cool time, cooling water temperature, data memory gap are set on PC;
6) open infrared heater, when after the basal temperature that cylinder cap to be measured is heated to arrange, load coil energising, continue heating cylinder cap to be measured, in the time that thermopair detects that the temperature of cylinder cap to be measured reaches set the highest control temperature, or while reaching the heat time, Programmable Logic Controller sends signal, load coil power-off, start pump working, by Cooling of Cylinder Head to be measured to basal temperature, or reach after cool time, Programmable Logic Controller sends signal and switches off the pump immediately, stops cooling water circulation, so far completes one action circulation; So repeat above-mentioned do action, until set cycle index.
The present invention proposes the engine test system that can substitute current cylinder cap thermal shock test.The particularly current stage, thermal modeling test is not all considered the impact of mechanical constraint, and the present invention has introduced pretightning force as mechanical constraint, can simulate more realistically actual condition, accurately research and analyse heat fatigue, the thermal shock state of cylinder cap, thereby improve the confidence level of test findings.
Accompanying drawing explanation
Fig. 1 is the cylinder cap Heat Shock Test Bench structural representation of considering pretightning force;
Fig. 2 is inductive coil canoe schematic diagram of the present invention;
Fig. 3 is induction heating schematic diagram of the present invention;
Fig. 4 is cooling schematic diagram of the present invention;
Fig. 5 is control system schematic diagram of the present invention;
In figure: the first rotary switch 1, cylinder cap to be measured 2, bolt 3, valve mechanism 4, infrared heater 5, heat insulating mattress 6, cylinder pad 7, load coil 8, false body 9, fixing with stand 10, induction heater control system 11, infrared heater control system 12, water pump 13, rising pipe 14, water tank 15, well heater 16, the second rotary switch 17, electric wire 18, water inlet pipe 19, recirculatory pipe 20, first handle switch 21, entering water electromagnetic valve 22, second handle switch 23, temperature controller 24.
Embodiment
As Fig. 1, 3, shown in 4, the cylinder cap Heat Shock Test Bench of considering pretightning force comprises test unit and control system, wherein test unit comprises the first rotary switch 1, cylinder cap 2 to be measured, bolt 3, valve mechanism 4, infrared heater 5, heat insulating mattress 6, cylinder pad 7, load coil 8, false body 9, fixing with stand 10, induction heater control system 11, infrared heater control system 12, water pump 13, rising pipe 14, water tank 15, well heater 16, the second rotary switch 17, electric wire 18, water inlet pipe 19, recirculatory pipe 20, first handle switch 21, entering water electromagnetic valve 22, second handle switch 23, temperature controller 24 and thermopair,
On cylinder cap 2 to be measured, install valve mechanism 4 additional, cylinder cap 2 to be measured, heat insulating mattress 6, cylinder pad 7, false body 9 is connected in turn, and fixing by bolt 3, cylinder cap to be measured 2 both sides, front and back arrange infrared heater 5, in false body 9, be provided with load coil 8, false body 9 is placed on fixing with on stand 10, infrared heater 5 is connected with infrared heater control system 12, in water tank 15, be provided with well heater 16, temperature controller 24, well heater 16 is connected with Programmable Logic Controller through temperature controller 24, water tank 15 water delivering orifices are connected with cylinder cap 2 water inlets to be measured through rising pipe 14, rising pipe 14 is provided with water pump 13, the first rotary switch 1, water tank 15 recirculatory pipes are connected with cylinder cap 2 water delivering orifices to be measured, be two-way from the moisture of water inlet pipe, a-road-through is toward load coil 8, another road is through first handle switch 21, entering water electromagnetic valve 22 is controlled, flow into water tank 15, overflow pipe is divided into two-way, a-road-through is toward the gap of water tank 15 upper ends, another road is connected to water tank 15 lower ends through second handle switch 23, load coil 8 is connected with induction heater control system 11 through electric wire 18, load coil 8 is connected with water tank 15 refluxing openings through recirculatory pipe 20, on water inlet pipe 19, be provided with the second rotary switch 17, the thermopair that cylinder cap 2 to be measured is provided with, thermopair is connected to testing table control system successively by signal wire, induction heater control system 11 is connected with Programmable Logic Controller respectively with infrared heater control system 12, test unit is by control system control.
As shown in Figure 5, control system comprises temperature transmitter, an AD module, the 2nd AD module, the 3rd AD module, relay, Programmable Logic Controller, communication module, PC, printer, display; Programmable Logic Controller is connected with an AD module, the 2nd AD module, the 3rd AD module, relay, communication module respectively, temperature transmitter is connected with an AD module, the 2nd AD module, the 3rd AD module respectively, communication module is connected with PC, and PC is connected with printer, display.
The cylinder cap thermal shock test method of considering pretightning force comprises the steps:
1) 4 thermopairs are welded on respectively near cylinder cap to be measured 2 intake and exhaust doorways near near two sides place, front and back, atomizer, centre position, ridge area place;
2) choose a block length and width dimensions respectively the rectangular parallelepiped cast iron identical with width dimensions with the length of cylinder cap 2 to be measured make false body 9, be cast with threaded hole carrying out bolt junction with cylinder cap 2 to be measured, by false body 9 middle parts just to cylinder cap to be measured 2 fire power face places, the circle take fire power face the end of as, false body 9 is punched with right cylinder form, install additional after heat insulating mattress 6, cylinder pad 7, be connected with cylinder cap 2 to be measured with bolt 3;
3) on bolt 3, apply and the pretightning force of cylinder cap 2 equal sizes to be measured;
4) select plane thread formula induction heating head, make two independently inductive coils of semi-circular canoe;
5) control model, test number, cylinder cap parameter to be measured, cycle index, basal temperature, cylinder cap heating-up temperature to be measured or heat time, Cooling of Cylinder Head temperature to be measured or cool time, cooling water temperature, data memory gap are set on PC;
6) open infrared heater 5, when after the basal temperature that cylinder cap 2 to be measured is heated to arrange, load coil 8 is switched on, continue heating cylinder cap 2 to be measured, in the time that thermopair detects that the temperature of cylinder cap 2 to be measured reaches set the highest control temperature, or while reaching the heat time, Programmable Logic Controller sends signal, load coil 8 power-off, start water pump 13 and work, and cylinder cap 2 to be measured is cooled to basal temperature, or reach after cool time, Programmable Logic Controller sends signal and switches off the pump immediately 13, stops cooling water circulation, so far completes one action circulation; So repeat above-mentioned do action, until set cycle index.
Consider versatility and the simplicity of testing table, having adopted the false body 9 of designed, designed to carry out bolt with cylinder cap 2 to be measured is connected, like this in the time adopting the cylinder cap of different model to carry out thermal shock test, can be by changing the size of false body 9 and material with the diversified requirement of adequacy test system.False body 9 be shaped as rectangular parallelepiped, be cast with corresponding threaded hole carrying out bolt junction with cylinder cap 2 to be measured, be the firing chamber of simulation cylinder head fire power face below, false body middle part is punched with right cylinder form, in order to place load coil 8.For simulating actual conditions more realistically, between cylinder cap to be measured and false body, add cylinder pad 6, between cylinder cap 2 to be measured and false body 9, add heat insulating mattress 6, be placed on cylinder pad 7, can completely cut off like this heat transmission between cylinder cap fire power face and false body, make fire power face in heating process, can reach in the short period of time the maximum temperature that test sets.
Consider the cylinder lid surface various ducts that distributing, be unfavorable for the circulation of homogeneous heating and chilled water, therefore on cylinder cap 2 to be measured, install valve mechanism 4 additional, so that fire power face base closed, get through chilled water Inlet and outlet water duct on two surfaces, cylinder cap to be measured left and right, internal direct is connected to cylinder cap water channel, adopts seal pad to seal in unnecessary cylinder cap outside surface to be measured duct simultaneously.
Thermopair is for gathering the temperature value of each measuring point on cylinder cap, as the major control signal of Heat Shock Test Bench.Can adopt K type thermopair to detect cylinder cap temperature, 4 measuring points are installed.Thermopair is welded on cylinder cap to be measured by thermocouple welding instrument.
The thermocouple lead of each measuring point is directly connected on the temperature transmitter in temperature transmitter case.Temperature transmitter is converted to the electromotive force of the thermopair on cylinder cap the standard two-wire system signal of 4～20mA, then imports on 4 general-purpose simulation amount load modules of PLC by twisted-pair feeder.These load modules carry out A/D conversion to the signal importing into, then give PLC by test bit, using the major control signal of Heat Shock Test Bench under temperature model, all data are uploaded in monitoring PC computing machine and are counted database by RS232 communication port simultaneously, in order to post-processed.
User can be according to the heating head shape of cylinder cap type and test demand designed, designed induction heater, to reach the object of simulating different heated perimeter and heating intensity for the heated part of different cylinder caps.This testing table is selected plane thread formula induction heating head, and the concrete canoe of coil can need to be set voluntarily according to cylinder cap type and test.As far as possible even for guaranteeing the heating efficiency of fire power face; the inductive coil arrangement mode that this pilot system adopts as shown in Figure 2; be two independently semi-circular canoe be connected in parallel; wherein arrow indication is direction of current; can be heated and heat the fire power face of whole cylinder cap to be measured under prerequisite not reducing central part like this; simultaneously corresponding two valve centers of cylinder cap respectively, the center of two back-shaped positions, to reach this test demand.
Heat Shock Test Bench adopts cooling water circulation to carry out cooling to cylinder cap 2 to be measured and load coil 8.Cylinder cap 2 left and right sides to be measured have been got through chilled water Inlet and outlet water duct, and cylinder cap water channel inner and to be measured communicates, and are connected with water tank 15 by water pipe, are driven circulating water under simulation actual condition by water pump 13.Cooling water temperature can arrange voluntarily before test on temperature controller 24.Duration of test, within temperature control system will remain that cooling water temperature is stabilized in set temperature ± 5 ℃ scope.Constant for guaranteeing coolant water temperature, interior well heater 16, hot water gap and the cold water water intaking valve installed of water tank 15.Temperature controller 24 is according to thermal resistance signal, the action of control heater 16 and water intaking valve.When water temperature is during than low 5 ℃ of set cooling water temperature, drive relay closes, cooling water heater 16 is switched on, to the chilled water heating in water tank 15; When water temperature is during than high 5 ℃ of set cooling water temperature, drive cold water water intaking valve to open, along with adding of cold water, the hot water that is positioned at water tank 15 tops automatically overflows along gap, thereby the cooling water temperature in water tank 15 is declined.The interior temperature control of water tank 15 self-organizing system, is controlled by temperature controller 24.Cooling schematic diagram as shown in Figure 4.
(1) first rotary switch 1, Cooling of Cylinder Head Water flow adjusting valve to be measured, for regulating Cooling of Cylinder Head discharge to be measured, to regulate cooldown rate.
(2) second rotary switches 17, load coil 8 cooling water flow adjustable valves, for regulating load coil 8 cooling water flows, fully cooling to guarantee load coil 8.
(3) first handle switch 21, the manual water intaking valve of cooling water tank 15, adds water for testing forward direction cooling water tank 15, in the time that gap has water to overflow, please close this valve.
(4) second handle switch 23, cooling water tank 15 draining valves.In the time that time interval of twice test is longer, in order to prevent scale, or winter for antifreeze, please after off-test, open this valve, drain the water in water tank 15.
(5) well heater 16, in the time that in water tank 15, water temperature is lower than design temperature, well heater 16 is controlled heating by temperature controller 24.
(6) entering water electromagnetic valve 22, in the time that water temperature exceedes design temperature in water tank 15, controls it by temperature controller 24 and opens, and in water tank 15, is filled with cold water, to keep water tank 15 temperature constant.
For warranty test carries out safely, testing table can also arrange following safety and warning device:
(1) cylinder cap temperature alarm.The highest control temperature that exceedes setting when heated cylinder lid surface temperature is more than 30 ℃, and while also not automatically switching to cooling procedure, safety and warning device are reported to the police, and close the action of whole pilot system, and on PC, show fault category.Otherwise possible ablation cylinder lid surface or burn out thermopair.
(2) the too low warning of induction heater cooling water channel hydraulic pressure.Too low when hydraulic pressure in cooling water pipeline, inadequate to the intensity of cooling of induction heater, safety and warning device are reported to the police, and close the action of whole pilot system, and on PC, show fault category.
Control system schematic diagram as shown in Figure 5.The control of testing table and surveillance are for realizing the automatic control & monitor to process of the test.Its main components, comprises that PLC installs concentratedly in electrical control cabinet, PC for process monitoring and test figure recording processing of exterior arrangement.PLC is the MELSEC FX of MIT series Programmable logic Controller (PLC), for signals collecting and the control to testing table various piece.Relation between PC and PLC is: in process of the test, even if close PC, PLC still can normally work, and test is carried out as usual, and just data recording is interrupted.Control system adopts upper and lower computer structure, has the PLC of higher reliability as control core, has complementary advantages, and makes the simple easy operating of whole test and has very high stability and security.
Finally; what more than announce is only the specific embodiment of the present invention; all distortion that those of ordinary skill in the art can directly derive or associate from content disclosed by the invention only adopt cylinder cap Heat Shock Test Bench and the method thereof of the consideration pretightning force of temporal mode as cylinder cap 2 to be measured is not provided with thermopair, also should think within protection scope of the present invention.
Claims (1)
1. consider the cylinder cap Heat Shock Test Bench of pretightning force for one kind, it is characterized in that comprising test unit and control system, wherein test unit comprises the first rotary switch (1), cylinder cap to be measured (2), bolt (3), valve mechanism (4), infrared heater (5), heat insulating mattress (6), cylinder pad (7), load coil (8), false body (9), fixing with stand (10), induction heater control system (11), infrared heater control system (12), water pump (13), rising pipe (14), water tank (15), well heater (16), the second rotary switch (17), electric wire (18), water inlet pipe (19), recirculatory pipe (20), overflow pipe, first handle switch (21), entering water electromagnetic valve (22), second handle switch (23), temperature controller (24) and thermopair, on cylinder cap to be measured (2), install valve mechanism (4) additional, cylinder cap to be measured (2), heat insulating mattress (6), cylinder pad (7), false body (9) is connected in turn, and fixing by bolt (3), before and after cylinder cap to be measured (2), both sides arrange infrared heater (5), in false body (9), be provided with load coil (8), false body (9) is placed on fixing with on stand (10), infrared heater (5) is connected with infrared heater control system (12), in water tank (15), be provided with well heater (16), temperature controller (24), well heater (16) is connected with Programmable Logic Controller through temperature controller (24), water tank (15) water delivering orifice is connected with cylinder cap to be measured (2) water inlet through rising pipe (14), rising pipe (14) is provided with water pump (13), the first rotary switch (1), water tank (15) recirculatory pipe is connected with cylinder cap to be measured (2) water delivering orifice, be two-way from the moisture of water inlet pipe, a-road-through is toward load coil (8), another road is through first handle switch (21), entering water electromagnetic valve (22) is controlled, flow into water tank (15), overflow pipe is divided into two-way, a-road-through is toward the gap of water tank (15) upper end, another road is connected to water tank (15) lower end through second handle switch (23), load coil (8) is connected with induction heater control system (11) through electric wire (18), load coil (8) is connected with water tank (15) refluxing opening through recirculatory pipe (20), on water inlet pipe (19), be provided with the second rotary switch (17), cylinder cap to be measured (2) is provided with thermopair, thermopair is connected to control system successively by signal wire, induction heater control system (11) is connected with Programmable Logic Controller respectively with infrared heater control system (12), test unit is by control system control,
Described control system comprises temperature transmitter, an AD module, the 2nd AD module, the 3rd AD module, relay, Programmable Logic Controller, communication module, PC, printer, display; Programmable Logic Controller is connected with an AD module, the 2nd AD module, the 3rd AD module, relay, communication module respectively, temperature transmitter is connected with an AD module, the 2nd AD module, the 3rd AD module respectively, communication module is connected with PC, and PC is connected with printer, display.
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| CN101893536A (en) * | 2010-07-13 | 2010-11-24 | 浙江大学 | Heated structural member thermal shock and thermal fatigue test stand |
| CN102401807A (en) * | 2011-11-09 | 2012-04-04 | 浙江大学 | Heat transfer test system of high heat-flow density heated test piece |
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