Hydraulic design method and system
Technical Field
The invention relates to the technical field of hydraulic design, in particular to a hydraulic design method and a hydraulic design system.
Background
In the aspect of industrial model selection at present, a conventional model selection mode is that a design institute designs a water pump system according to the operation requirement of an end user, and a pump factory performs model matching and supply according to system parameters provided by the design institute. In this process, there are two main intervals that result in significant differences between the actual operating parameters of the pump and the design requirements. 1. The difference between the system design parameters provided by the system design and the actual operation requirements; 2. the difference between the pump plant model and the system design parameters.
1. System design parameter and actual operation requirement difference provided by system design
The traditional hydraulic design method in China adopts a pump binary design method appearing in the seventies of the last century. The hydraulic working environment is simplified by analyzing the water pump impeller flow channel and the pump body flow channel on a curved surface, and the fluid flow state of the impeller flow channel is taken as a variable. On the basis, the whole impeller hydraulic model is designed. In view of its simplified operating condition data, it takes more empirical data, i.e., reference coefficients, in its design process and then generates a model through iterative calculations. The hydraulic model generated by the design method has a certain difference with the actual hydraulic model, and the environmental influence in three-dimensional spaces such as an impeller and an impeller outlet vortex is less considered. Therefore, the system design is carried out based on the method, so that the provided system design parameters have certain gaps with actual operation requirements.
2. Difference between pump plant model and system design parameters
When a pump factory designs the type and the application range of a pump, the application range of the pump is defined aiming at the optimal operation interval of the pump. According to the performance curve of the pump, the efficiency curve of the pump is a parabola, and the optimal operation interval is an interval at the top end of the parabola.
After receiving the system design parameters, the pump factory judges the application range of the pump of which type according to the system design parameters, and can include the design parameters, and then determines the type of the pump according to the system design parameters. According to the model of the pump selected by the method, system design parameters can be in the middle section of the optimal operation range, namely the range with the highest operation efficiency of the pump, and the operation efficiency of the pump is the highest when the pump operates under the operation working condition of the section; it is also possible that the design parameters are at the edge of the optimum operating range, at a distance from the optimum operating point for the two different types of pump. Assuming that the system design parameters can reflect the requirements of the operation site on the operation of the pump, the operation working efficiency of the pump is lower than the normal output level. If deviations of system design parameters from actual operating requirements are taken into account, it is likely that the operating interval of the pump has completely deviated from the optimal operating interval.
The high-efficiency working area of the pump is a limited area, and once the high-efficiency working area deviates, the efficiency is low and the energy consumption is remarkably wasted.
Therefore, the hydraulic design is carried out by adopting the prior art, the equipment has low use efficiency and large power consumption.
Disclosure of Invention
The invention provides a hydraulic design method and a hydraulic design system for solving the existing problems.
In order to solve the above problems, the technical solution adopted by the present invention is as follows:
a hydraulic design method comprising the steps of: s1: selecting the type of a pump according to actual requirements and scanning the pump to obtain a three-dimensional model of the pump; the pump comprises a pump shell, wherein an impeller is arranged in the pump shell, the impeller is connected with a pump shaft, and the pump shaft is used for driving the impeller to rotate; s2: intercepting a two-dimensional graph according to the three-dimensional model of the pump, wherein the surface of the two-dimensional graph is vertical to the surface of the rotating shaft; s3: performing two-dimensional hydraulic calculation on the two-dimensional graph; s4: connecting the results of the two-dimensional hydraulic calculation in series to obtain a hydraulic model, wherein the hydraulic model comprises a motion state and an energy conversion state; s5: the hydraulic model is checked through a simulation technology, and the hydraulic model is adjusted according to a checking result; s6: determining the hydraulic model.
Preferably, the new two-dimensional graph is cut when the size of the impeller of the three-dimensional model changes by more than 2% of the size of the impeller.
Preferably, the type of pump comprises a positive displacement pump, a vane pump or a jet pump.
Preferably, the test results include flow, head, efficiency and energy consumption of the incompressible fluid.
Preferably, the pump is scanned using a three-dimensional laser scanning device.
Preferably, the method further comprises the following steps: s7: determining a material of the pump according to the hydraulic model.
The present invention also provides a hydraulic design system comprising: a first module: selecting the type of a pump according to actual requirements and scanning the pump to obtain a three-dimensional model of the pump; the pump comprises a pump shell, wherein an impeller is rotationally connected in the pump shell, a rear cover is arranged on the pump shell, a rotating shaft is rotationally connected on the rear cover, and the rotating shaft is connected with the impeller and used for driving the impeller to rotate; a second module: intercepting a two-dimensional graph according to the three-dimensional model of the pump, wherein the surface of the two-dimensional graph is vertical to the surface of the rotating shaft; a third module: performing two-dimensional hydraulic calculation on the two-dimensional graph; a fourth module: connecting the results of the two-dimensional hydraulic calculation in series to obtain a hydraulic model, wherein the hydraulic model comprises a motion state and an energy conversion state; a fifth module: the hydraulic model is checked through a simulation technology, and the hydraulic model is adjusted according to a checking result; a sixth module: determining the hydraulic model.
Preferably, a new two-dimensional graph is intercepted when the size of the impeller of the three-dimensional model changes by more than 2%.
Preferably, the type of pump comprises a positive displacement pump, a vane pump or a jet pump.
Preferably, the test results include flow, head, efficiency and energy consumption of the incompressible fluid.
The invention has the beneficial effects that: the method comprises the steps of providing a hydraulic design method and a hydraulic design system, directly collecting the requirements on hydraulic equipment in an operation working condition by an object-oriented sampling method, and avoiding a fuzzy space caused by system design parameters; meanwhile, the three-dimensional model is used as a design reference, the hydraulic model is closer to reality, and the hydraulic efficiency of the final user side is improved in the whole process from the targeted setting of hydraulic parameters, the establishment of the hydraulic model and the output of hydraulic parts.
Drawings
FIG. 1 is a schematic illustration of a hydraulic design process in an embodiment of the present invention.
FIG. 2 is a schematic illustration of yet another hydraulic design method in an embodiment of the present invention.
FIG. 3 is a schematic illustration of a hydraulic design system in an embodiment of the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects to be solved by the embodiments of the present invention more clearly apparent, the present invention is further described in detail below with reference to the accompanying drawings and the embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element. In addition, the connection may be for either a fixing function or a circuit connection function.
It is to be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in an orientation or positional relationship indicated in the drawings for convenience in describing the embodiments of the present invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed in a particular orientation, and be in any way limiting of the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of the present invention, "a plurality" means two or more unless specifically limited otherwise.
The pump is an energy conversion device; there are both useful and non-useful power in the energy conversion process. Useful work is the fully utilized energy converted or transferred, while useless work is lost. Generally, efficiency maximization is a major goal pursued in energy conversion processes. Therefore, how to reduce the loss and improve the efficiency becomes one of the most concerned issues for designers. According to the working principle, the method comprises the following steps:
the displacement pump sucks and discharges liquid by periodically increasing and decreasing the working volume caused by the movement of the working member, and directly increases the pressure energy of the liquid by the extrusion of the working member. The motion mode of the motion part is divided into: reciprocating pumps and rotary pumps. According to different structures of the moving parts: piston pump and plunger pump, including gear pump, screw pump, vane pump and water ring pump.
The impeller pump is characterized in that an impeller drives liquid to rotate at a high speed to transfer mechanical energy to the conveyed liquid. The impeller type can be divided into the following according to different impeller and flow passage structure characteristics of the pump: centrifugal pump, axial-flow pump, mixed-flow pump, peripheral pump.
The jet pump is to inject fluid by high speed jet produced by working fluid and then increase the energy of the injected fluid by momentum exchange.
The pump can be further divided into: vertical pumps, horizontal pumps; the method is divided into the following parts according to the number of suction ports: single-suction pump, double-suction pump; according to the prime mover driving the pump: electric pump, steam turbine pump, diesel engine pump, pneumatic diaphragm pump.
It will be appreciated that the hydraulic design method of the present invention is applicable to all pumps as described above, i.e. is a general method. The impeller is arranged in the pump shell and is fastened on the pump shaft, and the pump shaft is directly driven by the motor. The center of the pump shell is provided with a liquid suction pipe. The liquid enters the pump through the bottom valve and the suction pipe. The liquid discharge port on the pump housing is connected to a discharge pipe.
Before the pump is started, the pump shell is filled with the conveyed liquid; after starting, the impeller is driven by the shaft to rotate at high speed, and the liquid between the blades must also rotate along with the impeller. Under the action of centrifugal force, the liquid is thrown from the center of the impeller to the outer edge and obtains energy, and the liquid leaves the outer edge of the impeller at high speed and enters the volute pump shell. In the volute, the liquid is decelerated due to the gradual expansion of the flow passage, part of kinetic energy is converted into static pressure energy, and finally the static pressure energy flows into a discharge pipeline at higher pressure and is sent to a required place. When the liquid flows from the center of the impeller to the outer edge, a certain vacuum is formed in the center of the impeller, and the liquid is continuously pressed into the impeller because the pressure above the liquid level of the storage tank is higher than the pressure at the inlet of the pump. It can be seen that as long as the impeller is constantly rotating, liquid is constantly being drawn in and out.
As shown in fig. 1, the present invention provides a hydraulic design method, comprising the steps of:
s1: selecting the type of a pump according to actual requirements and scanning the pump to obtain a three-dimensional model of the pump; the pump comprises a pump shell, wherein an impeller is arranged in the pump shell, the impeller is connected with a pump shaft, and the pump shaft is used for driving the impeller to rotate;
s2: intercepting a two-dimensional graph according to the three-dimensional model of the pump, wherein the surface of the two-dimensional graph is vertical to the surface of the rotating shaft;
s3: performing two-dimensional hydraulic calculation on the two-dimensional graph;
s4: connecting the results of the two-dimensional hydraulic calculation in series to obtain a hydraulic model, wherein the hydraulic model comprises a motion state and an energy conversion state;
s5: the hydraulic model is checked through a simulation technology, and the hydraulic model is adjusted according to a checking result;
s6: determining the hydraulic model.
The method of the invention makes up the gap in the prior art, so that the design parameters can more approach the actual operation requirement, and the equipment model selection is more suitable for the actual operation requirement, thereby realizing the requirements of improving the working efficiency and reducing the energy consumption. The method comprises the steps of firstly obtaining a three-dimensional model of a pump, then cutting off a two-dimensional image, wherein the information provided by the three-dimensional model is relatively rich, the three-dimensional model is sliced, and then two-dimensional hydraulic calculation results obtained by hydraulic calculation of the two-dimensional image are connected in series to obtain a hydraulic model; an object-oriented sampling method is adopted to directly collect the requirements on hydraulic equipment in the operating condition and avoid a fuzzy space caused by system design parameters; meanwhile, the three-dimensional model is used as a design reference, the hydraulic model is closer to reality, and the hydraulic efficiency of the final user side is improved in the whole process from the targeted setting of hydraulic parameters, the establishment of the hydraulic model and the output of hydraulic parts.
It can be understood that the hydraulic design established on the basis of the three-dimensional model is like infinitely dividing the three-dimensional space between the impeller and the pumping chamber, and a complete and real mathematical model of fluid flow is established through the analysis of each working point in the flow channel. Compared with the traditional design working principle, the working principle is similar to that of the medical image CT and the traditional shooting. The CT technique performs an infinite number of slices for a target object, each slice is equivalent to one shot, so as to achieve an accurate target.
The method of the invention is directly aimed at the design process of limited blade number, and establishes a function of space coordinates (R, X, Z) to truly reflect the process of fluid motion. The movement of fluid in the environment with limited blade number has the main part close to the movement with infinite blade number (namely the ideal environment assumed in the traditional design) to perform constant-speed movement, and part of the movement is influenced by friction force, inertia and the like to form backflow, so that outlet vortex and the like are caused. The actual fluid flow not only varies along the flow line, but any point along the cross-section may be different, especially in the region close to the blade, where the difference in the movement pattern and the theoretical state is significant. The blade designed by the method is in an irregular curved surface shape, and the structure of the impeller blade can adapt to the real flow state of the fluid and control the velocity distribution of fluid particles in the impeller. Different from the traditional hydraulic design, the hydraulic conditions are assumed to be all the same, and the liquid flows among the blades are also all the same, so that the problem of low actual output efficiency of the pump is fundamentally solved.
The method of the invention calculates the fluid distribution condition from the angle of the whole system, monitors the performance of all process pipelines in the device, analyzes the hydraulic efficiency characteristic, researches the requirement and distribution of the system to the hydraulic efficiency, gradually subdivides the requirement and the distribution to specific equipment, and identifies the bad factors of the hydraulic performance in the process pipelines.
And modeling in the system by inputting data of the current system operation condition, reproducing the hydraulic characteristics of the system, and quantitatively analyzing the energy loss of the system. Then, aiming at the energy loss source, the hydraulic balance is adjusted, the system resistance is reduced, the water pump efficiency is improved, the high energy consumption phenomenon is eliminated, and the effect of energy conservation and optimization is achieved.
In particular, in one embodiment of the invention, the pump may be scanned using a dimensional laser scanning device, such as a Faro three-dimensional laser scanner; the scanned image is then input into three-dimensional software to obtain a three-dimensional model of the pump. The three-dimensional software may be Solidworks.
And then intercepting the two-dimensional graph in the three-dimensional model according to the structure of the impeller, and intercepting a new two-dimensional graph when the size change in the impeller is judged to exceed 2% of the size of the impeller, so as to perform new calculation. Therefore, the approximation of hydraulic calculation and three-dimensional data is realized. Rather than simply being approached with empirical data.
Performing two-dimensional hydraulic calculation on the two-dimensional graph; the results of two-dimensional hydraulic calculation are connected in series to obtain a hydraulic model, and the hydraulic model is constructed by considering the actual condition of the impeller instead of being based on rough assumption, so that the efficiency is improved greatly compared with that of the hydraulic model in the prior art.
The prior art generally adopts laboratory simulation to carry out model detection, but there is the gap in laboratory simulation's operating mode and prior art, so the operating mode of simulation can not represent actual condition, and the effect of its inspection can not represent actual operation effect naturally. The invention relates to a simulation of fluid dynamics (CFD computational fluid dynamics) for carrying out virtual model inspection on a hydraulic model, wherein the inspection result comprises the flow, the lift, the efficiency and the energy consumption of incompressible fluid.
The distribution of important results such as liquid flow speed, pressure, turbulence and mass distribution rate is displayed by various post-processing graphs of simulation software, and the internal characteristics and the external characteristics of the model are checked by utilizing the fluid track. The core part is a CFD solver with powerful functions, and can solve physical phenomena such as flow, heat transfer, turbulence, cavitation and the like of incompressible fluid. Fluid flow and heat transfer models (including natural convection, steady and unsteady flow, laminar flow, turbulent flow, etc.) are calculated, and the flow characteristics of each physical problem are selected to optimize the calculation speed, stability, accuracy, etc. On the basis, a special module of the pump is provided for grid generation and parameter setting of the pump. And carrying out accurate numerical prediction on various working conditions of the pump design prototype. And careful and accurate numerical analysis and diagnosis are carried out on complex problems in practical application, and a reasonable modification scheme is provided.
After the transformation scheme is determined, the efficiency verification is carried out, the operation state of field operation is ensured to be predicted, and the safe operation and the driving protection are carried out.
As shown in fig. 2, the hydraulic design method provided by the present invention further includes:
s7: determining a material of the pump according to the hydraulic model.
Different working conditions require different materials. For example, some materials are corrosive, soaked for a long time, volatile, etc. The more the subject is known, the more specific the material requirements, the better the product can be designed. Is a process of benefiting and refining. Collecting or testing the performance data of the common materials for comparative analysis; performing stator and rotor electromagnetic field analysis to obtain stator and rotor iron loss, winding copper loss and other data; defining materials by distributing multiple physical attributes such as heat conductivity, heat capacity and the like, carrying out heat transfer analysis, calculating the flow of heat in a wall, judging different types of heating elements and heating values, and carrying out material matching on the materials; at the same time, the effect of the fluid on the temperature of the structural component was examined. And (5) equalizing the temperature distribution and stress analysis, and determining the optimal material and model size.
The loss of the pump mainly comprises copper loss, iron loss, additional loss, mechanical loss and the like. The iron loss is generated when various magnetic fields generated in the motor change in the iron core, is one of main losses in the motor, and generally accounts for a larger proportion of the total loss. Therefore, the research on the formation mechanism of the iron core loss, the components and the specific gravity of the iron core loss can accurately predict, calculate and test the iron core loss, and the method has very important significance for improving the efficiency, finding out the local heating point, reasonably changing the structural design, improving the material utilization rate and improving the overall design level.
As shown in fig. 3, the present invention also provides a hydraulic design system, comprising:
a first module: selecting the type of a pump according to actual requirements and scanning the pump to obtain a three-dimensional model of the pump; the pump comprises a pump shell, wherein an impeller is rotationally connected in the pump shell, a rear cover is arranged on the pump shell, a rotating shaft is rotationally connected on the rear cover, and the rotating shaft is connected with the impeller and used for driving the impeller to rotate;
a second module: intercepting a two-dimensional graph according to the three-dimensional model of the pump, wherein the surface of the two-dimensional graph is vertical to the surface of the rotating shaft;
a third module: performing two-dimensional hydraulic calculation on the two-dimensional graph;
a fourth module: connecting the results of the two-dimensional hydraulic calculation in series to obtain a hydraulic model, wherein the hydraulic model comprises a motion state and an energy conversion state;
a fifth module: the hydraulic model is checked through a simulation technology, and the hydraulic model is adjusted according to a checking result;
a sixth module: determining the hydraulic model.
Through energy consumption analysis of a heat supply network circulating system of a certain group in Shanxi, through detailed calculation, optimization and energy-saving transformation can be carried out through the hydraulic design law of the invention, the energy-saving effect reaches 30%, and the electricity consumption of a single pump can be saved by about 874,435 degrees every year.
Through energy consumption analysis of a desulfurization slurry pump of a certain group in Shanxi province and through detailed calculation, optimization and energy-saving transformation can be carried out through the hydraulic design method, the energy-saving effect reaches 25%, and the electricity can be saved by about 672,435 degrees by a single pump every year.
In a specific hydraulic design, assuming that A is the original design operating point: flow Q1, lift H1, shaft power N1 and water pump efficiency eta 1. The actual working condition point of the actual measurement system is B, the flow Q2, the lift H2, the shaft power N2 and the water pump efficiency eta 2.
Compared with the original design, the practice operation condition is the operation with low lift, large flow, low efficiency and high energy consumption.
A pipeline characteristic curve of the system is obtained through detection and analysis of actual operation working conditions, a C point with the flow on the curve being the design flow Q2 is an operation point of the optimal working condition (Q2 and H3) of the water system, and the optimal working condition of the system is the flow Q2, the lift H3, the shaft power N3 and the water pump efficiency eta 3.
According to the actual operation requirement on site, the optimal working condition point is moved to the actual operation interval by adjusting the hydraulic efficiency curve, so that the efficiency of the water pump is improved; and the lift is adjusted to the actual operation requirement range, so that the shaft power is reduced, the input power is further reduced, and the energy-saving effect is realized.
It will be appreciated that the above is merely exemplary and that in practice the method of optimisation is not limited to the above examples.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.