CN113931829A - Reciprocating mechanical optimization regulation and control method based on load distribution - Google Patents
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Abstract
A reciprocating machine optimization regulation and control method based on load distribution belongs to the technical field of reciprocating compressor control. Aiming at the problem that the reverse angle is reduced when the load of the reciprocating compressor using the stepless air flow adjusting system is reduced, the reverse angle is optimized by redistributing the load on the side of the shaft cover on the premise of ensuring that the total load is unchanged, and then the corresponding adjusting rule under the full load is obtained. The method comprises the following steps: 1) acquiring relevant parameters of a compressor unit, including structural parameters and operation parameters; 2) calculating the comprehensive piston force to obtain a reverse angle; 3) and optimally modeling and solving the load distribution of the compressor. The method optimizes the control method for stepless air volume adjustment of the reciprocating compressor, solves the problem that the reverse angle is reduced along with the reduction of the load during air volume adjustment, realizes the optimization of the reverse angle of the unit in the full working condition load range, and effectively improves the energy efficiency, the safety and the reliability of the compressor.
Description
Technical Field
The invention belongs to the technical field of reciprocating compressor control methods, and relates to a reciprocating machine optimization regulation and control method based on load distribution.
Background
The reciprocating compressor is a universal core power device with large application amount and wide application range in industries such as petroleum, chemical engineering and the like, reliability, safety, energy conservation and consumption reduction are long-term requirements of compressor equipment of enterprises, and the importance of a reasonable and efficient control method and technology to the compressor equipment is self-evident. The reverse angle is an important index for measuring the lubricating effect of the crosshead pin and the connecting rod small-end bushing of the reciprocating compressor, and the small reverse angle indicates that the lubricating effect of the connecting rod small-end bushing and the crosshead pin is poor, so that the sintering of the part can be caused, and the production shutdown is caused, and even the safety of people is threatened.
In general, a reciprocating compressor does not need to run at full load actually, a stepless air volume adjusting system has a remarkable effect on energy conservation and consumption reduction of the compressor, and the flow adjustment of the jacking air suction valve is a common flow adjusting system. However, the reverse angle under the regulation method is in a decreasing trend along with the reduction of the total load, the fault hidden danger of burning of the connecting rod small-end bearing bush still exists after the flow regulation system is started on site, and the reverse angle is even in a multi-stage mode, so that the contact time of the bushing and the pin is shortened, the poor cooling performance and the poor lubricating performance of the small-end bearing bush are possibly caused, the service life of the small-end bearing bush is shortened, and the safety and the efficiency of the compressor are further influenced.
The existing method is to check the reverse angle under each load through checking, and avoid the load section with smaller reverse angle, although the method avoids the problem of bearing bush fault caused by too small reverse angle to a certain extent, the method limits the load adjusting range, and provides an optimization control method based on load distribution in order to ensure that the compressor can safely adjust the flow under the full load, so that the comprehensive piston force is improved through load redistribution, and the reverse angle is increased to different degrees, and the reverse angle optimization of the unit in the full working condition range is realized.
Disclosure of Invention
The invention relates to a reciprocating machine optimal regulation and control method based on load distribution, which is characterized by comprising the following steps of:
step one, acquiring relevant parameters of a compressor unit:
1.1 obtaining compressor set structural parameters
For the convenience of subsequent calculation, the piston area A of the compressor needs to be determinedpArea A of piston rodrAnd reciprocating mass msAnd the crank-connecting rod ratio lambda is r/l, wherein r is the radius of the compressor crank, and l is the distance between the centers of the large head and the small head of the compressor connecting rod.
1.2 obtaining compressor operating parameters
Determining the working speed N (unit r/min) of compressor, further calculating the rotation angular speed omega pi N/30 of crank, and setting a certain load distribution pair etap=[ηh,ηc]Wherein etahCover side load after load redistribution, ηcFor the axle side load after load redistribution, the original data of the dynamic pressure of the cover side when the compressor operates under the load distribution pair is obtainedAnd axial dynamic pressure raw dataIn order to facilitate the subsequent calculations,further dispersing the dynamic pressure original data to obtain the dynamic pressure P of the cover sidehAnd axial side dynamic pressure PcAnd the dynamic pressure is the real-time pressure change condition of the compressor in a complete cycle cylinder.
Secondly, calculating the comprehensive piston force to obtain a reverse angle;
2.1 calculating the reciprocating inertial force
The moving part of the compressor will generate inertia force when doing linear motion or rotary motion with unequal speed, and the acceleration of the piston is a omega when moving2r (cos θ + λ cos2 θ), where θ is the crank angle at which the piston motion tdc is the starting position; omega is the crank rotation angular velocity; r is the crank radius; λ is the crank-to-link ratio. Then the reciprocating inertial force is FIs=msa, i.e. FIs=msrω2cosθ+msrω2λ cos2 θ, whereinReferred to as the first order reciprocating inertial force,referred to as second order reciprocating inertial forces.
2.2 calculation of gas force
The gas force acting on the piston is the difference value of the product of the gas pressure in each cavity at two sides of the piston and the corresponding piston area, different cylinder structure calculation formulas are different, and for a double-acting cylinder, the gas force F acting on the piston isg=Pc×(Ap-Ar)-Ph×Ap+Pb×ArIn which P isbAt atmospheric pressure.
2.3 calculating the composite piston force
The combined piston force is the algebraic sum of the gas force, reciprocating inertia force and reciprocating friction force acting along the cylinder centerline, i.e. Fp=Fg+FIs+FfsIn which F isfsExpressing the reciprocating friction force, it is apparent that the combined piston force is a function of the crank angle θ.
2.4 calculating the reverse angle
Make Fp-theta curve, finding out the intersection point theta according to the principle of sign change of values before and after the intersection point of the abscissa axis and the curve1、θ2…θmWherein theta1<θ2<···<θmAnd m is an even number, if m is 1, it is only one intersection point, the comprehensive piston force is only reversed once in one period, and the reverse angle alpha is 180 degrees; if there are two intersection points theta1、θ2If the reverse angle α is min ((θ)2-θ1),(360-(θ2-θ1))). If more than two intersection points exist, the comprehensive piston force is stated to be reversed for multiple times in one period, and the reverse angle is in a multi-stage mode, wherein the reverse angle calculation formula is that alpha is min (sum ((theta)2-θ1)+…+(θm-θm-1)),360-sum((θ2-θ1)+···+(θm-θm-1) In which m is an even number).
Thirdly, optimally modeling and solving the load distribution of the compressor:
3.1 load distribution optimization modeling
The compressor load distribution optimization model comprises decision variables, an objective function and constraint conditions. Wherein the decision variable is the compressor head side load distribution pair etap=[ηh,ηh]Equivalent to η - η of the compressor cover side load offset Δ ηhAnd eta is the actual total mass load flow of the compressor. The objective function is max (α) ═ f (Δ η), and it is required to obtain the maximum value of the inversion angle as much as possible. Constraint condition of etah+η c2 η, meaning that the sum of the loads on the head side and the shaft side after the load redistribution should equal the actual total mass load of the compressor; wherein the loads on the cover side and the shaft side are both in the load adjustable range, namely eta is more than or equal to 0h≤100,0≤ηcLess than or equal to 100; at the same time, alpha is more than or equal to alpha0In which α is0Is set to an acceptable reversal angle minimum. Typically not less than 15 degrees.
Piston rod load reversal must be continued for a period of time to allow adequate ingress and functioning of the lubricating oil. This time is expressed in crank angle as a reverse angle. The general company or standard specifies not less than 15 degrees.
3.2 load distribution optimization solution
I) Determining whether a heavy load distribution is required:
first, when the total compressor load is at a boundary value, that is, when the full load η is 100 or the zero load η is 0, the compressor load does not need to be redistributed.
Secondly, the load is distributed evenly, i.e. the load on the shaft cover side is the same etah=ηcAngle of reversal alpha when etaoriginalIf α isoriginal≥α0Then no load sharing is required, and Δ η is equal to 0.
II) determining the load distribution and calculating the reversal angle according to the total load:
when eta is less than 50, the load offset delta eta is used as a starting point, delta d is used as a load offset gradient step length, and if eta is less than 50, the load offset delta eta is used as a starting point, and if delta d is used as a load offset gradient step length, the load offset gradient step length is increasedIf the number is an integer, the load offset sequence is (q) { η, η - Δ d, …, η - (I-1) × Δ d | I ═ 1, 2, 3 …, I }; if it isIf the number is not an integer, establishing a load offset sequence of ═ η, η - Δ d, …, η - (I-1) × Δ d, 0| I ═ 1, 2, 3 …, I }; whereinIs composed ofRounded down values.
When eta is more than or equal to 50, the load offset delta eta is 0 as a starting point, delta d is used as a load offset gradient step length, and if eta is more than or equal to 50, the load offset delta eta is equal to 0 as a starting point, and if delta d is equal to a load offset gradient step lengthIf the number is an integer, establishing a load offset sequence of Ω ═ {0, Δ d, …, (J-1) × Δ d | J ═ 1, 2, 3, …, J }; if it isIf not, establishing a load offset sequence of 0, Δ d, …, (J-1) × Δ d, 100- η | J equal to 1, 2, 3, …, J }; whereinIs composed ofRounded down values.
First, the head-side load η is adjustedh=η-ΩkWherein Ω iskAny load offset value in the load offset omega sequence is adopted, k is a data label, and the corresponding axle side load at the moment is eta according to the constraint conditionc=η+ΩkThus load distribution pair ηp=[η-Ωk,η+Ωk]. The first and second steps are performed in the load distribution pair to obtain a reverse angle alpha under the load distributionk。
Secondly, traversing each offset in omega in sequence to obtain a load distribution pair, and then calculating to obtain a reverse angle sequence { alpha k1, 2, 3. K, where K is the number of data in Ω, the maximum value in the sequence and the offset corresponding to the maximum value are obtained, and it is assumed that the mth offset reverse angle is at most αMCorresponding offset is ΩM。
Finally, at the full duty load typical of compressorsRepeating the steps to obtain the optimal reverse angle A ═ alpha corresponding to the load1,α2,α3,…,αnAnd amount of cover side load offsetWhere n is the typical total load, an optimized regulation relationship is obtained
The load distribution control method for the reciprocating compressor realizes the optimization of the reverse angle of the unit in the full working condition range by reasonably redistributing the load on the side of the shaft cover on the premise of ensuring that the total load is not changed, avoids the problem that the contact time of a connecting rod small-end bushing and a crosshead pin is shortened when a gas quantity adjusting system reduces the load, so that the cooling property and the lubricating property of the small-end bushing are poor, the service life of the small-end bushing is shortened, and effectively improves the safety and the reliability of the compressor.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 shows the distribution η of the loadp=[35,65]Dynamic pressure after lower dispersion;
FIG. 3 shows the distribution η of the loadp=[35,65]The stress curve of the compressor is shown;
FIG. 4 illustrates exemplary change in bank angle before and after load redistribution under full operating conditions.
Detailed Description
The principles and embodiments of the present invention will be described in detail below with reference to the accompanying drawings and a DW-12/2 compressor implementation:
as shown in fig. 1, a reciprocating machine optimization regulation and control method based on load distribution mainly comprises the following processes:
step one, acquiring relevant parameters of a compressor unit:
1.1 obtaining compressor set structural parameters
For the convenience of subsequent calculation, the piston area A of the compressor is determinedp=0.0491m2Area A of piston rodr=0.0064m2And reciprocating mass msThe crank radius r of the compressor is 0.09m, the center distance l between the big end and the small end of the connecting rod of the compressor is 0.45m, and the crank-connecting rod ratio lambda is 0.2.
1.2 obtaining compressor operating parameters
The operating speed N of the compressor is determined to be 300r/min, and the angular speed ω of rotation of the crank is further calculated to be 31.4159, given the total load 50 and the load distribution ηp=[35,65]For example, obtain its operationDynamic pressure raw data of time cover side and shaft side, and further dispersing the obtained raw data into the raw data respectively containing 360 data pointsAndrepresenting the head side dynamic pressure at a head side load of 35,the dynamic pressure on the shaft side at a load of 65 on the shaft side is shown in fig. 2.
Secondly, calculating the comprehensive piston force to obtain a reverse angle;
2.1 calculating the reciprocating inertial force
The acceleration of the piston of the compressor is a ═ r ω when the piston moves2(cos θ + λ cos2 θ) and a reciprocating inertial force FIs=msa, i.e. FIs=msrω2cosθ+msrω2λ cos2 θ, second order reciprocating inertial forceThe maximum value is only lambda times of the first-order reciprocating inertia force, so the maximum value can be ignored, and the reciprocating inertia force replaces F by the first-order reciprocating inertia forceIs=7098.9cosθ (θ=0,1,2···359)。
2.2 calculation of gas force
The calculation formulas of the gas forces of different cylinder structures are different, the cylinder structure form of the embodiment is a double-acting type, and the gas force acting on the piston
2.3 calculating the composite piston force
The combined piston force is an algebraic sum of the gas force acting along the cylinder centerline, the reciprocating inertia force and the reciprocating friction force, wherein the friction force is much smaller than the other two terms, and the calculation is more complicated, so that the selection is ignored here.So the piston force is synthesized
2.4 calculating the reverse angle
According to FpAnd (3) finding out the abscissa of the intersection point as {14, 194} by the principle of changing the sign of values before and after the intersection point of the theta curve and the abscissa curve, wherein the abscissa has two intersection points, the comprehensive piston force is alternately reversed twice in one period, and the reverse angle is 180 degrees, as shown in figure 3.
Thirdly, optimally modeling and solving the load distribution of the compressor:
3.1 load distribution optimization modeling
The compressor load distribution optimization model comprises decision variables, an objective function and constraint conditions. Wherein the decision variable is the compressor head side load distribution etap=[ηh,ηc]Equivalent to η - η of the compressor cover side load offset Δ ηh. The objective function is max (α) ═ f (Δ η), and it is required to obtain the maximum value of the inversion angle as much as possible. Constraint η in this exampleh+ηc=100;0≤ηh≤100,0≤ηcLess than or equal to 100; setting an acceptable reversal angle minimum value alpha 0160 degrees, the reverse angle should satisfy alpha is more than or equal to alpha0。
3.2 load distribution optimization solution
I) Determining whether a heavy load distribution is required:
in this example, since the total load η of the compressor is 50, the load is considered to be equal to the same η in the load distribution, i.e., the load on the side of the shaft coverh=ηcReverse angle alpha at 50 ═ foriginal149 °, in this example αoriginal<α0It is necessary to redistribute the load.
II) determining the load distribution and calculating the reversal angle:
in this example, η is 50, so the load offset Δ η is 0 as the starting point, and Δ d is 5 as the load offset step, whereIf the number is an integer, the load offset sequence Ω is {0, 5, 10, …, 50 }.
First, the head-side load η is adjustedhWhen the constraint condition is satisfied, the corresponding axle side load is eta c50, so the load distribution pair is ηp=[50,50]. Performing the first and second steps with this load distribution pair results in a reversal angle of 149 deg. at this load distribution.
Next, sequentially traversing each offset in Ω to obtain a load distribution pair, and then calculating to obtain a reverse angle sequence {149, 103, 102, 102, 136, 148, 169, 179, 180, 177, 163 }, so as to find that the maximum value in the sequence is 180, and the offset corresponding to the maximum value is 15, so that when the compressor load is 50, the cover-side load is adjusted to be 35, the shaft-side load is adjusted to be 65, the maximum reverse angle can be obtained, and the maximum reverse angle is 180 °.
Finally, at the full duty load typical of compressorsRepeating the above steps to obtain the optimal reverse angle a of the corresponding load as {178, 179, 179, 179, 178, 180, 175, 171, 167, 169, 148} and the cover side load offsetAn optimized regulation relationship is thus obtainedThe reversal angle before and after optimization is shown in fig. 4. The optimal load distribution and the optimal front-to-back reversal angle values are shown in table 1 below.
TABLE 1 example load distribution
Claims (5)
1. A reciprocating machine optimization regulation and control method based on load distribution is characterized by comprising the following steps:
obtaining relevant parameters of the compressor unit, calculating the comprehensive piston force to further obtain a reverse angle, establishing a compressor unit load distribution optimization model, solving the compressor unit load distribution optimization model, and combining the optimal results under different loads to obtain an optimized regulation rule.
2. The method of claim 1, wherein the compressor train related parameters comprise:
obtaining the structural parameters of the compressor set and determining the piston area A of the compressorpArea A of piston rodrAnd reciprocating mass msThe crank connecting rod ratio lambda is r/l, wherein r is the radius of the compressor crank, and l is the distance between the centers of the big head and the small head of the compressor connecting rod;
obtaining the running parameters of the compressor, determining the working speed N of the compressor in r/min, further calculating the rotation angular speed omega of the crank to pi N/30, and setting a certain load distribution pair etap=[ηh,ηc]Wherein etahCover side load after load redistribution, ηcFor the axle side load after load redistribution, the original data of the dynamic pressure of the cover side when the compressor operates under the load distribution pair is obtainedAnd axial dynamic pressure raw dataFurther dispersing the dynamic pressure original data to obtain the dynamic pressure P of the cover sidehAnd axial side dynamic pressure PcAnd the dynamic pressure is the real-time pressure change condition of the compressor in a complete cycle cylinder.
3. The method of claim 1, wherein calculating the composite piston force to derive the reversal angle comprises:
calculating reciprocating inertia force, and making the moving part of compressor do linear motion or rotate at different speedWhen the piston moves, inertia force is generated, and the acceleration of the piston is a ═ omega when the piston moves2r (cos θ + λ cos2 θ), where θ is the crank angle at which the piston motion tdc is the starting position; omega is the crank rotation angular velocity; r is the crank radius; lambda is the crank link ratio; the reciprocating inertial force is FIs=msa, i.e. FIs=msrω2cosθ+msrω2λ cos2 θ, whereinReferred to as the first order reciprocating inertial force,referred to as second order reciprocating inertial force;
calculating the gas force, wherein the gas force acted on the piston is the difference value of the product of the gas pressure in each cavity at two sides of the piston and the corresponding piston area, the calculation formulas of different cylinder structures are different, and for a double-acting cylinder, the gas force F acted on the piston isg=Pc×(Ap-Ar)-Ph×Ap+Pb×ArIn which P isbIs at atmospheric pressure;
calculating the composite piston force, which is the algebraic sum of the gas force, reciprocating inertia force and reciprocating friction force acting along the cylinder centerline, i.e. Fp=Fg+FIs+FfsIn which F isfsRepresenting the reciprocating friction force, it is clear that the combined piston force is a function of the crank angle θ;
calculating a reverse angle, making Fp-theta curve, finding out the intersection point theta according to the principle of sign change of values before and after the intersection point of the abscissa axis and the curve1、θ2…θmWherein theta1<θ2<…<θmAnd m is an even number, if m is 1, it is only one intersection point, the comprehensive piston force is only reversed once in one period, and the reverse angle alpha is 180 degrees; if there are two intersection points theta1、θ2If the reverse angle α is min ((θ)2-θ1),(360-(θ2-θ1) ); if there are twoThe above intersection points indicate that the integrated piston force is reversed many times in one cycle, and the reverse angle is multi-stage, and at this time, the reverse angle calculation formula is α ═ min ((θ) (2-θ1)+…+(θm-θm-1)),360-sum((θ2-θ1)+…+(θm-θm-1) In which m is an even number).
4. The method of claim 1, wherein the establishing a compressor rack load distribution optimization model comprises:
the compressor load distribution optimization model comprises decision variables, an objective function and constraint conditions; wherein the decision variable is the compressor head side load distribution pair etap=[ηh,ηc]Equivalent to the compressor cover side load offset Δ η ═ η - ηhWherein eta is the actual total mass load flow of the compressor; the objective function is max (alpha) ═ f (delta eta), and the maximum value of the reversal angle is required to be obtained as much as possible; constraint condition of etah+ηc2 η, meaning that the sum of the loads on the head side and the shaft side after the load redistribution should equal the actual total mass load of the compressor; wherein the loads on the cover side and the shaft side are both in the load adjustable range, namely eta is more than or equal to 0h≤100,0≤ηcLess than or equal to 100; at the same time, alpha is more than or equal to alpha0In which α is0For a set acceptable minimum reversal angle of 45 degrees, the model is mathematically expressed as:
opt α=f(Δη)
s.t.ηh+ηc=2η
0≤ηh≤100
0≤ηc≤100
α≥α0
5. the method of claim 1, wherein said solving said compressor rack load distribution optimization model comprises:
I) determining whether a heavy load distribution is required:
first, if the total compressor load is at a boundary value, i.e., when the full load η is 100 or the zero load η is 0, the compressor load does not need to be redistributed;
secondly, the load equality η at the load even distribution, i.e. the axle cover side, is calculatedh=ηcAngle of reversal alpha when etaoriginalIf α isoriginal≥α0No load reallocation is required, where α0The minimum value of the set reversal angle is obtained, and the delta eta is 0;
II) determining the load distribution and calculating the reversal angle according to the total load:
when eta is less than 50, the load offset delta eta is used as a starting point, delta d is used as a load offset gradient step length, and if eta is less than 50, the load offset delta eta is used as a starting point, and if delta d is used as a load offset gradient step length, the load offset gradient step length is increasedIf the number is an integer, the load offset sequence Ω ═ { η, η - Δ d, …, η - (I-1) × Δ d | I ═ 1, 2, 3 …, I }; if it isIf not, establishing a load offset sequence omega ═ { eta, eta-delta d, …, eta- (I-1) × delta d, 0| I ═ 1, 2, 3 …, I }; whereinIs composed ofA rounded down value;
when eta is more than or equal to 50, the load offset delta eta is 0 as a starting point, delta d is used as a load offset gradient step length, and if eta is more than or equal to 50, the load offset delta eta is equal to 0 as a starting point, and if delta d is equal to a load offset gradient step lengthIf the number is an integer, establishing a load offset sequence Ω ═ {0, Δ d, …, (J-1) × Δ d | J ═ 1, 2, 3, …, J }; if it isIf the number is not an integer, the load offset sequence Ω is set to {0, Δ d, …, (j-1) × Δ d, 100- η | J ═ 1, 2, 3, …, J }; whereinIs composed ofA rounded down value;
first, the head-side load η is adjustedh=η-ΩkWherein Ω iskAny load offset value in the load offset omega sequence is adopted, k is a data label, and the corresponding axle side load at the moment is eta according to the constraint conditionc=η+ΩkThus load distribution pair ηp=[η-Ωk,η+Ωk](ii) a The load distribution pair is used to obtain a reverse angle alpha under the load distributionk;
Secondly, traversing each offset in omega in turn, calculating load distribution pairs and obtaining a reverse angle sequence { alphakAnd l K is 1, 2, 3 … K, wherein K is the number of data in omega, the maximum value in the sequence and the offset corresponding to the maximum value are obtained, and the M-th offset reverse angle is assumed to be maximum alphaMCorresponding offset is ΩM;
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Citations (5)
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CN108506199A (en) * | 2017-02-27 | 2018-09-07 | 中国石化工程建设有限公司 | Reciprocating compressor flow control system |
CN111472961A (en) * | 2020-02-26 | 2020-07-31 | 无锡康茨压缩机配件与系统有限公司 | Stepless air quantity regulation load control method for compressor by adopting side regulation |
CN211874706U (en) * | 2020-02-25 | 2020-11-06 | 沈阳远大压缩机自控系统有限公司 | Automatic multi-bag full-flow clearance multi-stage adjusting system of reciprocating compressor |
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WO2008147591A1 (en) * | 2007-05-31 | 2008-12-04 | Lycoming Engines, A Division Of Avco Corporation | Techniques for measuring engine horsepower |
CN102562547A (en) * | 2012-02-06 | 2012-07-11 | 武汉理工大学 | Stepless airflow regulation method for high-pressure reciprocating compressor |
CN108506199A (en) * | 2017-02-27 | 2018-09-07 | 中国石化工程建设有限公司 | Reciprocating compressor flow control system |
CN211874706U (en) * | 2020-02-25 | 2020-11-06 | 沈阳远大压缩机自控系统有限公司 | Automatic multi-bag full-flow clearance multi-stage adjusting system of reciprocating compressor |
CN111472961A (en) * | 2020-02-26 | 2020-07-31 | 无锡康茨压缩机配件与系统有限公司 | Stepless air quantity regulation load control method for compressor by adopting side regulation |
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