单电机叶片可调对旋风机设计研究.pdf

万方数据 万方数据 太原理工大学硕士研究生学位论文 I 单电机叶片可调对旋风机设计研究 摘 要 随着煤矿开采技术的不断发展，煤矿巷道的掘进距离在不断增加，而 在巷道通风过程中，巷道通风所需风量、风压与巷道距离成正比，这就导 致煤矿局部对旋通风机在通风时存在风量、风压与通风距离不匹配的问题 在短距离通风时风量过大、能耗浪费严重，容易吹起煤尘造成二次污染； 在远距离通风时，对旋风机一级电机未充分利用、二级电机容易过载。因 此，本文在对局部通风系统运行特性研究的基础上，提出了一种单电机叶 片可调对旋风机方案并对其结构进行了优化，建立了风机的仿真模型，对 风机关键部件进行了仿真与试验研究。 首先，对某巷道进行了通风阻力的计算，并通过 B 型（压入式）风管 试验装置采集了 FBD No8.0 型风机在不同通风阻力下的试验数据，得出了 风机风量、风压、轴功率以及效率随通风距离变化的曲线。以 FBD No8.0 型对旋风机试验数据为基础，对某巷道局部通风系统在 03000 m 整个通风 过程下的恒转速通风、单双级切换通风、变频通风三种通风方式的运行特 性进行了研究，结果表明单双级切换通风比恒转速通风节能 5左右，变 频通风比恒转速通风节能 30。 之后，在煤矿局部通风运行特性研究的基础上，提出了单电机叶片可 调对旋风机方案，研发了风机的对旋传动装置及叶片角度调节机构。对叶 片角度可调叶轮进行了研制，并利用逆向造型对叶片进行了三维建模。在 叶片三维模型的基础上建立了单电机叶片可调对旋风机及 FBD No8.0 型风 万方数据 太原理工大学硕士研究生学位论文 II 机的整体模型，并对 FBD 型风机的仿真模型进行了试验验证。由于两种风 机的两级叶轮区域及风机后段结构相同，故验证后的 FBD 型风机仿真模型 的叶轮及风机后段区域可直接应用于单电机叶片可调对旋风机中。而对于 单电机叶片可调对旋风机的前段区域，则选用与 FBD 风机后段区域相同的 方法建立仿真模型，在最大程度上确保单电机叶片可调对旋风机整体仿真 模型的可靠性。 然后，利用 Fluent 仿真软件对单电机叶片可调对旋风机入口集流器、 整流罩、扩压器等主要通流部件进行了数值模拟。得出了风机集流器的合 理参数圆弧半径与风机入口水力直径的比值 r/DC应取 0.2 以上，集流器 长度 L 应取 0.8 r，集流器与风筒连接处的角度 α 应取 0 。研究了整流罩及 扩压器对风机性能的影响，得出了扩压器长度与风筒直径相等时的最优扩 散角为 16 18 。 最后，对单电机叶片可调对旋风机的叶片角度调节机构进行了试验研 究。叶片角度调节机构驱动装置的模态试验表明驱动装置在风机运行时 不会产生共振；叶片角度调节机构测试试验表明其结构能够满足设计要 求；对研制的前后级叶轮进行了双面（动）平衡校正，校正结果表明校 正后的前后级叶轮平衡等级达到 G5.6，满足技术标准。 关键词对旋风机，单电机，叶片角度调节，通流部件，通风节能 万方数据 太原理工大学硕士研究生学位论文 III DESIGN AND RESEARCH OF SINGLE MOTOR BLADE ADJUSTABLE CONTRA-ROTATING FAN ABSTRACT With the development of coal mining technology, the driving distance of coal mine roadway is increasing, the volume and pressure of wind are proportional to the distance of the roadway. This leads to the problem that the volume and pressure of the wind and ventilation distance do not match during the ventilation of the mine local fan. In the short-distance ventilation, the air volume is excessive, the energy is wasteful, and it is easy to arouse the secondary pollution caused by coal dust. In the case of long-distance ventilation, the primary motor of the contra-rotating fan is underloaded, and the secondary motor is overloaded. Therefore, based on the research of the operating characteristics of the local ventilation system, a new type of single motor blade adjustable contra-rotating fan was designed. Then the simulation and experimental research of the fan were carried out. Firstly，this paper calculated the ventilation resistance of a roadway, then collected the data of FBD No. 8.0 fan under different ventilation resistance by B type fan experimental device and obtained the relationship between fan perance and ventilation distance. The operating characteristics of the 万方数据 太原理工大学硕士研究生学位论文 IV ventilation system under three ventilation modes of constant-speed ventilation, single and double stage switching ventilation and variable frequency ventilation were studied. The results show tha single and double stage switching ventilation is about 5 energy-saving than constant-speed ventilation, and variable-frequency ventilation is about 5 energy-saving than constant-speed ventilation. Then, based on the research of the operating characteristics of the local ventilation system, the design scheme of a single motor blade adjustable contra-rotating fan was proposed. This paper developed the contra-rotating transmission and blade angle adjustment mechanism and established Three-dimensional modeling of blade by reverse engineering. Based on the three-dimensional model of the blade, the overall model of single motor blade adjustable contra-rotating fan and the FBD No8.0 fan were established, and the simulation model of the FBD fan was verified. Since the area of impeller and the rear section of the fans are the same，The simulation model of the FBD fan’s impeller and the rear section can be directly applied to single motor blade adjustable contra-rotating fan. For the front section of single motor blade adjustable contra-rotating fan, the same as the rear section of the FBD fan is used to establish the simulation model. This could ensure the reliability of the overall simulation model of the blade adjustable contra-rotating fan. After that, the Fluent simulation software was used to simulate the main 万方数据 太原理工大学硕士研究生学位论文 V flow components of single motor blade adjustable contra-rotating fan. The simulation results show that the ratio of the arc radius of current collector to the inlet hydraulic diameter of the fan should be 0.2 or more; the ratio of the length of the current collector to the radius of the collector arc should be 0.8; the angle between the collector and the air duct should be 0 degree. This paper also studied the effect of fairing and diffuser on the perance of the fan,the result shows that the optimum angle of diffuser is 16 18 when the diffuser length is equal to the diameter of the air cylinder. In the end, the experimental research on the blade angle adjustment mechanism of single motor blade adjustable contra-rotating fan was carried out. The modal test shows that the the blade angle adjustment mechanism does not resonate when the fan is running. Blade angle adjustment mechanism test shows that its structure can meet the design requirements. The dynamic balance correction of the impellers was carried out and the calibration result shows that the impellers’ balance level reaches G5.6, which meets the technical standards. KEY WORDScontra-rotating fan, single motor, blade angle adjustment, flow components, ventilation energy saving 万方数据 太原理工大学硕士研究生学位论文 VI 万方数据 太原理工大学硕士研究生学位论文 VII 目 录 摘 要 ........................................................................................................................................... I ABSTRACT ............................................................................................................................. III 第一章 绪论 .............................................................................................................................. 1 1.1 课题背景及意义 .......................................................................................................... 1 1.2 国内外研究现状 .......................................................................................................... 3 1.2.1 对旋轴流风机性能研究 ................................................................................... 3 1.2.2 对旋风机叶片角度及变频调节研究 ............................................................... 6 1.3 课题研究内容及技术路线 .......................................................................................... 9 第二章 煤矿局部通风系统运行特性研究 ............................................................................ 11 2.1 测试平台节流器开度与巷道通风阻力的关系 ........................................................ 11 2.1.1 煤矿局部通风系统风阻特性 ......................................................................... 11 2.1.2 风机 B 型测试平台简介 ................................................................................ 13 2.1.3 节流器开度与巷道风阻的关系 ..................................................................... 14 2.2 恒转速通风及单双电机切换通风运行特性研究 .................................................... 16 2.2.1 恒转速通风运行特性研究 ............................................................................. 16 2.2.2 单双电机切换通风运行特性研究 ................................................................. 18 2.3 变频调节通风运行特性研究 .................................................................................... 21 2.3.1 转速与最大通风距离的关系 ......................................................................... 21 2.3.2 变频调节通风运行特性 ................................................................................. 23 2.4 本章小结 .................................................................................................................... 24 第三章 单电机叶片可调对旋风机方案及仿真模型的建立 ................................................ 27 3.1 单电机叶片可调对旋风机方案 ................................................................................ 27 3.1.1 单电机叶片可调对旋风机组成 ..................................................................... 27 3.1.2 叶片可调叶轮 ................................................................................................. 28 3.2 叶片角度调节机构 .................................................................................................... 30 3.2.1 组成及工作原理 ............................................................................................. 30 3.2.2 风叶转动装置 ................................................................................................. 31 万方数据 太原理工大学硕士研究生学位论文 VIII 3.2.3 驱动装置 ......................................................................................................... 32 3.2.4 液压系统 ......................................................................................................... 33 3.3 仿真模型验证 ............................................................................................................ 36 3.3.1 弯掠组合叶片逆向建模 ................................................................................. 36 3.3.2 仿真模型的建立及网格的划分 ..................................................................... 38 3.3.3 网格无关性检验与模型试验验证 ................................................................. 40 3.4 本章小结 .................................................................................................................... 41 第四章 单电机叶片可调对旋风机集流器性能研究 ............................................................ 43 4.1 集流器圆弧半径对风机性能的影响 ........................................................................ 43 4.1.1 风机入口模拟风室的建立 ............................................................................. 43 4.1.2 圆弧半径对风机压力的影响 ......................................................................... 44 4.1.3 圆弧半径对风机效率的影响 ......................................................................... 45 4.1.4 圆弧半径对风机轴功率的影响 ..................................................................... 46 4.1.5 圆弧半径对风机内流场的影响 ..................................................................... 47 4.2 集流器长度对风机性能的影响 ................................................................................ 49 4.2.1 集流器长度对风机压力性能的影响 ............................................................. 49 4.2.2 集流器长度对风机效率的影响 ..................................................................... 51 4.3 集流器与风筒连接处的角度对风机性能的影响 .................................................... 52 4.3.1 集流器角度对风机压力的影响 ..................................................................... 52 4.3.2 集流器角度对风机效率的影响 ..................................................................... 53 4.4 本章小结 .................................................................................................................... 54 第五章 单电机叶片可调对旋风机整流罩及扩压器性能研究 ............................................ 55 5.1 单电机叶片可调对旋风机整流罩性能分析 ............................................................ 55 5.1.1 整流罩对风机性能的影响 ............................................................................. 55 5.1.2 整流罩对风机内流场的影响 ......................................................................... 56 5.1.3 整流罩与集流器的耦合作用 ......................................................................... 57 5.2 单电机叶片可调对旋风机扩压器性能分析 ............................................................ 59 5.2.1 扩压器对风机性能的影响 ............................................................................. 59 5.2.2 扩压器扩散角的定义 ..................................................................................... 60 万方数据 太原理工大学硕士研究生学位论文 IX 5.2.3 扩压器扩散角对风机性能的影响 ................................................................. 61 5.3 扩散角对风机内流场的影响 .................................................................................... 63 5.3.1 静压分析 ......................................................................................................... 63 5.3.2 流线分析 ......................................................................................................... 64 5.3.3 湍动能分析 ..................................................................................................... 65 5.4 本章小结 .................................................................................................................... 66 第六章 单电机叶片可调对旋风机关键部件试验研究 ........................................................ 67 6.1 叶片角度调节机构模态试验 .................................................................................... 67 6.1.1 模态测试流程 ................................................................................................. 67 6.1.2 叶片角度调节机构驱动装置的自由模态 ..................................................... 68 6.1.3 叶片角度调节机构驱动装置工作模态 ......................................................... 69 6.2 叶片角度调节机构液压性能试验 ........................................................................... 71 6.2.1 试验方案 ......................................................................................................... 71 6.2.2 试验结果分析 ................................................................................................. 73 6.3 叶片可调叶轮动平衡试验 ........................................................................................ 74 6.3.1 叶片可调叶轮平衡方式的选择 ..................................................................... 74 6.3.2 叶片可调叶轮动平衡理论计算 ..................................................................... 75 6.3.3 叶片可调叶轮动平衡试验分析 ..................................................................... 76 6.4 本章小结 .................................................................................................................... 78 第七章 结论与展望 ................................................................................................................ 79 7.1 结论 ............................................................................................................................ 79 7.2 展望 ............................................................................................................................ 80 参考文献 .................................................................................................................................. 81 致谢 .......................................................................................................................................... 87 攻读硕士学位期间发表的学术论文及参与的项目 .............................................................. 89 万方数据 太原理工大学硕士研究生学位论文 X 万方数据 太原理工大学硕士研究生学位论文 1 第一章 绪论 1.1 课题背景及意义 本课题源于山西省科技重大专项 “矿用外置单电机可调对旋通风机关键技术及装 备” （项目编号MJ2016-02） 。 据中国能源大数据报告2018统计，在我国 2017 年能源生产结构中，原煤占比 68.6，原油占比 7.6，天然气占比 5.5，水电、核电、风电等占比 18.3，这说明虽 然我国目前工业发展水平处于煤炭经济向石油经济转化阶段， 但以煤炭为主要能源的格 局在短时间内难以改变。在煤矿安全生产方面，虽然我国煤矿安全生产形势逐渐好转， 但与发达国家相比仍有较大差距。2006-2017 年间，我国煤炭行业中瓦斯和顶板事故是 造成死亡人数最多的事故，占比分别为 35.5和 27.8，而作为全国主要产煤地，山西 省发生特重大事故死亡人数位居全国第一，总死亡人数第二[1]，在这些事故中，瓦斯事 故所占比例最大，一次性死亡人数较多。矿井通风是控制瓦斯浓度和减少瓦斯事故最主 要的手段，局部通风机是工作面巷道通风系统的核心设备，在降低瓦斯浓度、为井下提 供新鲜空气、保证工作面通风的连续性和稳定性方面发挥了极其重要的作用。 图 1-1 对旋风机结构示意图 Figure.1-1 Structure diagram of counter-rotating fan 目前，矿用局部通风机的类型主要有对旋轴流风机和单级轴流风机两种。对旋轴流 风机（简称对旋风机）主要由风筒、集流器、整流罩、前级电机、后级电机、前后两级 叶轮以及扩压器等部分组成，如图 1-1 所示[2]。集流器主要用于改善风机入口条件，引 万方数据 太原理工大学硕士研究生学位论文 2 导气流平稳进入风机，然后气流通过前段整流