附壁式射流元件内部流动研究及结构优化
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摘要
本课题来源于国家高技术研究发展计划(863计划)“精确喷灌技术与产品”(编号2011AA100506)、国家农业科技成果转化基金(863计划)“变量喷洒轻小型喷灌机组完善与中试”(编号2011GB2C100015)。
全射流喷头是我国具有自主知识产权的一种新型节水灌溉产品,应用水流附壁效应完成喷头直射、步进和反向的功能,具有结构简单、造价低、喷洒性能等优点。从全射流喷头现阶段的研究来看,附壁射流元件的内部流动理论研究是全射流喷头结构优化的关键。因此,本文采用理论分析、试验研究与数值计算相结合的方法,通过研究全射流喷头射流元件中的附壁流动特性,掌握小位差比率射流元件水流附壁规律,为全射流喷头的优化设计提供理论依据,同时为其它新型射流控制元件的开发奠定理论基础,促进水射流技术在工农业生产的更广泛应用。本文主要研究工作和创新点有：
(1)从自由紊动射流理论及附壁射流理论出发,推导射流元件内附壁流场关键参数的计算公式。对附壁点距离进行了编程计算。对全射流喷头射流元件的切换性能进行分析和研究,并提出将切换响应时间tq、间隙补气速度uj、附壁力Fj、最大附壁力点距离xf作为衡量射流元件性能的重要参数。
(2)首次采用PIV设备对位差比率小于1的附壁式射流元件内部流动进行研究。搭建射流元件内部流动PIV试验台,设计和加工透明观测样机,对不同结构尺寸的样机在不同流量下的附壁射流流场进行了PIV测量。研究结果表明：位差比率D/b不变,附壁点距离xr随着流量的变化很小；相同流量下,附壁点距离随着位差比率的增大而增大；相同位差比率的样机,在补气孔距离h为3mmm时附壁点距离最短；在Q=3m3/h,作用区长度L为60mm时,位差比率大于0.5的样机无法实现附壁,因此将研究范围缩小到位差比率小于0.5的样机。通过PIV试验研究结果,初步得出了盖板间隙取值范围,即：左间隙值gp<2mm,右间隙值g2<1.5mmm。
(3)建立全射流喷头射流附壁力模型,对射流元件内水流附壁冲击力进行了分析和计算。搭建通用喷头力测量试验台,通过测量喷头运转驱动力和转体摩擦力初步得到射流元件水流附壁冲击力Fj的间接试验值,并与理论计算和数值模拟结果进行了比较,其变化趋势相同。
(4)结合CATIA知识工程顾问模块建立了一套包括三维几何模板、网格划分和数值计算在内的附壁射流元件模型参数化设计流程。
建立了适合于小位差比率附壁式射流元件两相流数值计算模型。通过与PIV内部流场测量结果对比,选择SST湍流模型及表面自由两相流模型进行模拟,其附壁点距离的结果与PIV试验误差在5%以内,位差比率和补气孔距离对附壁射流流场的影响规律与PIV试验完全一致。
(5)数值模拟分析了关键几何参数对于附壁射流性能的影响。保持其他结构参数相同,随着位差比率的增大,附壁点距离增大。但当位差比率大于0.5时,需要将作用区加长到70mmm水流才能实现附壁,不宜应用于射流喷头中。将射流元件的位差比率选择范围缩小到0.15-0.4范围内,并根据数值模拟计算得到的附壁点距离值对理论计算值进行了修正,得到了不同位差比率下附壁点距离的理论值和模拟值之间的函数关系式。附壁点距离随着补气孔位置的升高先减小随后增大,当h=3mm时,射流模型完全附壁所需要的长度最短。盖板间隙尺寸直接决定间隙补气速度uj,对附壁流场影响较大。通过模拟将盖板间隙的取值范围进一步缩小：盖板左间隙g1控制在0.5-1.5mm,盖板右间隙g2控制在0.25-1.25mm。
(6)通过正交化数值模拟对结构参数进行优化,并设计开发出外取水射流元件及喷头。以切换响应时间tq、附壁力Fj、最大附壁力点距离xf作为正交模拟中衡量射流元件性能的指标,通过正交数值模拟得到了各位差比率所对应的最佳结构参数组合。在射流元件内部流动特性研究的基础上,对全射流喷头进行了结构优化和改进,设计出外取水射流元件及PXSBW40双向步进外取水全射流喷头。介绍了PXSBW40双向步进式全射流喷头的工作原理,分析了正向步进和反向步进的工作过程,并与PXH40喷头和PY40喷头进行了水力性能对比,结果表明PXSBW40双向步进式全射流喷头水力性能和运转稳定性优于另外两种喷头。
The research on the inner flow of the offset fluidic component and its structural optimization is one of the contents of China National Key Technology R&D Program (No.2011AA100506)"Precise sprinkling irrigation technology and products". National Agriculture Science and Technology Achievements Transformation Fund (No.2011GB2C100015)"Perfection and Pilot Test on Variable Light-duty Irrigation Equipment"
The fluidic sprinkler controlled by clearance was an original invention of China. The offset effect in the fluidic component drove the sprinkler and controlled its rotating direction, so the fluidic sprinkler was characterized with simple structure, low cost and good hydraulic performance. Based on the current research status of the fluidic sprinkler, the study on the inner flow theory of the fluidic component was the key of the structural optimization of the fluidic sprinkler. The theoretical analysis, experiments and numerical simulations were combined to study the inner flow characteristic of the fluidic component of the fluidic sprinkler and the offset flow law of the fluidic component with small offset ratio. The research results would be adapted into the structural optimization of the fluidic sprinkler and the development of new fluidic component to extend the application range of the fluidic technology.
The main research contents and results were as follows:
(1) Based on the theories of free turbulence jet and wall attachment jet, the key parameters of the offset flow were analyzed and the source program was written and applied to calculate the offset distance under different offset ratios. The switching performance of the fluidic component of the fluidic sprinkler was analyzed and studied, the switching response time tq, the air velocity of the clearance uj, the offset force Fj and the distance of the max offset force point xf were brought out as parameters of the switching performance.
(2) The inner flow of the offset fluidic component with small offset ratio (D/b<1) was investigated with PIV for the first time. The fluidic component inner flow PIV test rig was set up and the visualized prototypes with different structural sizes were designed and processed to measure the offset flow under different flow rates. The test results indicated that:the offset distance rarely change with increasing flow rates, in a certain flow rate, the offset distance increased with the offset ratio; in a certain offset ratio, the value of the offset distance reaches the minimum while the air supplement hole distance is3mm; when Q=3m3/h, the length of the component L=40mm, the jet in prototypes with offset ratio bigger than0.5cannot attach to the wall, so the following research focused on prototypes with offset ratio smaller than0.5. The range of the clearance was achieved by the PIV test:left clearance g1<2mm, right clearance g2<1.5mm.
(3) The wall-attachment driving force model was established. Formulas for wall-attachment driving force were deduced. The general sprinkler force test rig was set up, and the jet offset force was indirectly obtained by the testing of the sprinkler driving force and the sliding friction. The test results were compared with the theoretical values and the simulation results.
(4) The parameterized design of the offset fluidic component model was brought forward, which including three-dimensional geometric template, mesh generation and numerical simulation, by using the knowledge engineering function of CATIA.
Based on the results of the PIV tests, the small offset ratio fluidic two-phase flow numerical model was established. By comparing with the results of the PIV tests, the numerical model with SST model and free surface model has a minimum error of5%on offset distance, the effect of offset ratio and air supplement hole distance on the offset flow simulated by the numerical model agree with that of the PIV test. Which means the numerical model could replace the PIV test to take further research.
(5) The impact of key structural parameters of the fluidic sprinkler on the wall-attaching performance was simulated and analyzed numerically. With no changes in other parameters including the air supplement hole distance and the cover clearance, the offset distance increased as the offset ratio rose. But if it was higher than0.5, the working area in the spray body had to be lengthened to70mm in order to achieve the wall attachment in the flow, which was not practical in the sprinklers. In this respect, the offset ratio of the fluidic component was ranged from0.15to0.4. Then the relations between the theoretical and numerical results of the offset distance calculated toward different offset ratios were obtained after the theoretical offset distance was modified in reference to the numerical one. The offset distance first declined, then increased as the air supplement hole distance rose; at the value h=3mm, the length required for a complete water attachment of the jet model was the shortest. The influence of the cover clearance on the wall attaching flow field was significant. The size on the left clearance is within0.5-1.5mm, and that on the right is within0.25-1.25mm.
(6) The structural parameter optimization based on orthogonal simulation were carried out and a new fluidic component and sprinkler were developed. The switching response time, offset force and distance of max offset force point were taken as the main factors in the orthogonal evaluation of the performance of fluidic sprinkler, and the premium combination under different offset ratios was figured out. The structure of the fluidic sprinkler was optimized based on the study of the inner flow characteristic of the fluidic component. The PXSBW40two-way stepping fluidic sprinkler with extermination fetching tubes was designed. The characteristics and working principle of the PXSBW40sprinkler were introduced, both working processes of the forward-stepping and the backward-stepping were analyzed. Also, the hydraulic performance was compared with those of the sprinklers typed PXH40and PY40. The results indicated that the new sprinkler PXSBW40outperformed the other two sprinklers in hydraulic performance and operation stability.
全射流喷头是我国具有自主知识产权的一种新型节水灌溉产品,应用水流附壁效应完成喷头直射、步进和反向的功能,具有结构简单、造价低、喷洒性能等优点。从全射流喷头现阶段的研究来看,附壁射流元件的内部流动理论研究是全射流喷头结构优化的关键。因此,本文采用理论分析、试验研究与数值计算相结合的方法,通过研究全射流喷头射流元件中的附壁流动特性,掌握小位差比率射流元件水流附壁规律,为全射流喷头的优化设计提供理论依据,同时为其它新型射流控制元件的开发奠定理论基础,促进水射流技术在工农业生产的更广泛应用。本文主要研究工作和创新点有：
(1)从自由紊动射流理论及附壁射流理论出发,推导射流元件内附壁流场关键参数的计算公式。对附壁点距离进行了编程计算。对全射流喷头射流元件的切换性能进行分析和研究,并提出将切换响应时间tq、间隙补气速度uj、附壁力Fj、最大附壁力点距离xf作为衡量射流元件性能的重要参数。
(2)首次采用PIV设备对位差比率小于1的附壁式射流元件内部流动进行研究。搭建射流元件内部流动PIV试验台,设计和加工透明观测样机,对不同结构尺寸的样机在不同流量下的附壁射流流场进行了PIV测量。研究结果表明：位差比率D/b不变,附壁点距离xr随着流量的变化很小；相同流量下,附壁点距离随着位差比率的增大而增大；相同位差比率的样机,在补气孔距离h为3mmm时附壁点距离最短；在Q=3m3/h,作用区长度L为60mm时,位差比率大于0.5的样机无法实现附壁,因此将研究范围缩小到位差比率小于0.5的样机。通过PIV试验研究结果,初步得出了盖板间隙取值范围,即：左间隙值gp<2mm,右间隙值g2<1.5mmm。
(3)建立全射流喷头射流附壁力模型,对射流元件内水流附壁冲击力进行了分析和计算。搭建通用喷头力测量试验台,通过测量喷头运转驱动力和转体摩擦力初步得到射流元件水流附壁冲击力Fj的间接试验值,并与理论计算和数值模拟结果进行了比较,其变化趋势相同。
(4)结合CATIA知识工程顾问模块建立了一套包括三维几何模板、网格划分和数值计算在内的附壁射流元件模型参数化设计流程。
建立了适合于小位差比率附壁式射流元件两相流数值计算模型。通过与PIV内部流场测量结果对比,选择SST湍流模型及表面自由两相流模型进行模拟,其附壁点距离的结果与PIV试验误差在5%以内,位差比率和补气孔距离对附壁射流流场的影响规律与PIV试验完全一致。
(5)数值模拟分析了关键几何参数对于附壁射流性能的影响。保持其他结构参数相同,随着位差比率的增大,附壁点距离增大。但当位差比率大于0.5时,需要将作用区加长到70mmm水流才能实现附壁,不宜应用于射流喷头中。将射流元件的位差比率选择范围缩小到0.15-0.4范围内,并根据数值模拟计算得到的附壁点距离值对理论计算值进行了修正,得到了不同位差比率下附壁点距离的理论值和模拟值之间的函数关系式。附壁点距离随着补气孔位置的升高先减小随后增大,当h=3mm时,射流模型完全附壁所需要的长度最短。盖板间隙尺寸直接决定间隙补气速度uj,对附壁流场影响较大。通过模拟将盖板间隙的取值范围进一步缩小：盖板左间隙g1控制在0.5-1.5mm,盖板右间隙g2控制在0.25-1.25mm。
(6)通过正交化数值模拟对结构参数进行优化,并设计开发出外取水射流元件及喷头。以切换响应时间tq、附壁力Fj、最大附壁力点距离xf作为正交模拟中衡量射流元件性能的指标,通过正交数值模拟得到了各位差比率所对应的最佳结构参数组合。在射流元件内部流动特性研究的基础上,对全射流喷头进行了结构优化和改进,设计出外取水射流元件及PXSBW40双向步进外取水全射流喷头。介绍了PXSBW40双向步进式全射流喷头的工作原理,分析了正向步进和反向步进的工作过程,并与PXH40喷头和PY40喷头进行了水力性能对比,结果表明PXSBW40双向步进式全射流喷头水力性能和运转稳定性优于另外两种喷头。
The research on the inner flow of the offset fluidic component and its structural optimization is one of the contents of China National Key Technology R&D Program (No.2011AA100506)"Precise sprinkling irrigation technology and products". National Agriculture Science and Technology Achievements Transformation Fund (No.2011GB2C100015)"Perfection and Pilot Test on Variable Light-duty Irrigation Equipment"
The fluidic sprinkler controlled by clearance was an original invention of China. The offset effect in the fluidic component drove the sprinkler and controlled its rotating direction, so the fluidic sprinkler was characterized with simple structure, low cost and good hydraulic performance. Based on the current research status of the fluidic sprinkler, the study on the inner flow theory of the fluidic component was the key of the structural optimization of the fluidic sprinkler. The theoretical analysis, experiments and numerical simulations were combined to study the inner flow characteristic of the fluidic component of the fluidic sprinkler and the offset flow law of the fluidic component with small offset ratio. The research results would be adapted into the structural optimization of the fluidic sprinkler and the development of new fluidic component to extend the application range of the fluidic technology.
The main research contents and results were as follows:
(1) Based on the theories of free turbulence jet and wall attachment jet, the key parameters of the offset flow were analyzed and the source program was written and applied to calculate the offset distance under different offset ratios. The switching performance of the fluidic component of the fluidic sprinkler was analyzed and studied, the switching response time tq, the air velocity of the clearance uj, the offset force Fj and the distance of the max offset force point xf were brought out as parameters of the switching performance.
(2) The inner flow of the offset fluidic component with small offset ratio (D/b<1) was investigated with PIV for the first time. The fluidic component inner flow PIV test rig was set up and the visualized prototypes with different structural sizes were designed and processed to measure the offset flow under different flow rates. The test results indicated that:the offset distance rarely change with increasing flow rates, in a certain flow rate, the offset distance increased with the offset ratio; in a certain offset ratio, the value of the offset distance reaches the minimum while the air supplement hole distance is3mm; when Q=3m3/h, the length of the component L=40mm, the jet in prototypes with offset ratio bigger than0.5cannot attach to the wall, so the following research focused on prototypes with offset ratio smaller than0.5. The range of the clearance was achieved by the PIV test:left clearance g1<2mm, right clearance g2<1.5mm.
(3) The wall-attachment driving force model was established. Formulas for wall-attachment driving force were deduced. The general sprinkler force test rig was set up, and the jet offset force was indirectly obtained by the testing of the sprinkler driving force and the sliding friction. The test results were compared with the theoretical values and the simulation results.
(4) The parameterized design of the offset fluidic component model was brought forward, which including three-dimensional geometric template, mesh generation and numerical simulation, by using the knowledge engineering function of CATIA.
Based on the results of the PIV tests, the small offset ratio fluidic two-phase flow numerical model was established. By comparing with the results of the PIV tests, the numerical model with SST model and free surface model has a minimum error of5%on offset distance, the effect of offset ratio and air supplement hole distance on the offset flow simulated by the numerical model agree with that of the PIV test. Which means the numerical model could replace the PIV test to take further research.
(5) The impact of key structural parameters of the fluidic sprinkler on the wall-attaching performance was simulated and analyzed numerically. With no changes in other parameters including the air supplement hole distance and the cover clearance, the offset distance increased as the offset ratio rose. But if it was higher than0.5, the working area in the spray body had to be lengthened to70mm in order to achieve the wall attachment in the flow, which was not practical in the sprinklers. In this respect, the offset ratio of the fluidic component was ranged from0.15to0.4. Then the relations between the theoretical and numerical results of the offset distance calculated toward different offset ratios were obtained after the theoretical offset distance was modified in reference to the numerical one. The offset distance first declined, then increased as the air supplement hole distance rose; at the value h=3mm, the length required for a complete water attachment of the jet model was the shortest. The influence of the cover clearance on the wall attaching flow field was significant. The size on the left clearance is within0.5-1.5mm, and that on the right is within0.25-1.25mm.
(6) The structural parameter optimization based on orthogonal simulation were carried out and a new fluidic component and sprinkler were developed. The switching response time, offset force and distance of max offset force point were taken as the main factors in the orthogonal evaluation of the performance of fluidic sprinkler, and the premium combination under different offset ratios was figured out. The structure of the fluidic sprinkler was optimized based on the study of the inner flow characteristic of the fluidic component. The PXSBW40two-way stepping fluidic sprinkler with extermination fetching tubes was designed. The characteristics and working principle of the PXSBW40sprinkler were introduced, both working processes of the forward-stepping and the backward-stepping were analyzed. Also, the hydraulic performance was compared with those of the sprinklers typed PXH40and PY40. The results indicated that the new sprinkler PXSBW40outperformed the other two sprinklers in hydraulic performance and operation stability.
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