高速重载轴向柱塞泵新型混合支撑浮动斜盘减摩抗磨机理研究

The swash plate type axial piston pump is one of the most important power elements of hydraulic transmission systems for the major equipment in the national infrastructure as well as the national defense and military industry. The problems of the narrow high efficiency area and the low wear life caused by the friction and wear of friction pairs within pumps have always been the challenges plaguing the researchers and designers. For this reason, an innovative wear resistance and antifriction technology based upon the hybrid support floating swash plate is put forward in this project. The related core fundamental scientific problems are studied theoretically and experimentally in this project to achieve the breakthrough of this innovative technology, utilizing the combined technical means of mathematical modeling, multidisciplinary coupling simulation analysis and experimental research. The hybrid support floating principle of the heavy load swash plate is explored in this project, consisting of the hydrostatic balancing support system and the special-shaped bearings support system. The mechanical-electrical-hydraulic coupling virtual prototype model, as well as the fluid-solid-heat coupling lubrication model of the oil film within the friction interfaces of friction pairs, are established for the innovative hybrid support floating swash plate type axial piston pump. The macroscopic and microscopic dynamics behavior of the hybrid support floating swash plate under the action of high pressure heavy load and the driving of high speed multi-degree-of-freedom composite motion is explored and optimized. The action mechanism and the influence rules of the working performance of the hybrid support floating swash plate on the thin oil film within the friction interfaces of friction pairs are revealed. The high reliability and long service life design and optimization method for the hybrid support floating swash plate is established. With the design and optimization method, the physical prototypes of the hybrid support floating swash plate and the corresponding hybrid support floating swash plate type axial piston pump are developed and manufactured. The experimental researches are conducted to verify the performance of the hybrid support floating swash plate, with the developed physical prototypes, the retrofitted test bench of friction pairs, the comprehensive experimental platform of axial piston pump, as well as the tribological instruments and equipments. The researches have the important scientific significance to change the long-standing deficiency of traditional fixed swash plate type axial piston pumps of poor efficiency at low displacements, promoting the energy-saving and efficiency improvement of the swash plate type axial piston pump and pump control system under full operating conditions, as well as enhancing the reliability and the service life of the swash plate type axial piston pump.

轴向柱塞泵是国家基础建设和国防军工重大装备中液压传动系统的核心动力元件，由于其摩擦副摩擦磨损而导致的泵高效区狭窄与磨损失效问题一直是困扰业界的难题。本项目提出一种新型的混合支撑浮动斜盘减摩抗磨技术，采用数学建模、多学科耦合仿真与实验测试相结合的方法，探索重载斜盘由静压支撑与异形轴承支撑构成的混合支撑浮动原理，建立混合支撑浮动斜盘式轴向柱塞泵机电液耦合虚拟样机模型，以及摩擦副界面油膜热流固耦合润滑模型，探索并优化混合支撑浮动斜盘宏微观动力学行为响应规律，揭示混合支撑浮动斜盘对摩擦副界面变间隙稀薄油膜的作用机理与工作性能影响规律，建立混合支撑浮动斜盘高可靠性长寿命设计优化方法，研制混合支撑浮动斜盘样品与相应的整泵样机，改造搭建浮动斜盘作用下摩擦副测试平台，结合泵综合试验台与摩擦学仪器设备，开展实验研究。研究成果为拓宽轴向柱塞泵高效区、提高其服役寿命开辟了新的途径，具有重要的研究价值与科学意义。

轴向柱塞泵是国家基础建设和国防军工重大装备中液压传动系统的核心动力元件，由于其摩擦副摩擦磨损而导致的泵高效区狭窄与磨损失效问题一直是困扰业界的难题。本项目研究提出了一种新型的浮动斜盘减摩抗磨技术，研究了保留传统柱塞滑靴的混合支承及完全静压支承浮动斜盘式轴向柱塞泵，以及锥形柱塞式完全静压支承浮动斜盘式轴向柱塞泵结构原理，建立了其结构设计方法，以目前工程机械用典型的传统斜盘式轴向柱塞泵技术参数作为输入条件，设计了三种浮动斜盘式轴向柱塞泵，建立了其机电液耦合虚拟样机模型，以及柱塞副、滑靴副、配流副三大摩擦副界面油膜流固耦合润滑模型，采用数学建模、多学科耦合仿真与实验测试相结合的方法，探索了浮动斜盘式轴向柱塞泵多体机构的动力学行为响应规律，揭示了混合支撑浮动斜盘对摩擦副界面变间隙稀薄油膜的作用机理与工作性能影响规律，完成了项目研究提出的三种新型浮动斜盘式轴向柱塞泵的三维模型、设计图纸与工艺图纸的优化、绘制与出图。研究表明：与传统斜盘式轴向柱塞泵相比较，混合支承浮动斜盘式轴向柱塞泵对滑靴副的摩擦功率损失降低率为29.45%，锥形柱塞式完全静压支承浮动斜盘轴向柱塞泵对柱塞副摩擦功率损失降低率为36.98%，球铰处摩擦副摩擦功率损失增大率为9.72%；对于本项目研究中的设计案例，即一台排量80cc/r、额定压力32MPa、自吸最高转速2400r/min的浮动斜盘式轴向柱塞泵来说，混合支撑式浮动斜盘轴向柱塞泵摩擦功率损失降低了372.86w，完全静压支撑锥形柱塞式浮动斜盘轴向柱塞泵摩擦功率损失降低了1101w。对于锥形柱塞式浮动斜盘泵，由于锥形柱塞副侧向力的减小、锥形柱塞密封环的可靠密封作用、锥形柱塞副更佳的润滑冷却环境、回转盘一体式的抗倾覆结构，浮动斜盘式轴向柱塞泵表现出来了比传统斜盘式轴向柱塞泵更易于实现高速化的技术特点，顺应了工程机械电动化发展趋势与技术要求，浮动斜盘式轴向柱塞泵表现出了巨大的工程化应用潜力，本项目的基础研究为其走向工程化应用奠定了必要的理论基础。