Mass and hot spot temperature rise balance optimization of dry-type on-board traction transformers for EMUs
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摘要: 针对干式车载牵引变压器质量-热点温升在优化过程中存在的相互制约问题，提出了将简化计算流体动力学模型仿真与多目标算法相结合的优化方法；为提升计算流体动力学温升仿真计算效率，基于热、电传递类比等效原理，提出了干式车载牵引变压器绕组的计算流体动力学等效简化建模方法，并建立了可模拟运行条件的温升试验平台，以验证简化建模方法的有效性；基于多场耦合下简化模型的温升仿真结果和响应面法，构建出可反映干式车载牵引变压器热点温升与质量结构参数之间内在规律的数学显式模型；在进一步考虑车载牵引变压器电、磁与尺寸约束的基础上，提出了基于非支配排序多目标遗传算法的均衡优化方法，并将优化方案与初始方案进行对比。研究结果表明：等效简化建模方法快速、简洁且具有较高的计算准确性，在170匝绕组仿真模型中将仿真时长由4.00 h缩短至0.67 h，简化模型与具体模型温升仿真计算结果间的平均相对差值为0.609%，最大相对差值为2.169%；简化建模方法通过等效原理消除了计算流体动力学模型的微小间距，在保证网格质量的前提下大幅减少了固体区域网格数量，计算效率的提升程度与需简化的变压器绕组匝数正相关；所得优化方案与初始方案相比，干式车载牵引变压器热点温升下降了33.57%，质量减少了29.20%。Abstract: To address the mutual constraint between the mass and hot spot temperature rise of dry-type on-board traction transformers during the optimization process, an optimization method combining the simplified computational fluid dynamics (CFD) model simulation with the multi-objective algorithm was proposed. To enhance the computational efficiency of the CFD temperature rise simulation, a simplified modeling method for the CFD of dry-type on-board traction transformer winding was proposed based on the thermal-electric transfer analogical equivalence principle. A temperature rise test platform for simulating the operating conditions was established to validate the effectiveness of the simplified modeling method. Based on the simulation results of temperature rise and response surface method using the simplified model under the coupling of multiple fields, a mathematical explicit model reflecting the intrinsic relationship between the hot spot temperature rise and mass structural parameters of the dry-type on-board traction transformer was constructed. Furthermore, in view of the constraints of electricity, magnetism, and dimensions of the on-board traction transformer, an equilibrium optimization method based on the non-dominated sorting multi-objective genetic algorithm was proposed, and the optimized scheme was compared with the initial scheme. Research results demonstrate that the equivalent simplified modeling method is rapid and concise, and it has a high computational accuracy. In the simulation model with 170 turns of winding, the simulation time reduces from 4.00 h to 0.67 h. The average relative difference between the simplified model and the specific model in the temperature rise simulation results is 0.609%, and the maximum relative difference is 2.169%. The simplified modeling method eliminates the tiny spacing of the CFD model by using the equivalent principle and significantly reduces the number of solid region grids while ensuring the grid quality. The improvement of the computational efficiency is positively correlated with the number of winding turns to be simplified. Compared with the initial scheme, the optimized scheme reduces the hot spot temperature rise of the dry-type on-board traction transformer by 33.57% and decreases the mass by 29.20 %.
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图 7 质量与热点温升均衡优化流程
Figure 7. Balanced optimization process of mass and hot spot temperature rise
图 10 最优方案电、磁场仿真结果
Figure 10. Electricity and magnetism fields simulation results of optimal scheme
表 1 干式OBTT基本参数
Table 1. Basic parameters of dry-type OBTT
参数 数值 电压等级/kV 25.00/1.85 额定功率/(V·A) 6 300 频率/Hz 50 
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表 2 干式OBTT材料属性
Table 2. Material properties of dry-type OBTT
参数 铜导体 绝缘纸 环氧树脂 空气 密度/(kg·m-3) 8 978.000 930.000 1 600.000 1.225 热导率/(W·m-1·K-1) 387.600 0 0.190 0 0.250 0 0.024 2 比热容/(J·kg-1·K-1) 381.00 1 340.00 1 000.00 1 006.43 黏度/(kg·m-1·s-1) 1.789×10-5 相对磁导率 0.999 1.000 1.000 1.000 电导率/(S·m-1) 5.8×107 5.4×10-15 4.0×10-13 0
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表 3 模型温升结果对比
Table 3. Comparison of model temperature rise results
测温位置 试验结果/K 具体模型 等效简化模型 温升/K 与试验结果的相对差值/% 温升/K 与试验结果的相对差值/% 3~5匝 35.892 38.447 7.12 39.281 9.44 11~13匝 53.155 57.748 8.64 57.979 9.08 31~33匝 65.492 70.207 7.19 70.442 7.56 51~53匝 72.772 76.997 5.81 77.264 6.17 76~78匝 78.275 82.511 5.41 82.673 5.62 81~83匝 79.581 83.319 4.70 83.492 4.91
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表 4 结构参数敏感性分析
Table 4. Structural parameter sensitivity analysis
mm2 结构参数 基本对比点 单参数变化值 温升变化/K 质量变化/kg 低压单匝截面积 160 180 -18.84 126.5 200 -33.14 268.4 低压风道宽度 7 8 -1.97 20.7 9 -3.43 41.5 铁心半径 110 120 -3.79 -72.9 130 -6.17 -40.7 高压单匝截面积 5 6 -3.61 163.6 7 -6.38 305.5
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表 5 自由变量取值范围
Table 5. Ranges of values for free variables
自由变量 优化范围 低压单匝导体截面积/mm2 150~220 低压风道宽度/mm 6~10 铁心半径/mm 100~140 高压单匝导体截面积/mm2 4~8
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表 6 仿真试验点与响应
Table 6. Simulate test points and responses
组号 铁心半径/mm 低压风道宽度/mm 低压单匝截面积/mm2 高压单匝截面积/mm2 热点温升/K 1 108 6 206 6 90.01 2 103 8 169 5 115.64 3 128 7 183 5 98.07 4 101 6 164 5 126.95 5 121 8 194 8 90.63 6 112 6 218 4 82.08 7 108 9 182 5 101.11 8 125 5 176 4 108.34 9 110 5 205 5 93.36 10 105 7 152 4 135.34 11 117 5 210 7 87.35 12 106 9 151 7 132.93 13 137 9 179 6 97.47 14 126 7 197 5 88.74 15 134 6 189 5 93.84 16 131 8 171 6 105.92 17 133 8 166 4 110.04 18 123 9 192 7 90.64 19 130 8 215 7 76.82 20 127 10 197 6 85.93 21 112 10 217 7 77.31 22 117 10 155 8 123.06 23 136 7 178 6 100.22 24 103 7 158 7 129.22 25 115 9 186 6 96.41 26 114 6 201 6 91.34 27 138 6 161 7 116.47 28 122 8 202 8 85.23 29 139 9 167 7 107.63 30 119 7 211 5 82.02
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表 7 NSGA-Ⅱ参数设置
Table 7. Parameter setting for NSGA-Ⅱ
控制参数 数值 最大迭代次数 20 000 种群大小 200 交叉概率 0.8 变异概率 0.2 精英比例 0.15
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