A Review of Matching Technology of Eddy Current Retarder for High Maneuvering Platform

doi:10.12382/bgxb.2022.0926

Abstract

Abstract:

The development of high maneuvering platforms shows that the improvement of maneuverability such as high-speed driving leads to the increase of continuous braking power, and excessive temperature rise of friction parts with single mechanical braking, so it is urgent to conduct more research on retarder matching of the braking system. Firstly, the design input of retarder matching is clarified by analyzing the typical braking conditions of the high maneuvering platform. Then, a new type of eddy current retarder scheme suitable for high maneuvering brake matching is proposed by analyzing the development status and characteristics of multiple types of retarder technologies, and the main key technologies required for the development of the new type of eddy current retarder are analyzed and studied. Finally, the new retarder matching effect is studied against the background of 40t high maneuvering platform, to provide a new way for the braking technology of retarder matching for high maneuvering platforms.

Key words: high mobility platform, braking, eddy current retarder, special vehicle

CLC Number:

U463.53

NING Keyan, LI Desheng, TIAN Jinshan, GAI Jiangtao, OUYANG Wei, LAN Hai, PANG Huiren. A Review of Matching Technology of Eddy Current Retarder for High Maneuvering Platform[J]. Acta Armamentarii, 2023, 44(1): 1-10.

Figures/Tables 22

Fig.1 Frequent braking-cumulative temperature rise test (81 times, continuous power 30kW)

Fig.2 Comprehensive frequency distribution of braking in each deceleration zone

Table 1 Comprehensive braking load spectrum for full life driving

减速度/ (m·s^-2)	速度当量/(km·h)
减速度/ (m·s^-2)	42	56
2	887次	543次
4	60次	32次

Table 2 Retarding matching index system

编号	参数	数值
1	累积制动能量分担比例/%	≥60
2	坡降制动能量分担比例/%	≥100
3	峰值缓速功率/MW	≥1.2
4	响应时间/s	≤0.3
5	本体匹配功率密度/(MW·m^-3)	≥21
6	匹配扭矩比例控制范围/%	≤85
7	匹配转速范围占比/%	≥85
8	自主可控性/%	100

Fig.3 Hydraulic retarder products

Fig.4 RENK HSWL 354

Fig.5 Eddy current retarder products

Fig.6 Thermal derating of the eddy current retarder braking torque

Fig.7 Basic structure of the water-cooling embedded eddy current retarder

Table 3 Comparison of R&D indexes of retarder

参数	传统液缓	基于液缓的高机动缓速匹配要求	电缓研制目标
匹配功率密度/(MW·m^-3)	名义68.1	20.1	22.8
峰值缓速功率/kW	6032	1470	1433
扭矩/(N·m)	16000	4000	3800
最高转速/(r·min^-1)	3600	3600	3600
截止转速/(r·min^-1)	1500	900	600
非匹配转速占比%	42%	25%	17%
缓速起效时间/s	0.8	0.4	0.3

Table 4 Comprehensive comparison of R&D of retarder

参数	电缓速研制目标	常规液力缓速现状和高机动缓速匹配预期
匹配功率密度/(MW·m^-3)	22.8	20.1
响应时/s	≤0.3	0.5~0.8→0.4
空损/kW-(3600r/min)	<10	12~23→12
匹配扭矩受控范围	10%~100%	40%~100% (难度大)
匹配用转速占比%	75%→85%	60%~50%→75%
能耗比(缓速功率/相关消耗)	>220	含压力油箱维持所需能耗,随使用漏损增加而增加
所需液压源	常规润滑冷却系统	用压力油箱和相关专用管道满足大流量充油
控制系统(含状态监测)复杂程度	相对简单(电流及冷却流量开关控制)	复杂(大流量充放及背压控制)
比例可控性	容易(控制电流,电流与扭矩线性比例特性)	难(控制大口径锥阀,其压力与扭矩的非线性特性)
产品制造难度(自主化)	小	大

Fig.8 Steady-state temperature on the stator

Table 5 Breaking characteristics of three kinds of eddy current retarder

参数	传统风冷电缓	内嵌式液冷电缓	湿式双凸极电缓
电磁结构	多线圈励磁毂式结构	单线圈励磁内嵌结构	单线圈励磁双凸极结构
散热方式	风冷散热	水套散热	发热表面直接喷淋冷却
(24V)额定功率/kW	425	540	623
额定控制能耗比	201	214.3	218
(26V)极限功率/kW	452	620	726
极限控制能耗比	183	209	215
极限功率密度/(MW·m^-3)	15.7	21.5	25.2
热衰退	≥50%	≈20%	≈15%

Fig.9 Structure of the doubly salient eddy current retarder

Fig.10 Torque and temperature characteristic curves of the doubly salient eddy current retarder

Fig.11 Influence of excitation on torque

Fig.12 Influence of magnetic saturation coefficient on torque

Fig.13 Effect of conductivity on braking torque of the eddy current retarder at different speeds

Table 6 Vehicle parameters

参数	数值	备注
机械制动响应时间/s	0.3	计算参数
缓速分担计算阻力对应减速度/(m· $s - 2$ )	0.5	计算参数
主动轮半径/m	0.3	参考参数
侧减速比	4	参考参数
缓速到机械制动增扭比	1.3	参考参数
最高车速/(km·h^-1)	80	计算参数
整车质量/t	40	计算参数

Table 6 Vehicle parameters

参数	数值	备注
机械制动响应时间/s	0.3	计算参数
缓速分担计算阻力对应减速度/(m· $s - 2$ )	0.5	计算参数
主动轮半径/m	0.3	参考参数
侧减速比	4	参考参数
缓速到机械制动增扭比	1.3	参考参数
最高车速/(km·h^-1)	80	计算参数
整车质量/t	40	计算参数

Table 7 Matching energy of 0.8MW eddy current retarder (full life braking load spectrum)

工况	整车减速度/ (m·s^-2)	制动初速度/ (m·s^-1)	制动系统分担减速度/ (m·s^-2)	全寿命周期该工况次数	全寿命周期制动总能量/MJ	全寿命周期缓速分担总能量/MJ	每次制动联合制动系统分担能量/MJ	每次制动缓速系统分担能量/MJ	缓速分担/%
1	2	11.67	1.5	887	2037	761	2.30	0.86	37
2	2	15.56	1.5	543	2217	953	4.08	1.75	43
3	4	11.67	3.5	60	161	26	2.68	0.43	16
4	4	15.56	3.5	32	152	28	4.76	0.88	18
合计				1522	4568	1767			39

Table 8 Matching energy of 1.5MW eddy current retarder (emergency braking)

工况	整车减速度/ (m·s^-2)	制动初速度/ (m·s^-1)	制动系统分担减速度/ (m·s^-2)	全寿命周期该工况次数	全寿命周期制动总能量/MJ	全寿命周期缓速分担总能量/MJ	每次制动联合制动系统分担能量/MJ	每次制动缓速系统分担能量/MJ	缓速分担/%
紧急制动1	4	23.61	3.5	3	33	12	10.98	4.15	38
紧急制动2	5	23.61	4.5	1	11	3	11.29	3.32	29

Table 9 Evaluation of control power, cooling flow and cooling power of eddy current retarder

工况	全时		短时		车辆电源控制用电		传动系统		车辆辅助散热系统
工况	平均功率/kW	持续时间/s	峰值功率/MW	持续时间/s	功率(48V)/ kW	持续时间/s	冷却流量/ (L·min^-1)	润滑油过缓速温升/℃	冷却功率/kW	持续时间/s
高机动频繁制动 (分担40%)	12	6000	0.7	1	0.055	6000	50	7.15	114	6000
12kW坡降(机械制动分担60kW)	60	500			0.067	500	135	13.24	84	500
最高车速最大减速度制动	250	4	1.0	1	1.250	4	135	55.15
以上工况的短时情况综合			1.0	1	4.545	1

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