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双吸蜗壳泵的优化设计
根据双吸入腔的形状，我们可以对双吸蜗壳泵的叶轮进口进行最优化的设计。因此，为了预测这类泵的性能，需要对所有的液压元件（叶轮，双吸室、出水蜗壳，或/和磨损间隙）进行建模。最近几年，得益于并行计算系统的发展，利用CFD来进行大规模流体分析在涡轮机械研究中已变得越来越普遍。使用CFD来进行非稳态流分析也为人们所普遍接受。
According to the shape of the double suction chamber, we can optimize the design of the inlet of the impeller of the double suction volute pump. Therefore, in order to predict the performance of this type of pump, all the hydraulic components (impeller, double suction chamber, outlet worm shell, or / and wear gap) need to be modeled. In recent years, thanks to the development of parallel computing systems, the use of CFD to carry out large-scale fluid analysis has become more and more common in the study of turbomachinery. The use of CFD for unsteady flow analysis is also widely accepted.
Ebara设计了两种类型的双吸蜗壳泵。一种旨在高效率，另一种则是针对低关闭扬程。Ebara通过使用DoE和CFD的方法对泵进行了优化设计。为了实现上述设计目标，Ebara再次确认了对所有液压元件进行优化设计的重要性，这些液压元件不仅仅有叶轮，还包括双吸室和出水蜗壳。采用等比例缩小的模型来对泵的性能进行实验验证。本文介绍了研发的结果。
Ebara designed two types of double suction volute pump. One is designed for high efficiency, and the other is aimed at low closure lift. Ebara was designed to optimize the pump by using DoE and CFD. In order to achieve the above design goals, Ebara reconfirmed the importance of optimization design for all hydraulic components. These hydraulic components include not only impeller, but also double suction chamber and water outlet volute. The performance of the pump is experimentally verified by a model with equal proportions. The results of the research and development are introduced in this paper.
此前的研究提出了一些针对涡轮机械（如混流泵，低温泵，带有吸入弯管的离心泵）的优化设计方法。此外，还有一些关于提高双吸蜗壳泵工作效率的优化设计方法的研究。首先，研究人员优化了叶轮，之后他们设计了双吸室和出水蜗壳。最后，利用CFD预测了整个流场。
Previous studies have proposed a number of optimal design methods for turbomachinery (such as mixed flow pumps, low temperature pumps, and centrifugal pumps with suction pipes). In addition, there are some research on the optimization design method for improving the working efficiency of the double suction volute pump. First, the researchers optimized the impeller, and then they designed a double suction chamber and a water outlet spiral case. Finally, the whole flow field is predicted by CFD.
图1. 双吸蜗壳泵的例子
Figure 1. example of double suction volute pump
因为液体需要通过双吸室才能进入叶轮旋转，所以非常有必要根据旋转速度来设计叶轮的入口形状。然而，双吸室环绕在出水蜗壳周围，所以必须在设计双吸室之前先对出水蜗壳进行设计。一方面，需要知道叶轮的出口流量以便将其作为设计出水蜗壳的入口边界条件。因此，在这项研究中，我们首先使用一个假定的入口条件来设计叶轮。然后，设计了出水蜗壳。接着，设计了双吸室，最后利用双吸室出口的流量条件重新对叶轮进行了设计。
Because the liquid needs to pass through the double suction chamber to enter the impeller rotation, it is very necessary to design the inlet shape of the impeller according to the speed of rotation. However, the double suction chamber is surrounded by the outlet spiral case, so the water outlet spiral case must be designed before the design of the double suction chamber. On the one hand, it is necessary to know the outlet flow of the impeller so that it can be used as the inlet boundary condition for the design of the outlet worm shell. Therefore, in this study, we first use a hypothetical inlet condition to design the impeller. Then, the water outlet worm shell is designed. Then, the double suction chamber was designed, and the impeller was designed with the flow condition of the double suction chamber at the end.
在每个组件的设计过程中，运用DoE方法和灵敏度分析来调研设计参数的最佳值。在下面的章节中具体介绍每个组件的设计过程。
In the design of each component, the DoE method and sensitivity analysis are used to investigate the optimum value of the design parameters. In the following sections, the design process of each component is described in detail.
利用CFD来评估每一台泵的性能。运用商业软件ANSYS Turbo Grid和ICEM制作计算网格，并利用ANSYS CFX来进行计算。采用了雷诺兹平均Navier-Stokes（RANS）算法。剪切应力传递（SST）模型被用于湍流模型中。在稳态分析中，采用冻结转子法来连接旋转坐标系（叶轮域）与静止坐标系之间的接口。使用改变参考系的方法来处理叶轮区域到蜗壳区域的流量，同时保持叶轮叶片与蜗舌之间的相对位置。
CFD is used to evaluate the performance of each pump. Use commercial software ANSYS Turbo Grid and ICEM to make computing grid, and use ANSYS CFX to calculate. The Reynolds average Navier-Stokes (RANS) algorithm is used. The shear stress transfer (SST) model is used in the turbulence model. In the steady state analysis, the frozen rotor method is used to connect the interface between the rotating coordinate system (Ye Lunyu) and the stationary coordinate system. The method of changing the reference frame is used to deal with the flow of the impeller area to the volute area, and the relative position between the impeller blade and the worm tongue is maintained.
对该研究中最后得到的泵的性能进行了实验验证。在一个水平的闭环测试模型上进行实验。使用水作为CFD和实验的工作流体。
The performance of the final pump in the study is verified experimentally. Experiments are carried out on a horizontal closed loop test model. Water is used as a working fluid for CFD and experiment.
高效双吸蜗壳泵的设计
Design of high efficiency double suction volute pump
为了实现高效率，分别对叶轮、双吸室和出水蜗壳进行灵敏度分析。通过DoE的方法减少了分析次数，从而高效地研究了设计参数的影响。根据DoE理论中的正交表，采用CFD方法对几何形状进行设计和分析。灵敏度分析证实了用于控制目标的设计参数的重要性。我们通过使用这些重要的设计参数来设计有价值的几何形状。
In order to achieve high efficiency, the sensitivity analysis of impeller, double suction chamber and water outlet worm shell is carried out respectively. The number of analysis is reduced by the method of DoE, and the influence of the design parameters is studied efficiently. According to the orthogonal table in the DoE theory, the CFD method is used to design and analyze the geometric shape. The sensitivity analysis confirms the importance of the design parameters used to control the target. We design valuable geometric shapes by using these important design parameters.
叶轮设计优化
Optimization of impeller design
选择了六个叶轮设计参数。这些参数可能会影响泵的效率。这些参数包括入口直径、出口宽度、出口叶片角、叶片半径、轮毂半径、倾角、后缘堆积角，每个参数都会在三个层次上变化（低、中和高），使用L27正交表来研究叶轮几何形状的27个例子。
Six impeller design parameters are selected. These parameters may affect the efficiency of the pump. These parameters include the accumulation of entrance diameter, exit width, blade angle, blade radius, hub radius and angle, trailing edge angle, each parameter will change at three levels (low, medium and high), 27 examples of using L27 orthogonal table to study the geometry of the impeller.
在周期性边界条件下，采用具有一螺距叶片通道的稳态流分析方法对每一个叶轮的性能进行评估。规定固定的总压力和流向作为入口边界条件。该入口流向主要根据原始的双吸室CFD分析结果而定。采用一个固定的质量流量条件作为出口边界条件。网格的数量大约在100万。Ebara使用CFD的计算结果来研究叶轮设计参数对叶轮效率的影响。
Under the periodic boundary condition, the steady flow analysis method with one pitch blade channel is used to evaluate the performance of each impeller. The fixed total pressure and flow direction is defined as the inlet boundary condition. The flow direction is mainly based on the results of the original double suction chamber CFD analysis. A fixed mass flow condition is used as an outlet boundary condition. The number of grids is about 1 million. Ebara uses the calculation results of CFD to study the effect of the design parameters of the impeller on the impeller efficiency.
出水蜗壳的优化设计
Optimal design of water outlet spiral case
在本文中，Ebara使用一个参考叶轮，它是利用前面小节中的设计参数配置的中间值设计得到的。根据三个参数在三个层次上的变化得到L9正交表，利用该表设计九个出水蜗壳。这三个参数分别是入口宽度、泵壳截面的角度，以及切水斜交角。出水蜗壳的横截面积是指定的，因此周向流速在任何径向位置上都与1 / r成比例，其中用r表示半径。
In this article, Ebara uses a reference impeller, which is designed by using the intermediate values of the design parameter configuration in the previous section. According to the changes of the three parameters at three levels, the L9 orthogonal table was obtained, and nine effluent volute was designed by using the table. These three parameters are entrance width, pump shell section and water cutting angle, oblique angle. The cross section area of the effluent volute is specified, so the circumferential velocity is proportional to 1 / R at any radial position, in which the radius is expressed with the R.
在出水蜗壳的优化过程中，吸入腔的几何形状还未确定，所以在稳态CFD分析中，用两根吸入管道来代替一个双吸室。计算求解域包括两个吸入管道、整个叶轮、出水蜗壳、外壳磨损环的间隙。入口和出口的边界条件与前一节提到的叶轮CFD分析中是完全一样的。根据初始双吸室的CFD结果来指定进口旋流的数量。网格元素的数量约为950万
In the optimization process of the spiral case, the geometry of the suction chamber has not been determined, so in steady state CFD analysis, two suction pipes are used instead of a double suction chamber. The calculation domain includes two suction pipes, the whole impeller, the water outlet spiral case, and the clearance of the wear ring of the shell. The boundary conditions at the entrance and exit are exactly the same as the impeller CFD analysis mentioned in the previous section. The amount of the inlet swirl is specified according to the CFD results of the initial double suction chamber. The number of grid elements is about 9 million 500 thousand
According to the shape of the double suction chamber, we can optimize the design of the inlet of the impeller of the double suction volute pump. Therefore, in order to predict the performance of this type of pump, all the hydraulic components (impeller, double suction chamber, outlet worm shell, or / and wear gap) need to be modeled. In recent years, thanks to the development of parallel computing systems, the use of CFD to carry out large-scale fluid analysis has become more and more common in the study of turbomachinery. The use of CFD for unsteady flow analysis is also widely accepted.
Ebara设计了两种类型的双吸蜗壳泵。一种旨在高效率，另一种则是针对低关闭扬程。Ebara通过使用DoE和CFD的方法对泵进行了优化设计。为了实现上述设计目标，Ebara再次确认了对所有液压元件进行优化设计的重要性，这些液压元件不仅仅有叶轮，还包括双吸室和出水蜗壳。采用等比例缩小的模型来对泵的性能进行实验验证。本文介绍了研发的结果。
Ebara designed two types of double suction volute pump. One is designed for high efficiency, and the other is aimed at low closure lift. Ebara was designed to optimize the pump by using DoE and CFD. In order to achieve the above design goals, Ebara reconfirmed the importance of optimization design for all hydraulic components. These hydraulic components include not only impeller, but also double suction chamber and water outlet volute. The performance of the pump is experimentally verified by a model with equal proportions. The results of the research and development are introduced in this paper.
此前的研究提出了一些针对涡轮机械（如混流泵，低温泵，带有吸入弯管的离心泵）的优化设计方法。此外，还有一些关于提高双吸蜗壳泵工作效率的优化设计方法的研究。首先，研究人员优化了叶轮，之后他们设计了双吸室和出水蜗壳。最后，利用CFD预测了整个流场。
Previous studies have proposed a number of optimal design methods for turbomachinery (such as mixed flow pumps, low temperature pumps, and centrifugal pumps with suction pipes). In addition, there are some research on the optimization design method for improving the working efficiency of the double suction volute pump. First, the researchers optimized the impeller, and then they designed a double suction chamber and a water outlet spiral case. Finally, the whole flow field is predicted by CFD.
图1. 双吸蜗壳泵的例子
Figure 1. example of double suction volute pump
因为液体需要通过双吸室才能进入叶轮旋转，所以非常有必要根据旋转速度来设计叶轮的入口形状。然而，双吸室环绕在出水蜗壳周围，所以必须在设计双吸室之前先对出水蜗壳进行设计。一方面，需要知道叶轮的出口流量以便将其作为设计出水蜗壳的入口边界条件。因此，在这项研究中，我们首先使用一个假定的入口条件来设计叶轮。然后，设计了出水蜗壳。接着，设计了双吸室，最后利用双吸室出口的流量条件重新对叶轮进行了设计。
Because the liquid needs to pass through the double suction chamber to enter the impeller rotation, it is very necessary to design the inlet shape of the impeller according to the speed of rotation. However, the double suction chamber is surrounded by the outlet spiral case, so the water outlet spiral case must be designed before the design of the double suction chamber. On the one hand, it is necessary to know the outlet flow of the impeller so that it can be used as the inlet boundary condition for the design of the outlet worm shell. Therefore, in this study, we first use a hypothetical inlet condition to design the impeller. Then, the water outlet worm shell is designed. Then, the double suction chamber was designed, and the impeller was designed with the flow condition of the double suction chamber at the end.
在每个组件的设计过程中，运用DoE方法和灵敏度分析来调研设计参数的最佳值。在下面的章节中具体介绍每个组件的设计过程。
In the design of each component, the DoE method and sensitivity analysis are used to investigate the optimum value of the design parameters. In the following sections, the design process of each component is described in detail.
利用CFD来评估每一台泵的性能。运用商业软件ANSYS Turbo Grid和ICEM制作计算网格，并利用ANSYS CFX来进行计算。采用了雷诺兹平均Navier-Stokes（RANS）算法。剪切应力传递（SST）模型被用于湍流模型中。在稳态分析中，采用冻结转子法来连接旋转坐标系（叶轮域）与静止坐标系之间的接口。使用改变参考系的方法来处理叶轮区域到蜗壳区域的流量，同时保持叶轮叶片与蜗舌之间的相对位置。
CFD is used to evaluate the performance of each pump. Use commercial software ANSYS Turbo Grid and ICEM to make computing grid, and use ANSYS CFX to calculate. The Reynolds average Navier-Stokes (RANS) algorithm is used. The shear stress transfer (SST) model is used in the turbulence model. In the steady state analysis, the frozen rotor method is used to connect the interface between the rotating coordinate system (Ye Lunyu) and the stationary coordinate system. The method of changing the reference frame is used to deal with the flow of the impeller area to the volute area, and the relative position between the impeller blade and the worm tongue is maintained.
对该研究中最后得到的泵的性能进行了实验验证。在一个水平的闭环测试模型上进行实验。使用水作为CFD和实验的工作流体。
The performance of the final pump in the study is verified experimentally. Experiments are carried out on a horizontal closed loop test model. Water is used as a working fluid for CFD and experiment.
高效双吸蜗壳泵的设计
Design of high efficiency double suction volute pump
为了实现高效率，分别对叶轮、双吸室和出水蜗壳进行灵敏度分析。通过DoE的方法减少了分析次数，从而高效地研究了设计参数的影响。根据DoE理论中的正交表，采用CFD方法对几何形状进行设计和分析。灵敏度分析证实了用于控制目标的设计参数的重要性。我们通过使用这些重要的设计参数来设计有价值的几何形状。
In order to achieve high efficiency, the sensitivity analysis of impeller, double suction chamber and water outlet worm shell is carried out respectively. The number of analysis is reduced by the method of DoE, and the influence of the design parameters is studied efficiently. According to the orthogonal table in the DoE theory, the CFD method is used to design and analyze the geometric shape. The sensitivity analysis confirms the importance of the design parameters used to control the target. We design valuable geometric shapes by using these important design parameters.
叶轮设计优化
Optimization of impeller design
选择了六个叶轮设计参数。这些参数可能会影响泵的效率。这些参数包括入口直径、出口宽度、出口叶片角、叶片半径、轮毂半径、倾角、后缘堆积角，每个参数都会在三个层次上变化（低、中和高），使用L27正交表来研究叶轮几何形状的27个例子。
Six impeller design parameters are selected. These parameters may affect the efficiency of the pump. These parameters include the accumulation of entrance diameter, exit width, blade angle, blade radius, hub radius and angle, trailing edge angle, each parameter will change at three levels (low, medium and high), 27 examples of using L27 orthogonal table to study the geometry of the impeller.
在周期性边界条件下，采用具有一螺距叶片通道的稳态流分析方法对每一个叶轮的性能进行评估。规定固定的总压力和流向作为入口边界条件。该入口流向主要根据原始的双吸室CFD分析结果而定。采用一个固定的质量流量条件作为出口边界条件。网格的数量大约在100万。Ebara使用CFD的计算结果来研究叶轮设计参数对叶轮效率的影响。
Under the periodic boundary condition, the steady flow analysis method with one pitch blade channel is used to evaluate the performance of each impeller. The fixed total pressure and flow direction is defined as the inlet boundary condition. The flow direction is mainly based on the results of the original double suction chamber CFD analysis. A fixed mass flow condition is used as an outlet boundary condition. The number of grids is about 1 million. Ebara uses the calculation results of CFD to study the effect of the design parameters of the impeller on the impeller efficiency.
出水蜗壳的优化设计
Optimal design of water outlet spiral case
在本文中，Ebara使用一个参考叶轮，它是利用前面小节中的设计参数配置的中间值设计得到的。根据三个参数在三个层次上的变化得到L9正交表，利用该表设计九个出水蜗壳。这三个参数分别是入口宽度、泵壳截面的角度，以及切水斜交角。出水蜗壳的横截面积是指定的，因此周向流速在任何径向位置上都与1 / r成比例，其中用r表示半径。
In this article, Ebara uses a reference impeller, which is designed by using the intermediate values of the design parameter configuration in the previous section. According to the changes of the three parameters at three levels, the L9 orthogonal table was obtained, and nine effluent volute was designed by using the table. These three parameters are entrance width, pump shell section and water cutting angle, oblique angle. The cross section area of the effluent volute is specified, so the circumferential velocity is proportional to 1 / R at any radial position, in which the radius is expressed with the R.
在出水蜗壳的优化过程中，吸入腔的几何形状还未确定，所以在稳态CFD分析中，用两根吸入管道来代替一个双吸室。计算求解域包括两个吸入管道、整个叶轮、出水蜗壳、外壳磨损环的间隙。入口和出口的边界条件与前一节提到的叶轮CFD分析中是完全一样的。根据初始双吸室的CFD结果来指定进口旋流的数量。网格元素的数量约为950万
In the optimization process of the spiral case, the geometry of the suction chamber has not been determined, so in steady state CFD analysis, two suction pipes are used instead of a double suction chamber. The calculation domain includes two suction pipes, the whole impeller, the water outlet spiral case, and the clearance of the wear ring of the shell. The boundary conditions at the entrance and exit are exactly the same as the impeller CFD analysis mentioned in the previous section. The amount of the inlet swirl is specified according to the CFD results of the initial double suction chamber. The number of grid elements is about 9 million 500 thousand
