渦卷式壓縮機族群設計最佳化之研究

Abstract

本論文為提出一套結合工程經驗之最佳化方案的系統設計流程，特色為應用互動判定法來解決工程實務上常面臨的離散式參數與非線性數學模型的目標函數。運用此系統設計流程，本研究實際應用於要求低成本與高性能化的渦卷式壓縮機之商品族群設計案例，所完成之設計成果，不但零件共用率達80% 以上，其性能也優於國際頂級商品，證明本論文之研究，頗具實用性。 本項系統設計流程包含：(1)渦卷式壓縮機設計架構創意；(2)建構設計參數化模型與模擬分析軟體，並完成相關測試驗證；(3)開發渦卷式壓縮機族群設計最佳化方案；(4)實作雛型壓縮機，並完成相關測試驗證。 所發展的族群設計最佳化方案包含：具離散式參數與非線性模型之目標函數的定義、關鍵設計參數的選擇、相關製造與組裝限制之拘束設定、以及植入工程經驗之互動判定法則的計算迴圈研究等。 本族群設計最佳化方案，以完成兩種用途的渦卷式壓縮機之族群設計為研究案例，並且皆完成雛型實作與性能測試驗證，所開發之雛型壓縮機的性能，皆能滿足國際商品目標的需求。第一案例之族群設計，為應用於定轉速的渦卷式壓縮機，第二案例則以第一案例所完成的族群設計目標及要求零件共用化為基礎，開發結合可變轉速之高效率馬達的渦卷式壓縮機，於相同運轉條件下，所開發之可變轉速的渦卷式雛型壓縮機，其能源效率比第一案例之定轉速渦卷式壓縮機，提高12%以上。 此外，為了匹配可變轉速之渦卷式壓縮機的開發，本研究也同步運用專利分析及功效矩陣比較法，匹配有限元電磁場計算模擬分析而進行永磁同步無刷馬達的實務創作，所完成之創意構想，已獲得台灣、中國大陸及美國等三地區的專利權。 本論文不僅完成系統設計最佳化方案的模擬演算，並且實際建構設計流程來進行工程實務開發，經由渦卷式壓縮機族群設計開發的實作及雛型樣品之性能測試驗證，證明所推導的方法與流程，皆具完整性與實用性。

This dissertation proposes a systematic optimum design procedure for the scroll type compressor (STC) family development. Based on engineering practices, an optimization algorithm combined with interactive session and discrete variable design has been carried out. The major result is that over 80% of the common components can be shared in the developed STC family. The STC prototype’s performance will be able to compete with other world-level commercial products. The major procedures of the proposed systematic design include: (1) to propose an innovative STC design structure, (2) based on the innovated STC structure, to build-up and validate the performance simulation tools, (3) to implement a practical STC family design process that combines with the optimization algorithm, (4) to evaluate the prototype’s performance of the developed STC family. The developed optimization algorithm comprises the non-linear objective function definition and critical design parameters selection to identify the constraints that relate to manufacturing and assembly limitations. An iterative process approach was carried out with interactive session using the given set of discrete variables which were decided by engineering experience. Two case studies of STC family design with optimization have been put into practice and prototyped. The first case of STC family design is used for constant speed application, and based on the design specifications and the requirement of sharing common as many components as possible. An equivalent STC operated at variable speed and controlled by an inverter-fed motor, has been investigated in this study also, and the efficiency is 12% higher than that of the first case of the STC family. In addition, an interior permanent magnet synchronous motor (IPMSM) has been innovated to be used in the variable-speed STC. This IPMSM innovation development is incorporated with function matrix, computer-aided engineering simulation and patent around skills. Meanwhile, the newly developed IPMSM has issued patents in Taiwan, mainland China and United States of America. This study has built-up an effective systematic optimum design algorithm and methodology in engineering practices. In the meantime, the innovated design process has been validated and put into STC family development. The results show that the developed STCs can compete with other commercial products in the world.