Optimal design of printed circuit heat exchanger considering manufacturing constraints
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摘要:
针对印刷电路板式换热器(PCHE)的微流道结构参数设计制造一体化问题，开展了考虑制造约束条件的换热器性能优化的研究。通过流体仿真分析了流道宽度、深度和深宽比对温度分布、压力损失和换热系数的影响。使用多目标遗传算法(MOGA)建立了换热性能的多参数多目标性能优化仿真模型，根据性能优化获得的设计参数建立微流道结构辊压成形工艺仿真模型，得到制造约束条件，将制造约束反馈到性能优化仿真模型中，得到宽为0.29 mm、深为0.39 mm的矩形微流道优化设计参数，且通过辊对辊(R2R)的辊压工艺实验验证了该优化方法的可行性。考虑制造约束的换热器优化设计方法在性能优化设计阶段引入工艺限制条件，是实现换热器一体化设计制造的有效手段。
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关键词:
- 印刷电路板式换热器(PCHE) /
- 多目标遗传算法(MOGA) /
- 换热性能 /
- 制造约束 /
- 辊压工艺
Abstract:Aiming at the integrated design and manufacturing of micro-channel structure parameters for printed circuit heat exchanger (PCHE), the performance optimization research of heat exchangers considering manufacturing constraints is carried out. Through fluid simulation, the influence of flow channel width, depth, and aspect ratio on temperature distribution, pressure loss, and heat transfer coefficient is analyzed. A multi-objective genetic algorithm (MOGA) is used to establish a multi-variable and multi-objective optimization simulation model for heat transfer performance. The results of the performance simulation are used to establish the microchannel structure rolling forming process, and the manufacturing constraints are obtained. The manufacturing constraints are fed back to the performance optimization simulation model. Consequently, the micro-channel design parameters with a width of 0.29 mm and a depth of 0.39 mm are obtained, and the feasibility of the optimization method was verified by the roll-to-roll (R2R) process test. The designed method of heat-exchanger optimization considering manufacturing constraints introduce process constraints in the stage of performance optimization design, and is proved an effective measure to achieve the integrated design and manufacture of heat exchangers.
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图 3 仿真模型边界条件示意图
Figure 3. Schematic diagram of boundary conditions of simulation model
图 4 微流道深度h和宽度w对温降ΔT的影响
Figure 4. Influence of microchannel deep h and width w on drop of temperature ΔT
图 6 微流道深度h和宽度w对压降ΔP的影响
Figure 6. Influence of microchannel deep h and width w on drop of pressure ΔP
图 7 w＜0.2时微流道深度h和宽度w对传热系数K的影响
Figure 7. Influence of microchannel deep h and width w on heat transfer coefficient K when w < 0.2
图 8 微流道深度h和宽度w对传热系数K的影响
Figure 8. Influence of microchannel deep h and width w on heat transfer coefficient K
图 9 微流道深宽比λ对温降ΔT的影响
Figure 9. Influence of microchannel aspect ratio λ on drop of temperature ΔT
图 10 微流道深宽比λ对压降ΔP的影响
Figure 10. Influence of microchannel aspect ratio λ on drop of pressure ΔP
图 11 微流道深宽比λ对传热系数K的影响
Figure 11. Influence of microchannel aspect ratio λ on heat transfer coefficient K
图 12 考虑制造约束的换热器优化设计方法
Figure 12. Optimal design method for heat exchangers considering manufacturing constraints
图 14 304不锈钢试样的电辅助变形行为
Figure 14. Electrically assisted deformation behavior of 304 stainless steel specimen
图 15 第1次优化后3种微流道尺寸的辊压仿真结果
Figure 15. Rolling simulation results of three microchannel sizes after the first optimization
图 16 优化方案1~3辊压后的仿真力对比
Figure 16. Simulation force comparison after rolling of optimization scheme 1-3
图 17 三种微流道尺寸辊压后的计算下压力对比
Figure 17. Calculated force comparison after rolling of three microchannel sizes
图 18 第2次优化后3种微流道尺寸的辊压仿真结果
Figure 18. Rolling simulation results of three microchannel sizes after the second optimization
图 19 优化方案4~6辊压后的仿真力对比
Figure 19. Simulation force comparison after rolling of optimization scheme 4-6
属性 密度/(kg·m-3) 比热容/(J·(kg·K)-1) 温度/℃ 热传导率/(W·(m·K)-1) 数值 7 900 502.48 20 14.6 50 15.1 100 16.1 200 17.9 400 18 600 20.8 800 23.9 
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表 2 流体材料属性
Table 2. Properties of fluid materials
流体 密度/(kg·m-3) 比热容/(J·(kg·K)-1) 热传导率/(W·(m·K)-1) 液态水 998.2 4 182 0.6 氩气 1.122 8 520.64 0.015 8
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表 3 第1次优化仿真数据结果
Table 3. The first optimization simulation results
方案 微流道宽度w/mm 微流道深度h/mm 温降ΔT/℃ 压降ΔP/MPa 传热系数K/(W·(m 2·K)-1) 质量m/g 优化方案1 0.12 0.3 235.79 20.3 1.34×105 0.20 优化方案2 0.1 0.37 240.54 20.3 1.33×105 0.20 优化方案3 0.29 0.39 124.18 20.2 1.25×105 0.17
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表 4 第2次优化仿真数据结果
Table 4. The second optimization simulation results
参数 微流道宽度w/mm 微流道深度h/mm 温降ΔT/℃ 压降ΔP/MPa 传热系数K/(W·(m2·K)-1) 质量m/g 优化方案4 0.29 0.32 133.93 0.17 1.26×105 0.18 优化方案5 0.22 0.32 158.72 0.20 1.28×105 0.19 优化方案6 0.17 0.31 185.35 0.24 1.30×105 0.19
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表 5 辊压填充结果
Table 5. Results of rolling
方案 深宽比λ d/mm 填充效果 优化方案1 2.5 0.11 未填充满 优化方案2 3.7 0.10 未填充满 优化方案3 1.34 0 填充满 优化方案4 1.1 0 填充满 优化方案5 1.45 0 基本填充满 优化方案6 1.82 0 部分填满 注：d为h与z的差值。
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表 6 第3次优化仿真数据结果
Table 6. The third optimization simulation results
参数 微流道宽度w/mm 微流道深度h/mm 深宽比λ 温降ΔT/℃ 压降ΔP/MPa 传热系数K/(W·(m 2·K)-1) 质量m/g 优化方案7 0.22 0.33 1.5 156.95 0.202 1.28×105 0.184 优化方案8 0.22 0.29 1.31 164.42 0.212 1.28×105 0.188 优化方案9 0.29 0.39 1.34 124.18 0.159 1.25×105 0.169
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