CN111441925A - 一种轻型五缸柱塞泵 - Google Patents
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract
本发明公开了一种轻型五缸柱塞泵，所述轻型五缸柱塞泵包括动力端总成和液力端总成，所述动力端总成与液力端总成连接，所述轻型五缸柱塞泵的缸间距为9in，所述动力端总成包括曲轴，所述曲轴包括曲颈和曲拐，所述曲颈与曲拐固定连接，所述曲拐有五个，所述曲颈有六个，所述曲颈与曲拐的旋转中心之间的距离为101.6mm，所述轻型五缸柱塞泵的冲程距离为203.2mm。该轻型五缸柱塞泵通过增加冲程、缩减传动比与提高承载能力以提高功率，同时通过减少缸间距、减小大齿轮的齿数与缩减大齿轮和小齿轮的齿厚的方式以减轻自重。该轻型五缸柱塞泵在重量和功率方面同时满足在固井作业工况恶劣的区域作业的条件，工作效率提高。
Description
技术领域
本发明涉及油气开采设备，具体涉及一种轻型五缸柱塞泵。
背景技术
在油气开采领域，固井是为了封隔各油气水层及夹层，防止油气水上窜，为后续的井下作业创造条件。固井施工的设计方案要通过固井设备来实现。固井设备包括固井车，固井车上装备有柱塞泵，而柱塞泵是输送固井液这一工作过程中用到的主要动力机械。常规的固井作业区域，现有的柱塞泵可以满足作业要求；固井作业工况恶劣的区域，需要使用比常规的固井作业区域功率和排量更大的柱塞泵。一般情况下，额定输入功率越大，柱塞泵的体积越大，则重量越重。
工况恶劣的区域内，现有的柱塞泵或者是功率足够但是重量超重，固井车的总重量不符合法规要求；或者是重量在规定的范围内，但是额定输入功率不足，会导致输出的压力和流量不满足固井作业的工况要求，降低作业效率。现有的柱塞泵不能在重量和功率方面同时满足在固井作业工况恶劣的区域作业的条件，工作效率低。
发明内容
本发明的目的克服现有技术的不足，提供一种轻型五缸柱塞泵，该轻型五缸柱塞泵通过增加冲程、增加转速与提高工作压力的方式提高功率，同时通过缩减缸间距、减小大齿轮的齿数与缩减大齿轮和小齿轮的齿厚的方式以减轻自重。该轻型五缸柱塞泵在重量和功率方面同时满足在固井作业工况恶劣的区域作业的条件，工作效率提高。
本发明的目的是通过以下技术措施达到的：一种轻型五缸柱塞泵，所述轻型五缸柱塞泵包括动力端总成和液力端总成，所述动力端总成与液力端总成连接，所述轻型五缸柱塞泵的缸间距为9in，所述动力端总成包括曲轴，所述曲轴包括曲颈和曲拐，所述曲颈与曲拐固定连接，所述曲拐有五个，所述曲颈有六个，所述曲颈与曲拐的旋转中心之间的距离为101.6mm，所述轻型五缸柱塞泵的冲程距离为203.2mm。
进一步地，所述动力端总成还包括齿轮副总成，所述齿轮副总成位于动力端总成内部，所述齿轮副总成包括小齿轮、小齿轮轴和大齿轮，所述小齿轮固定连接在小齿轮轴的两端，所述小齿轮轴与曲轴平行，所述大齿轮连接在曲轴两端，所述大齿轮通过减小齿数来减小传动比。
进一步地，所述齿轮副总成的传动比为5.5:1～6:1。
进一步地，所述大齿轮的宽度范围为125～135mm，所述小齿轮的宽度范围为135～145mm。
进一步地，所述大齿轮的宽度为127mm，所述小齿轮的宽度为141.7mm。
进一步地，所述曲颈上连接有经过强度强化的曲轴轴承，所述动力端总成还包括连杆十字头总成，所述连杆十字头总成包括连杆和十字头，所述连杆为整体式连杆，所述连杆包括连杆座总成和连杆体，所述连杆座总成和连杆体固定连接，所述连杆座总成与曲拐转动连接，所述连杆体远离连杆座总成的一端与十字头连接，所述连杆体和十字头之间设有连杆小头轴瓦，所述十字头上连接有用于限定连杆小头轴瓦位置的压板。
进一步地，五个所述曲拐从曲轴的一端起始，依次为曲拐Ⅰ、曲拐Ⅱ、曲拐Ⅲ、曲拐Ⅳ、曲拐Ⅴ，所述曲拐按照曲拐Ⅰ、曲拐Ⅴ、曲拐Ⅱ、曲拐Ⅲ和曲拐Ⅳ偏转运行。
与现有技术相比，本发明的有益效果是：1.技术人员将该轻型五缸柱塞泵的冲程距离增加到203.2mm，排量增加，流量增大，该轻型五缸柱塞泵的额定输入功率增加；2.该轻型五缸柱塞泵采用两种方式增大该轻型五缸柱塞泵的载荷，其一为采用经过强度强化的曲轴轴承，其二为采用整体式连杆结构，连杆体靠近十字头的一端连接连杆小头轴瓦，连杆小头轴瓦接触十字头的受力面为整体式连杆的承载面，连杆的承载面积增大，能够承受的载荷增大，该轻型五缸柱塞泵的工作压力随之增大，额定输入功率增大；3.技术人员将齿轮副总成的传动比缩减到5.5:1～6：1，传动比减小，转速增大，额定输入功率进一步增大；4.技术人员将该轻型五缸柱塞泵的缸间距缩减到9in，减轻了该轻型五缸柱塞泵的自重；5.大齿轮的齿数减小，则大齿轮的重量减少，动力端总成的宽度减小，该轻型五缸柱塞泵的自重进一步减小；6.技术人员将小齿轮的宽度缩减为141.7mm，大齿轮的宽度缩减为127mm，动力端总成的宽度减小，该轻型五缸柱塞泵的体积减小，进一步减轻自重；7.该轻型五缸柱塞泵通过使曲拐按照曲拐Ⅰ、曲拐Ⅴ、曲拐Ⅱ、曲拐Ⅲ和曲拐Ⅳ偏转运行的方式，减小液力端总成的振动，使液力端总成稳定进液，且使液力端总成的进液充足，保证该轻型五缸柱塞泵工作的稳定性。
下面结合附图和具体实施方式对本发明作详细说明。
附图说明
图1是轻型五缸柱塞泵的外部结构示意图。
图2是轻型五缸柱塞泵的内部结构示意图。
图3是动力端总成的结构示意图。
图4是齿轮副的结构示意图。
图5是连杆十字头的结构示意图。
标记说明：1、动力端总成，2、液力端总成，3、润滑管路，4、驱动法兰，5、驱动法兰平键，6、动力端壳体，7、液力端连接螺栓，8、曲轴，9、左大齿轮，10、连接平键，11、曲轴轴承，12、小齿轮轴，13、连杆十字头总成，14、卡箍，15、传感器接头，16、阀箱，17、压盖，18、压帽，19、凡尔弹簧，20、凡尔体，21、凡尔座，22、凡尔弹簧座套，23、柱塞，24、盘根密封总成，25、盘根压帽，26、连杆座总成，27、连杆体，28、连杆小头轴瓦，29、十字头，30、拉杆，31、右大齿轮，32、凡尔弹簧座，33、压板。
具体实施方式
如图1-5所示，一种轻型五缸柱塞泵，轻型五缸柱塞泵包括动力端总成1、液力端总成2、润滑管路3。动力端总成1的输入端与动力源连接，动力端总成1的输出端与液力端总成2连接，润滑管路3连接在动力端总成1上，用于给动力端总成1润滑。
动力端总成1包括动力端壳体6和动力端壳体6内部的连接件。连接件包括依次连接的齿轮副总成、曲轴8和连杆十字头总成13。曲轴8包括曲颈和曲拐，曲颈与曲拐固定连接。曲颈有六个，曲拐有五个。五个曲拐从曲轴8靠近动力端总成1的输入端起始，依次命名为曲拐Ⅰ、曲拐Ⅱ、曲拐Ⅲ、曲拐Ⅳ、曲拐Ⅴ。曲拐Ⅰ、曲拐Ⅴ、曲拐Ⅱ、曲拐Ⅲ和曲拐Ⅳ围绕曲颈的旋转中心偏转运行。曲拐的偏转运行方式，减小液力端总成2的振动，使液力端总成2稳定进液，且使液力端总成2的进液充足，保证该轻型五缸柱塞泵工作的稳定性。
曲颈和曲拐的旋转中心之间的距离为101.6mm，该轻型五缸柱塞泵的冲程距离为203.2mm。技术人员通过对该轻型五缸柱塞泵的设计和校核，增加冲程距离，轻型五缸柱塞泵的排量增加，流量增加。轻型五缸柱塞泵的最大流量可达到944.6L/min。轻型五缸柱塞泵的流量提升，额定输入功率提高。曲轴8的端部(在曲颈上)通过热装的方式连接有经过强度强化的曲轴轴承11。曲轴轴承11强度强化后，该轻型五缸柱塞泵能够承受更大的载荷，提高了该轻型五缸柱塞泵的承载能力，该轻型五缸柱塞泵的工作压力相应升高，额定输入功率增大。
连杆十字头总成13包括依次连接的连杆、十字头29和拉杆30。拉杆30和十字头29之间螺栓连接。连杆包括连杆座总成26和连杆体27，连杆体27和连杆座总成26固定连接。曲拐与连杆座总成26轴承连接，连杆体27远离连杆座总成26的一端与十字头29销接。
连杆为整体式连杆，整体式连杆相比于分体式连杆能够承受更大强度的载荷。连杆体27和十字头29之间连接有连杆小头轴瓦28，连杆小头轴瓦28压接在连杆体27远离连杆座总成26的一端，连杆小头轴瓦28压接在十字头29内。连杆小头轴瓦28增大连杆体27的承载面积，连杆的承载能力增大，该轻型五缸柱塞泵的工作压力增大，额定输入功率增大。
十字头29内部螺栓连接有两块压板33，压板33位于连杆小头轴瓦28两端，压板33与连杆小头轴瓦28的两端抵接，压板33用于限定连杆小头轴瓦28的位置。连杆小头轴瓦28通过压板33保持正常工作状态，方便拆卸，磨损后方便更换。
技术人员通过对该轻型五缸柱塞泵进行设计和校核，将齿轮副总成的传动比缩减到5.5:1～6:1之间。该轻型五缸柱塞泵的转速增加，流量增大，额定输入功率增大。增大该轻型五缸柱塞泵的承载能力、缩减传动比和增大该轻型五缸柱塞泵的冲程的举措相结合，实现了轻型五缸柱塞泵的额定输入功率升高至2500hp。
齿轮副总成包括小齿轮、小齿轮轴12和大齿轮。小齿轮固定连接在小齿轮轴12两端。大齿轮有两个，分别为左大齿轮9和右大齿轮31，左大齿轮9和右大齿轮31的旋向相反。左大齿轮9通过连接平键10与曲轴8的一端连接，右大齿轮31通过连接平键10与曲轴8的另一端连接。小齿轮和大齿轮啮合。小齿轮轴12与曲轴8平行，方便小齿轮和大齿轮传动。
小齿轮轴12的一端穿出动力端壳体6，小齿轮轴12的穿出端为动力端总成1的输入端，小齿轮轴12的穿出端与驱动法兰4连接，驱动法兰4与小齿轮轴12通过驱动法兰平键5连接。小齿轮轴12通过驱动法兰4与外部的动力源连接。技术人员缩减大齿轮的齿数，大齿轮的重量减小，动力端总成1的体积相应减小，则该轻型五缸柱塞泵的自重减小。
左大齿轮9和右大齿轮31的宽度相同，左大齿轮9和右大齿轮31的宽度范围为125～135mm，小齿轮的宽度范围为135～145mm。小齿轮的宽度为141.7mm，左大齿轮9和右大齿轮31的宽度为127mm。小齿轮轴12转动过程中会沿小齿轮的轴向发生偏移，小齿轮的宽度比左大齿轮9和右大齿轮31大，则左大齿轮9和右大齿轮31与小齿轮工作过程中始终啮合，传动的稳定性提高。技术人员通过对该轻型五缸柱塞泵的设计和校核，在满足该轻型五缸柱塞泵的额定输入功率的前提下，对左大齿轮9与右大齿轮31的宽度和小齿轮的宽度缩减，则该轻型五缸柱塞泵的宽度缩短，该轻型五缸柱塞泵的自重减轻。
技术人员将该轻型五缸柱塞泵的缸间距缩减到9in，该轻型五缸柱塞泵的体积减小，自重减小。该轻型五缸柱塞泵通过缩减大齿轮的齿数、缩减左大齿轮9、右大齿轮31和小齿轮的宽度与缩短缸间距的手段，使其自重在6t以下。
动力端总成1和液力端总成2之间连接有液力端连接螺栓7。液力端连接螺栓7用于支撑液力端总成2。液力端总成2包括与拉杆30连接的柱塞23、开有进液口和排液口的阀箱16、压盖17、压帽18与凡尔总成。柱塞23和连杆30之间通过卡箍14连接。阀箱16中空，柱塞23穿入阀箱16内部。阀箱16在与柱塞23共轴线的位置上开有通孔，压盖17在通孔处螺纹连接。压盖17起到密封阀箱16的作用，压帽18用于稳定压盖17的位置。排液口连接有传感器接头15，传感器接头15处连接有用于检测阀箱16内部压力的设备。使用者可以根据实际检测需要进行装配。
进液口和排液口装配有凡尔总成。凡尔总成包括凡尔体20、凡尔座21、凡尔弹簧座32、装配在凡尔体20与凡尔弹簧座32之间的凡尔弹簧19和用于固定凡尔弹簧座32的凡尔弹簧座套22。凡尔总成的设置保证了流体的单向通过，保证了轻型五缸柱塞泵的正常工作。柱塞23和阀箱16之间填充有盘根密封总成24，阀箱16和柱塞23通过盘根密封总成24密封连接，盘根压帽25用于固定盘根密封总成24。盘根密封总成24起到密封作用，提高了轻型五缸柱塞泵工作的稳定性。
润滑管路3向动力端总成1内部输送润滑油进行润滑。润滑管路3的两端穿入动力端总成1内，润滑管路3的中部开有用于进油的进油口，动力端总成1的底部开有用于回油的回油口。润滑管路3的设置，减少了连接件的摩擦，并且对工作时温度过高的连接件进行冷却，保证了轻型五缸柱塞泵连续工作。
本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (7)
1.一种轻型五缸柱塞泵，其特征在于：所述轻型五缸柱塞泵包括动力端总成和液力端总成，所述动力端总成与液力端总成连接，所述轻型五缸柱塞泵的缸间距为9in，所述动力端总成包括曲轴，所述曲轴包括曲颈和曲拐，所述曲颈与曲拐固定连接，所述曲拐有五个，所述曲颈有六个，所述曲颈与曲拐的旋转中心之间的距离为101.6mm，所述轻型五缸柱塞泵的冲程距离为203.2mm。
2.根据权利要求1所述的一种轻型五缸柱塞泵，其特征在于：所述动力端总成还包括齿轮副总成，所述齿轮副总成位于动力端总成内部，所述齿轮副总成包括小齿轮、小齿轮轴和大齿轮，所述小齿轮固定连接在小齿轮轴的两端，所述小齿轮轴与曲轴平行，所述大齿轮连接在曲轴两端，所述大齿轮通过减小齿数来减小传动比。
3.根据权利要求2所述的一种轻型五缸柱塞泵，其特征在于：所述齿轮副总成的传动比为5.5:1～6:1。
4.根据权利要求2所述的一种轻型五缸柱塞泵，其特征在于：所述大齿轮的宽度范围为125～135mm，所述小齿轮的宽度范围为135～145mm。
5.根据权利要求4所述的一种轻型五缸柱塞泵，其特征在于：所述大齿轮的宽度为127mm，所述小齿轮的宽度为141.7mm。
6.根据权利要求1所述的一种轻型五缸柱塞泵，其特征在于：所述曲颈上连接有经过强度强化的曲轴轴承，所述动力端总成还包括连杆十字头总成，所述连杆十字头总成包括连杆和十字头，所述连杆为整体式连杆，所述连杆包括连杆座总成和连杆体，所述连杆座总成和连杆体固定连接，所述连杆座总成与曲拐转动连接，所述连杆体远离连杆座总成的一端与十字头连接，所述连杆体和十字头之间设有连杆小头轴瓦，所述十字头上连接有用于限定连杆小头轴瓦位置的压板。
7.根据权利要求1所述的一种轻型五缸柱塞泵，其特征在于：五个所述曲拐从曲轴的一端起始，依次为曲拐Ⅰ、曲拐Ⅱ、曲拐Ⅲ、曲拐Ⅳ、曲拐Ⅴ，所述曲拐按照曲拐Ⅰ、曲拐Ⅴ、曲拐Ⅱ、曲拐Ⅲ和曲拐Ⅳ偏转运行。
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