CN114001020A

CN114001020A - Novel large-flow emulsion pump station

Info

Publication number: CN114001020A
Application number: CN202111247285.5A
Authority: CN
Inventors: 向虎; 陈国辉; 戴红兵; 张文全
Original assignee: Nanjing Liumei Machinery Co ltd
Current assignee: Nanjing Liumei Machinery Co ltd
Priority date: 2021-10-26
Filing date: 2021-10-26
Publication date: 2022-02-01

Abstract

The invention discloses a novel large-flow emulsion pump station. The invention provides the herringbone gear transmission structure externally hung on the two groups of helical gear sets, which reserves the advantage of eliminating axial force and overcomes the defects of high requirement on processing precision, complex assembly process and inconvenience in subsequent overhaul and maintenance; the crankshaft multi-point supporting technology of the non-integral split transmission case is adopted, the problems of large design size and heavy equipment of a crankshaft and the transmission case in a two-point supporting mode are solved, and the problems of high requirements on processing, manufacturing and assembling processes, and inconvenient field maintenance and later maintenance of the integral split transmission case are also solved; an independent external circulation lubricating system is provided, a transmission case and an oil tank are separated, the cleanliness and quality closed-loop management and control of lubricating oil are realized, and the premise is provided for realizing the advanced start of the lubricating system before the pump station starts the pump and the delayed stop of the lubricating system after the pump station stops the pump; the pump station integrally adopts a bilateral symmetry structure, and can meet the arrangement requirements of the left working face and the right working face of a coal mine.

Description

Novel large-flow emulsion pump station

Technical Field

The invention relates to the technical field of mechanical engineering hydraulic pressure, in particular to a novel large-flow emulsion pump station.

Background

The emulsion pump station is a necessary device of the comprehensive mechanized coal mining working face of the coal mine, is a power source of a working face hydraulic support, adopts a horizontal cylinder body structure, and drives components such as a crankshaft, a connecting rod, a slide block, a plunger piston and the like to move through primary gear transmission, so that mechanical energy is converted into hydraulic energy.

The emulsion pump station is originated in western countries such as England, Germany and the like in the 50 th century, and is imported and applied in the 70 th century in China, and the localization is gradually realized. The traditional domestic pump station is limited by historical production, design level, coal mine working condition characteristics and management level, the design concept of the traditional domestic pump station takes pollution-resistant design, working condition adaptability and maintainability as main starting points, and the requirements on the reliability, consistency and the like of products are not high. Based on the above concept, the design and manufacture of the traditional pump station tend to be low in cost, easy to maintain, simple in structure, capable of adapting to various working conditions for use and maintenance, and low in requirements on reliability and continuous fault-free operation of products. The traditional pump station generally adopts internal circulation systems such as mechanical unloading, splash lubrication and the like, and the crankshaft adopts a two-point support structure; the flow of a pump station is small, the pressure fluctuation is large, the liquid supply of the system is insufficient when the support rapidly descends and moves, and the initial support force of the support cannot be reliably ensured; the automation degree of the whole pump station system is not high, and basically no sensing protection measures exist.

In the years, the development of coal mine intellectualization thoroughly subverts the traditional operation mode and management mode, and coal mines develop towards automation and intellectualization rapidly. In the management concept, the development is towards less humanization and no humanization; the equipment develops towards high reliability, automation and intellectualization; the personnel use of the working face is more and more careful, the requirements on underground maintenance and repair of the equipment are more and more strict, the traditional maintenance personnel are greatly reduced, and the trend that the required high reliability and continuous non-failure operation time of the equipment are continuously increased is also inevitable.

Under the great trend of coal mine intellectualization, the domestic coal machine manufacturing industry begins to learn the foreign high-end equipment, and the same is true for a pump station according to the imported design and manufacture standards and equipment. Under the large background of high-end manufacturing and imported equipment domestic replacement initiated by domestic main coal users, the pump station industry design concept is changed, and the flow of a domestic pump station is rapidly improved to 630, 800, 1000 and 1250L/min flow levels from the traditional 400L/min; the pressure is developed from 31.5MPa of transmission to 37MPa, 40MPa and the like at present; the original three-plunger horizontal plunger pump is developed into the current five-plunger pump; in order to pursue the adaptability of flow, even a variable frequency pump station and a permanent magnet direct drive pump station appear.

With the great improvement of the flow, five plungers become inevitable, and the stress, assembly and production requirements of the crankshaft, the development current situation of domestic and foreign industries and the difference of processing equipment become the biggest problems and difficulties of coal equipment enterprises at present. Design standards and concepts can be rapidly promoted through talent introduction and learning and training, but the conversion of the manufacturing level, the process level and the management mode of industrial equipment needs a process, and the completely-split four-point support herringbone gear transmission structure or the six-point support helical gear transmission structure of the imported pump station is the main direction for learning and reference of domestic pump station enterprises at present. However, due to the limitations of the basic industry, the manufacturing level of the industry and the process level in China, the structural form of the imported pump station is found to have more problems in domestic replication. Firstly, the manufacturing cost is high, the actual effect of the pump station has a large gap compared with the actual effect of the pump station, secondly, the domestic coal mining process, the coal mining strength and the mode of the pump station are far beyond the national level developed abroad, and the imported pump station has a plurality of defects, so that the imported foreign technology and equipment can not be completely adapted to the development of the domestic coal mining requirement at present.

Based on the technical scheme, the applicant provides a new technical route for developing a novel large-flow emulsion pump station which is adaptive to the manufacturing level and the process level of the domestic basic industry and can meet the requirements of the domestic coal mining industry at the present stage and in the future.

Disclosure of Invention

In order to overcome the defects of an emulsion pump station on mechanism and function and meet the requirements of domestic coal mining process, coal mining strength and mode, the invention provides a novel large-flow emulsion pump station.

The technical scheme adopted by the invention is as follows: a novel large-flow emulsion pump station comprises a transmission box body, wherein a power shaft, a gear pair, a crankshaft, a connecting rod, a slide block and a plunger which are sequentially linked are arranged in the transmission box body; the power shaft and two ends of the crankshaft are respectively provided with a group of gear pairs in transmission connection, and the two groups of gear pairs are bevel gear sets with equal spiral angles and opposite directions and form a herringbone gear transmission structure together; the crankshaft is provided with a middle supporting device and an end supporting device which are respectively used for supporting a crankshaft neck and a front/rear end shaft of the crankshaft; the transmission case body adopts a non-integral split structure, and the middle supporting device adopts a split structure; the lubricating system is provided with a plurality of accurate lubricating tail ends and is used for supplying oil to all transmission parts in the transmission box body for lubrication.

Preferably, the transmission case body comprises a middle cavity and gear cavities on two sides, the power shaft and the crankshaft are arranged in the middle cavity in a penetrating mode, and two ends of the power shaft extend into the gear cavities and are in transmission connection through the gear pairs.

Preferably, the two gear chambers and the two gear pairs are symmetrically arranged on two sides of the middle chamber, and the positions of the power input ends of the power shafts in the transmission case body can be replaced left and right.

Preferably, the outer side cavity wall of the gear cavity is a detachable side end cover.

Preferably, the horizontal position of the power shaft in the transmission case is lower than the horizontal position of the crankshaft.

Preferably, the middle support means comprises: a journal bearing configured to bear a load at the crankshaft neck; the split bearing seat is configured to be an installation part of the journal bearing, is arranged in the transmission case body and is divided into a bearing base and a bearing cover, and the bearing base and the transmission case body are of an integrated structure.

Preferably, the end support means comprises: a shaft end bearing configured to bear a load at the front/rear end shaft; the shaft sleeve type bearing seat is provided with a flange and a shaft sleeve which are of an integrated structure, the flange is fixedly installed on the two side cavity walls of the middle cavity, and the shaft sleeve stretches into the transmission box body and is configured into an installation part of the shaft end bearing.

Preferably, the number of the middle supporting devices is even, and the middle supporting devices are symmetrically arranged along the gravity center point on the axis of the crankshaft.

Preferably, the lubrication system has an independent external circulation oil supply unit configured to forcibly input the lubricating oil to the plurality of lubrication terminals.

Preferably, the oil supply unit is provided with a control device which is configured to realize the advanced start of the oil supply unit before the pump of the emulsion pump station is started and realize the delayed stop of the emulsion pump station after the pump is stopped.

The invention has the following beneficial effects:

1. aiming at the advantages and the disadvantages of herringbone tooth transmission, the herringbone tooth transmission structure externally hung on the two groups of bevel gear sets is provided, the advantage that axial force can be eliminated by the herringbone teeth is reserved, and the defects that the herringbone teeth are high in machining precision requirement, complex in assembly process and inconvenient in subsequent overhaul and maintenance are overcome;

2. the crankshaft multi-point supporting technology of the non-integral split transmission case is provided, the problems of large design size and heavy equipment of the crankshaft and the transmission case caused by large stress of the crankshaft due to two-point support of a traditional pump station are solved, and the problems of high requirements on processing, manufacturing and assembling processes, and inconvenient field maintenance and later maintenance of a crankshaft multi-point supporting structure of a completely split transmission case are solved;

3. aiming at the high requirement of a high-end pump station on lubrication, the characteristics of domestic grease and use habits, an independent external circulation lubrication system is provided, a transmission case and an oil tank are structurally separated, the cleanliness and quality closed-loop management and control of lubricating oil are realized, meanwhile, the heat of the pump station is favorably reduced, the heat balance point of a cooling system and the pump station is improved, and the premise is provided for realizing the advanced start of the lubrication system before the pump station starts the pump and the delayed stop of the pump station after the pump station stops the pump;

4. the whole pump station adopts bilateral symmetry structure, and the direction of power shaft power input end is adjustable, can be according to left and right sides working face selection arrangement to the arrangement demand of working face about the adaptation colliery.

Drawings

FIG. 1 is a schematic diagram of an embodiment of the present invention.

FIG. 2 is a schematic sectional view of A-A in the example of the present invention.

FIG. 3 is a schematic view of the K-direction rotation in the embodiment of the present invention.

FIG. 4 is a schematic diagram of the direction G in the embodiment of the present invention.

Fig. 5 is a schematic diagram of lubrication according to an embodiment of the present invention.

FIG. 6 is a schematic cross-sectional view A-A of another embodiment of the present invention.

The oil pump comprises a transmission case body 1, a middle chamber 101, a gear chamber 102, a side end cover 103, a power shaft 2, a gear pair 3, a crankshaft 4, a connecting rod 5, a sliding block 6, a plunger 7, a middle supporting device 8a, a journal bearing 801, a bearing base 802, a bearing cover 803, an end supporting device 8b, a shaft end bearing 804, a shaft sleeve type bearing seat 805, a power shaft bearing 9, a connecting rod bearing bush 10, a connecting rod bushing 11, a first oil pipe 12, a first oil conveying channel 13, a first nozzle 14, a second oil conveying channel 15, a second nozzle 16, a third oil conveying channel 17, a third nozzle 18, a fourth oil conveying channel 19, a fourth nozzle 20, a fifth oil conveying channel 21, a fifth nozzle 22, a sixth oil conveying channel 23, a seventh oil conveying channel 24, an oil inlet 25, an oil tank 26, an oil pump 27, a second oil pipe 28, a filter 29, a cooler 30, an oil collecting tank 31 and a control device 32.

Detailed Description

The invention is further described with reference to the following figures and examples.

As shown in fig. 1 to 4, the present embodiment is a five-plunger and six-crankshaft supporting horizontal emulsion pump station, which is composed of a transmission case 1 and a plurality of transmission components in the transmission case, and the transmission components include a power shaft 2, a gear pair 3, a crankshaft 4, a connecting rod 5, a slider 6 and a plunger 7, which are linked in sequence.

As shown in fig. 1, the power shaft 2 is installed in the transmission case 1 through power shaft bearings 9 at both ends; the crankshaft 4 is mounted in the transmission case 1 through a middle supporting device 8a and an end supporting device 8b, the middle supporting device 8a supporting part or all of the crank journals of the crankshaft 4, and the end supporting device 8b supporting the front/rear end shafts of the crankshaft 4. The power shaft 2 is a gear shaft and forms a gear pair 3 together with a gear on the crankshaft 4; the big end of the connecting rod 5 is provided with a connecting rod bearing bush 10 which is arranged at the connecting rod neck of the crankshaft 4; a connecting rod bushing 11 is arranged at the small end of the connecting rod 5 and is arranged on the sliding block 6; the slide block 6 is arranged in a slide way in the transmission box body 1 and drives the plunger 7 to horizontally move along the cylinder sleeve.

As shown in fig. 1, the transmission case 1 includes a middle chamber 101 and gear chambers 102 on both sides; the power shaft 2 and the crankshaft 4 are arranged in the middle cavity 101 in a penetrating mode, and two ends of the power shaft and the crankshaft both extend into the gear cavity 102 and are in transmission connection through the gear pair 3; the gear pairs 3 in the two gear chambers 102 are two groups of bevel gear sets with the same spiral angle and opposite directions, and the two groups of bevel gear sets form a herringbone gear transmission structure. The structure adopts a herringbone gear transmission structure, so that the problem of axial force of helical gear transmission is solved; and the herringbone gear transmission is realized by the left and right groups of helical gears with the same helical angle and the opposite helical angles, and the herringbone gear transmission has the advantages of compact structure and small processing difficulty.

As shown in fig. 1, two gear chambers 102 and two sets of gear pairs 3 are symmetrically arranged on two sides of the middle chamber 101, and the power input end of the power shaft 2 can be replaced left and right in the transmission case 1. Two sets of helical gears adopt bilateral symmetry design for the direction of power shaft 2 power input end is adjustable, can adapt to the arrangement demand of different working faces about the colliery. In addition, the two gear chambers 102 and the lower portion of the middle chamber 101 communicate with each other to facilitate collection of the lubricating oil at the bottom of the transmission case 1.

As shown in fig. 1 to 4, the transmission case 1 is of a non-integral split structure, only the middle support device 8a is provided with a split bearing seat, and the outer cavity wall of the gear cavity 102 is of a detachable case cover structure, i.e., a side end cover 103. This structure is firstly simplified transmission case 1 structure, has reduced the degree of difficulty of processing, assembly and maintenance, secondly makes things convenient for the assembly and the maintenance of gear pair 3 and other driving medium.

As shown in fig. 1 and 2, the middle supporting device 8a includes a journal bearing 801 and a split bearing seat, the split bearing seat is disposed inside the transmission case 1 and is divided into a bearing base 802 and a bearing cover 803, and the bearing base 802 and the transmission case 1 are an integral structure and can be implemented by casting or welding. The end supporting device 8b comprises a shaft end bearing 804 and a shaft sleeve type bearing seat 805, the shaft sleeve type bearing seat 805 is provided with a flange and a shaft sleeve which are integrated, the flange is fixedly installed on the wall of the transmission case body 1, and the shaft sleeve extends into the transmission case body 1 and is used for installing the shaft end bearing 804. Generally, the requirements of the machining precision and the fit tolerance of the journal bearing 801 and the split bearing seat are higher than those of the shaft end bearing 804 and the shaft sleeve type bearing seat 805, and the specification of the journal bearing 801 is also larger than that of the shaft end bearing 804, so that the journal bearing 801 can be used as a main stress point of the crankshaft 4, and a better supporting effect is achieved. In addition, the middle support device 8a and the end support device 8b are arranged symmetrically along the center of gravity point on the axis of the crankshaft 4. The combination of the middle support device 8a and the end support device 8b optimizes the stress of the crankshaft 4, thereby reducing the failure rate, prolonging the service life of parts and reducing the size of the crankshaft 4 in design.

As shown in fig. 1 to 5, the lubrication system of the present embodiment includes an oil supply unit and a plurality of lubrication terminals, wherein the lubrication terminals respectively supply oil to each key transmission component for lubrication, and the oil supply unit is used for forcibly inputting lubricating oil to the plurality of lubrication terminals.

As shown in fig. 1 to 4, the lubrication tip includes:

nozzle number one 14 at the bearing seat of the crankshaft bearing 8;

a second nozzle 16 at the bearing seat of the power shaft bearing 9;

nozzle number three 18 at gear pair 3;

nozzle No. four 20 at slide 6;

nozzle number five 22 at plunger 7;

an oil hole or an oil groove at the connecting rod bearing shell 10;

the connecting rod bush 11 is provided with an oil hole or an oil groove.

As shown in fig. 1 to 5, the oil supply unit can be divided into two parts independent of the transmission case 1 and arranged on the transmission case 1, wherein the part independent of the transmission case 1 comprises:

a first oil pipe 12 as an oil supply pipe for lubricating oil;

an oil tank 26 that stores lubricating oil as an input end of the first oil pipe 12;

an oil pump 27 connected in series to the first oil pipe 12 as a power source for forced lubrication;

a second oil pipe 28, one end of which is communicated with the transmission case 1 and the other end of which is communicated with the oil tank 26 and is used as a return oil pipe of lubricating oil;

the filter 29 is connected in series with the first oil pipe 12 and is arranged in front of the oil pump 27 to play a role in filtering;

the cooler 30 is connected in series with the first oil pipe 12 and plays a cooling role after being placed in the oil pump 27;

the control device 32 controls the opening and closing of the oil pump 27 to realize the advance and delay lubrication cooling before the pump starting and after the pump stopping of the emulsion pump station, and the advance starting and the delay closing can be realized through a delay circuit, a programmable logic controller or manual control.

As shown in fig. 1 to 5, the oil supply unit includes a portion disposed on the transmission case 1:

the first oil delivery channel 13 is communicated with the first oil pipe 12 and supplies oil to the first nozzle 14 to lubricate and cool the crankshaft bearing 8;

a second oil delivery channel 15 which is communicated with the first oil pipe 12 and supplies oil to a second nozzle 16 for lubricating and cooling the power shaft bearing 9;

the third oil delivery channel 17 is communicated with the first oil pipe 12 and supplies oil to the third nozzle 18 to lubricate and cool the gear pair 3;

the fourth oil delivery channel 19 is communicated with the first oil pipe 12, supplies oil to the fourth nozzle 20 and lubricates and cools the sliding block 6;

the fourth oil delivery channel 21 is communicated with the first oil pipe 12, supplies oil to the fifth nozzle 22 and lubricates and cools the plunger 7;

the sixth oil delivery channel 23 is positioned in the crankshaft 4 and is divided into an axial channel and a radial channel, the axial channel extends from one end of the crankshaft 4 to the other end along the axial direction, one end of the axial channel is blocked, the other end of the axial channel is communicated with the first oil pipe 12 through an oil inlet nozzle 25, and the radial channel extends from the axial channel to the outer surface of a connecting rod neck of the crankshaft 4 to supply oil for the connecting rod bearing bush 10 for lubrication and cooling;

a seventh oil delivery channel 24, which is positioned in the connecting rod body of the connecting rod 5, extends from the connecting rod bearing bush 10 to the connecting rod bushing 11, and supplies oil to the connecting rod bushing 11 for lubrication and cooling;

and the oil collecting pool 31 is arranged at the lowest part of the bottom of the transmission case body 1, is communicated with one end of the second oil pipe 28 and is used for collecting lubricating oil at each lubricating tail end.

The lubricating system of this embodiment is independent, external, extrinsic cycle and to the accurate lubricated lubricating system of drive disk assembly, has accurate lubricated, controllable, lubricated abundant advantage of oil temperature.

The second embodiment shown in fig. 6 is another five-plunger six-point crankshaft supported horizontal emulsion pump station, which is different from the first embodiment in that the horizontal position of the power shaft 2 is lower than that of the crankshaft 4. Certain height and space need be reserved to the below cavity in the transmission case 1, firstly as lubricating system's the oil collecting space, secondly as maintenance and installation space, consequently sets up power shaft 2 in the position that is less than bent axle 4, can make full use of the below cavity in the body 1 to reduce transmission case 1's whole height, make it more be suitable for narrow space in the pit of colliery and use.

It should be understood that the above-described embodiments of the present invention are merely examples for illustrating the present invention, and are not intended to limit the embodiments of the present invention. Obvious variations or modifications of the present invention are possible within the spirit of the present invention.

Claims

1. A novel large-flow emulsion pump station comprises a transmission box body (1), wherein a power shaft (2), a gear pair (3), a crankshaft (4), a connecting rod (5), a slide block (6) and a plunger (7) which are sequentially linked are arranged in the transmission box body (1),

the method is characterized in that:

the power shaft (2) and the two ends of the crankshaft (4) are respectively provided with a group of gear pairs (3) for transmission connection, and the two groups of gear pairs (3) are bevel gear sets with equal spiral angles and opposite directions and form a herringbone gear transmission structure together;

the crankshaft (4) has a middle support device (8 a) and an end support device (8 b) for supporting a crank journal and a front/rear end shaft of the crankshaft (4), respectively;

the transmission case body (1) adopts a non-integral split structure, and the middle supporting device (8 a) adopts a split structure;

the lubricating system is provided with a plurality of accurate lubricating tail ends and is used for supplying oil to all transmission parts in the transmission box body (1) for lubrication.

2. The novel high flow emulsion pump station of claim 1,

the transmission case body comprises a middle cavity (101) and gear cavities (102) on two sides, the power shaft (2) and the crankshaft (4) are arranged in the middle cavity (101) in a penetrating mode, and two ends of the power shaft extend into the gear cavities (102) and are in transmission connection through the gear pair (3).

3. The novel high-flow emulsion pump station according to claim 2, characterized in that the two gear chambers (102) and the two gear pairs (3) are symmetrically arranged on both sides of the middle chamber (101), and the position of the power input end of the power shaft (2) in the transmission case (1) can be changed from side to side.

4. The novel high flow emulsion pump station according to claim 2, characterized in that the outside cavity wall of the gear chamber (102) is a detachable side end cap (103).

5. The new high flow emulsion pump station according to claim 2, characterized in that the horizontal position of the power shaft (2) in the transmission housing (1) is lower than the horizontal position of the crankshaft (4).

6. The new high flow emulsion pump station according to claim 1, characterized in that the middle support means (8 a) comprises:

a journal bearing (801) configured to bear a load at the crankshaft journal;

the split bearing seat is configured to be an installation part of the journal bearing (801), is arranged inside the transmission case body (1) and is divided into a bearing base (802) and a bearing cover (803), and the bearing base (802) and the transmission case body (1) are of an integrated structure.

7. The new high flow emulsion pump station according to claim 2, characterized in that the end support means (8 b) comprises:

a shaft end bearing (804) configured to bear a load at the front/rear end shaft;

the bearing comprises a shaft sleeve type bearing seat (805), wherein the shaft sleeve type bearing seat is provided with a flange and a shaft sleeve which are integrated, the flange is fixedly installed on the two side cavity walls of the middle cavity (101), and the shaft sleeve extends into the transmission box body (1) and is configured into an installation part of the shaft end bearing (804).

8. The new high flow emulsion pump station according to claim 1, characterized in that the number of said middle support means (8 a) is even and symmetrically arranged along the center of gravity point on the axis of said crankshaft (4).

9. The new high flow emulsion pump station according to claim 1, characterized in that the lubrication system has an independent external circulation oil supply unit with an oil tank (26) independent of the transmission housing (1) configured for forced input of lubrication oil to a plurality of the lubrication ends.

10. The new high flow emulsion pump station according to claim 9, characterized in that the oil supply unit has an individual power and control device (32) to achieve individual control, configured to achieve an advanced start of the oil supply unit before the emulsion pump station starts the pump, and a delayed stop after the emulsion pump station stops the pump.