CN201560210U - 花瓣万向节仿形感应器 - Google Patents
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Abstract
一种花瓣万向节仿形感应器，用于花瓣万向节的热处理；其特征是：包括由导体制成的感应器主体、感应器后座及电源；所述感应器主体呈环状且展开为曲线形，环状的感应器主体的曲线与花瓣万向节上的啮合曲线相适应；感应器主体连接在感应器后座上，并通过感应器后座与电源的输出端相连。它不仅可以使万向节工作面获得一定深度的淬火组织，而且可以保留万向节心部的调质组织，这样既保证了工作面的高耐磨性，又使其心部具有较高的综合机械强度和韧性，从而提高螺杆钻具整机的使用寿命。
Description
技术领域
本实用新型涉及一种花瓣万向节的热处理装置，具体是一种花瓣万向节仿形感应器。
背景技术
人类社会对石油的需求日益增多，导致钻井技术迅猛发展。螺杆钻具作为一种比较成熟的钻井工具，也广泛应用于各种钻井作业中。
螺杆钻具的失效方式很多，而万向节的失效方式约占50％左右。当前常用的万向节结构有花瓣式和球铰式两种，因花瓣万向节的强度高、加工简单而用量最大，故花瓣式万向节的零件寿命严重影响着螺杆钻具的整机寿命。
现今，花瓣式万向节的较为常用制作方式为以下两种：
1、整体厚壁钢管调质或淬火+中温回火后，切割而成。
2、以线切割加工成特定形状的花瓣，在花瓣表面加以渗碳或渗氮处理以提高配合面的硬度和耐磨性。
万向节的主要作用是将转子的行星运动转化为传动轴的同心运动，同时将马达的动力传递给传动轴及钻头。它的工作面主要承受周期性变化的扭动弯曲力、周间不均匀冲击力及摩擦力的作用，三花瓣之间磨损有较高的接触应力，所以要求万向节具有高度屈服强度，高度弯曲疲劳强度、接触疲劳强度和高的耐磨性。第一种制作方法，工件经调质处理后在承受力和弯曲方面比较容易达到要求，但调质组织很难具有高的耐磨性，花瓣凸部与凹部的大部分区域相互摩擦过量，使凸部径向尺寸变小，造成咬合间隙过大而失效，甚至造成万向节脱落；若工件采用整体淬火+中温回火的热处理方式，耐磨性方面可以解决，但花瓣在承受切向应力时，很容易在花瓣根部发生断裂，造成万向节的脱落。第二种制作方法，万向节经渗碳或渗氮处理以后虽然提高了配合面表面的硬度和耐磨性，但深度只有2mm左右，很难满足螺杆钻具连续工作200h的要求。
实用新型内容
为了克服上述现有技术存在的缺点，本实用新型的目的在于提供一种花瓣万向节仿形感应器，它不仅可以使万向节工作面获得一定深度的淬火组织，而且可以保留万向节心部的调质组织，这样既保证了工作面的高耐磨性，又使其心部具有较高的综合机械强度和韧性，从而提高螺杆钻具整机的使用寿命。
为解决上述问题，本实用新型采用以下技术方案：该花瓣万向节仿形感应器，包括由导体制成的感应器主体、感应器后座及电源；所述感应器主体呈环状且圆周展开为曲线形，环状的感应器主体的曲线与花瓣万向节上的啮合曲线相适应；感应器主体连接在感应器后座上，并通过感应器后座与电源的输出端相连。
当交变电流在导体中通过时，在所形成的交变磁场作用下，导体内会产生感应电动势。由于越接近心部感应电动势越大，导体中的电流便趋向于表面，电流强度从表面向心部呈指数衰减，即所谓交变电流的集肤效应。
由于电源电动势和自感应电动势的相互作用，同向电流系数中最大磁场强度在导体表面的外侧，反向电流在导体表面的内侧，这就是邻近效应。
利用邻近效应可以选择适当形状的感应器对被处理零件表面的一定部位进行集中加热，使电流集中在与感应器宽度大致相同的区段内。导体间的距离愈小，邻近效应表现的愈强烈。
本实用新型根据上述原理，使感应电流集中在工件工作面(即花瓣万向节啮合部位)的周围，使其快速升温，最终获得一定深度的淬硬层，而心部基本保持处理前的组织和性能，因而达到高强度，高耐磨性和高韧性的效果。
本实用新型的实际工作状况：工件放入感应器主体中，感应器主体通过感应器后座与中频电源相连。中频电源工作时，产生一定的交变电流，并输出给感应器主体，交变电流在感应器主体中产生交变磁场，在交变磁场的作用下，工件产生感应电动势，既而产生感应电流(即涡流)，从而使工件温度升高。
作为本实用新型的进一步的技术方案：
在该花瓣万向节仿形感应器中，所述感应器主体由方管制成。方管可保证感应器主体与花瓣万向节之间的感应面积的大小满足要求。
在该花瓣万向节仿形感应器中，所述电源为中频电源。
更进一步的：所述感应器主体由外边长14mm的方铜管制成。
本实用新型的有益效果是：它可以使工件工作面周围单方向15mm在3分钟内达到860-880℃，利用水基淬火液淬火，可以使工作面的硬度达到HRC52以上，纵深可达10mm，而工件心部仍然保持淬火之前的调质组织，硬度在HB300-330之间。这样既保证了万向节啮合部位的高耐磨性，又保证了万向节心部的综合机械性能和韧性。
附图说明
下面结合附图和实施例对本实用新型做进一步的说明：
图1为本实用新型实施例的结构示意图，
图2为本实用新型实施例中感应器主体的展开示意图，
图3为本实用新型实施例中感应器后座的结构示意图，
图4为图3的左视图，
图中：1感应器主体，2感应器后座，21铜管，3中频电源。
具体实施方式
如图1所示，该花瓣万向节仿形感应器包括感应器主体1、感应器后座2及中频电源3。所述感应器主体1呈环状且圆周展开为曲线形，如图2所示，环状的感应器主体1的曲线与花瓣万向节上的啮合曲线相适应。感应器主体1连接在感应器后座2上，并通过感应器后座2与中频电源3的输出端相连。所述感应器主体1由外边长14mm的方铜管制成。方管可保证感应器主体与花瓣万向节之间的感应面积的大小满足要求。
根据花瓣万向节的花瓣曲线，制作出与其线型相近的感应器主体1，从而达到仅使万向节工作面在短时间内达到淬火温度的效果。
该花瓣万向节仿形感应器的设计和制作步骤：
①利用花瓣万向节的现有切割曲线，经过研究和现场试验设计感应器主体1曲线。
②根据感应器主体1曲线，设计制作感应器主体模具曲线。
③借助数控火线切割机和必要的机床制作感应器主体模具。
④将感应器主体1的原材料——14mm方铜管内填满细沙，辅以气焊局部加温软化铜管，快速将铜管沿模具方向弯曲，制作出感应器主体1。
⑤根据中频电源3输出，制作感应器后座2，如图3、图4所示，并用14mm铜管21与感应器主体1相连，铜焊焊牢。
Claims (4)
1.花瓣万向节仿形感应器，其特征是：包括由导体制成的感应器主体、感应器后座及电源；所述感应器主体呈环状且圆周展开为曲线形，环状的感应器主体的曲线与花瓣万向节上的啮合曲线相适应；感应器主体连接在感应器后座上，并通过感应器后座与电源的输出端相连。
2.根据权利要求1所述的花瓣万向节仿形感应器，其特征是：所述感应器主体由方管制成。
3.根据权利要求1或2所述的花瓣万向节仿形感应器，其特征是：所述电源为中频电源。
4.根据权利要求3所述的花瓣万向节仿形感应器，其特征是：所述感应器主体由外边长14mm的方铜管制成。
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