CN208169068U - 一种用于压裂柱塞泵的复合传动装置 - Google Patents
一种用于压裂柱塞泵的复合传动装置 Download PDFInfo
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Abstract
本实用新型涉及一种用于压裂柱塞泵的复合传动装置,包括箱体、液力变矩器、行星减速机构、摩擦片制动器总成、综合控制阀、减速机构Ⅱ、电动执行器;其中,液力变矩器包括输入轴Ⅰ、三联供油泵、同步环、导轮、涡轮、涡轮轴、泵轮;行星减速机构的太阳轮同轴受驱动于涡轮轴,齿圈与摩擦片制动器总成中的摩擦片在液压控制下接触和分离;行星减速机构的行星架连接并驱动减速机构Ⅱ的输入轴Ⅱ;综合控制阀包括阀体、溢流阀阀芯、电磁开关阀;电动执行器经由丝杠连杆机构和同步环驱动拨叉;拨叉带动可调导轮叶片绕自身轴线回转。该装置通过全新的结构设计,解决了现有技术中缺乏压裂柱塞泵专用传动装置的问题,具有积极的技术意义。
Description
技术领域
本实用新型涉及一种用于压裂柱塞泵的复合传动装置,属于石油钻采及加工设备领域。
背景技术
在目前的石油钻采设备领域,柱塞泵是重要的部件;其中以F1300、F1600钻井泵、SQP2000、SQP2800五缸压裂柱塞泵为代表的往复式柱塞泵是装备量较大的柱塞泵种类之一。
在实际使用中,因为钻采和压井过程的实际工况需要,需要对柱塞泵进行宽范围调速。
以F1300钻井泵为例,目前普遍的配置为:柴油机+胎式离合器(气囊离合器)+机械减速机经皮带驱动钻井泵或柴油机+液力偶合器反车减速箱经万向轴驱动钻井泵。在采用“司钻法压井”作业时,为便于压井过程中节流阀和立压的控制,通常钻井泵的泵速取正常钻进泵速的1/2~1/4。为实现低泵冲,目前普遍采取的措施主要包括:柴油机低转速运转(由额定转速1300rpm调整至800~1000rpm),拆除三缸柱塞泵其中两个缸的介杆。这一操作方式带来的弊端:柴油机不适于长时间低速、大负荷运行,长时间在这一工况下会对柴油机造成不良影响;频繁拆装钻井泵缸套介杆会给泥浆工带来大量的重体力劳动。虽然液力偶合器反车减速箱具备一定的调速型能,但基于调速型液力偶合器的性能特点(与恒扭矩类设备匹配,调速范围推荐70%~100%),亦不能满足宽范围调速的要求。
以SQP2800五缸压裂柱塞泵为例,目前普遍的配置为:柴油机+多档(液力)机械变速箱经万向轴驱动柱塞泵。多档(液力)机械变速箱典型的代表有:TWIN DISC TA90-8501/8FLW-2302变速箱(9档)、艾利逊9832 OFS变速箱(9档)、CAT TH55-E70变速箱(7档)。由于目前没有专门的、针对压裂泵配套需求的专用变速箱,因而采用了大功率矿车用变速箱应用于压裂泵驱动。经匹配计算,以上三款变速箱4档及以上档位是不应使用的,因为在4档及以上档位柱塞泵的转速远超过了其许用转速,因而存在不适用的"富余"设计。另一方面,酸化压裂是一个非常复杂和多变的工况。在复杂地质条件下,压裂作业中泵压多交变,多冲击载荷;为确保压裂作业安全、为确保压裂泵不"超压",目前一般多采取柴油机降速、变速箱降档的程序联动模式。这种模式适应性比较差,不能满足"持续高压力"的作业需求。
因此,设计一种能更适合往复式柱塞泵调速驱动的专用传动装置,是本领域技术人员亟待解决的问题。
发明内容
现有技术中,往复式柱塞泵缺乏专用传动装置,采用的非专用调速装置存在与柴油机特性不匹配、对往复式柱塞泵在钻采和压井过程中的工况难以适应的问题;为解决这一问题,本实用新型全新提供一种用于压裂柱塞泵的复合传动装置,用于钻采压井过程中的往复式柱塞泵无级调速驱动。
本实用新型采用下述技术方案:
一种用于压裂柱塞泵的复合传动装置,其特征在于,包括:箱体、液力变矩器、行星减速机构、摩擦片制动器总成、综合控制阀、减速机构Ⅱ、电动执行器;
其中,所述液力变矩器包括输入轴Ⅰ、三联供油泵、同步环、导轮、涡轮、涡轮轴、泵轮;所述输入轴Ⅰ为整个传动装置的输入轴;所述三联供油泵设于液力变矩器输入端端面,两个泵连通液力变矩器工作腔,另一个泵通过综合控制阀连通摩擦片制动器总成供油口;所述导轮为叶片可调式,包括固定导轮叶片、可调导轮叶片;所述同步环安装于三联供油泵外缘且能够绕三联供油泵回转;
所述行星减速机构的太阳轮同轴连接并受驱动于所述涡轮轴,齿圈与摩擦片制动器总成中的摩擦片在液压控制下接触和分离;
所述所述行星减速机构的行星架连接并驱动减速机构Ⅱ的输入轴Ⅱ;减速机构Ⅱ的输出轴为整个传动装置的输出轴;
所述综合控制阀安装于摩擦片制动器总成供油口处,包括阀体、溢流阀阀芯、电磁开关阀,溢流阀阀芯与电磁开关阀并联设置于综合控制阀进油口处;所述溢流阀阀芯的出口经箱体内置管路连通润滑系统;
所述电动执行器为多回转智能型电动执行器,经由丝杠连杆机构驱动所述同步环;所述同步环连接多组拨叉;每组拨叉带动1个可调导轮叶片绕自身轴线回转;全部可调导轮叶片的回转为同步动作。
优选的,所述摩擦片制动器总成为多片式湿式摩擦片制动器总成。
或优选的,所述减速机构Ⅱ为齿轮式定轴单级减速机构。
或优选的,所述三联供油泵为星形布置,包括壳体、主动齿轮、3个从动齿轮;其中,壳体设有进油通道、3个供油腔,主动齿轮同轴并受驱动于所述输入轴Ⅰ,从动齿轮分别设于供油腔内。
本实用新型具有以下的优点:
(1)本实用新型将液力变矩器、行星减速机构、减速机构Ⅱ设于同一箱体,采用了一体化设计,使装置结构紧凑,占用空间小;
(2)使用多回转智能型电动执行器对可调导轮叶片进行调节与控制,易于实现恒泵冲(恒流量)、恒压力或计算机程序控制调节;
(3)基于液力变矩器自适应特性的特点,更适应于多交变、多冲击载荷的工况作业需求;
(4)基于液力传动柔性传动的特点,可以达到提升整个传动系统的传动品质并为发动机、传动系统、工作机提供良好的保护,提升系统工作寿命;
(5)基于导轮叶片可调式液力变矩器液力传动的特性、优点,可以实现宽范围(20%~100%)、高效率的、与恒扭矩类设备良好匹配的无级调速。
附图说明
图1 是本实用新型实施例结构示意图;
图2 是图1的左视结构示意图;
图3 是本实用新型实施例中综合控制阀21安装结构示意图;
图4 是本实用新型实施例中中三联供油泵19结构示意图;
图5 是图4的左视剖视示意图;
图6 是本实用新型实施例中综合控制阀21结构示意图;
图7 是图6的右视剖视示意图1;
图8 是图6的右视剖视示意图2;
其中:1.液力变矩器,2.行星减速机构,3.减速机构Ⅱ,4.电动执行器,5.箱体,6.输入轴Ⅰ,7.泵轮,8.涡轮,9.固定导轮叶片,10.可调导轮叶片,11.涡轮轴,12.太阳轮,13.摩擦片制动器总成,14.行星架,15.齿圈,16.丝杠连杆机构,17.同步环,18.拨叉,19.三联供油泵,20.滤油器,21.综合控制阀,22.壳体,23.主动齿轮,24.从动齿轮,25.阀体,26.溢流阀阀芯,27.换档阀阀芯,28.电磁阀。
具体实施方式
下面结合附图和实施例对本实用新型进一步说明。
如图1、图2所示,本实施例为一种用于压裂柱塞泵的复合传动装置,包括:箱体5、液力变矩器1、行星减速机构2、摩擦片制动器总成13、综合控制阀21、减速机构Ⅱ3、电动执行器4;
其中,本实施例中所述液力变矩器1为导轮叶片可调式液力变矩器1,包括输入轴Ⅰ6、三联供油泵19、同步环17、导轮、涡轮8、涡轮轴11、泵轮7;所述输入轴Ⅰ6为整个传动装置的输入轴;所述三联供油泵19设于液力变矩器1输入端端面,带有滤油器20。
导轮叶片可调式液力变矩器1为机械手册上有明确记载的标准结构。
所述导轮为叶片可调式,包括固定导轮叶片9、可调导轮叶片10;所述同步环17安装于三联供油泵19外缘且能够绕三联供油泵19回转;
所述行星减速机构2的太阳轮12同轴连接并受驱动于所述涡轮轴11;
所述摩擦片制动器总成13为多片式湿式摩擦片制动器总成,包括缸套、活塞及多片内、外齿摩擦片;其中缸套通过连接键与固定的箱体连接,外齿摩擦片通过外齿与固定的缸套相连接,内齿摩擦片通过内齿与齿圈15在液压控制下接触和分离;所述多片内、外齿摩擦片沿轴线间隔安装;当摩擦片制动器总成13在综合控制阀21中的电磁开关阀控制下充油时,活塞沿轴向压紧摩擦片,齿圈15经摩擦片、缸套、箱体制动,此时行星减速机构2处于“在档”状态;当摩擦片制动器总成13在电磁开关阀控制下排空油时,摩擦片与齿圈15脱离接触,齿圈15自由旋转,此时行星减速机构2处于“空档”状态;多片式湿式摩擦片制动器为已公开的现有成熟技术。
所述减速机构Ⅱ3为齿轮式定轴单级减速机构,包括输入轴Ⅱ、与输入轴Ⅱ同轴的主动齿轮、从动齿轮、与从动齿轮同轴的输出轴;所述行星减速机构2的行星架14连接并驱动减速机构Ⅱ3的输入轴Ⅱ;减速机构Ⅱ3的输出轴为整个传动装置的输出轴;
所述电动执行器4为多回转智能型电动执行器4,经由丝杠连杆机构16驱动所述同步环17;所述同步环17连接多组拨叉18;每组拨叉18带动1个可调导轮叶片10绕自身轴线回转;全部可调导轮叶片10的回转为同步动作。
如图4、图5所示,所述三联供油泵19的设置主要是为了满足整机液力传动、低压润滑、高压控制等系统供油要求,为星形布置,包括壳体22、主动齿轮23、3个从动齿轮24;其中,壳体22设有进油通道、3个供油腔,主动齿轮23通过花键与输入轴Ⅰ6同轴连接并受输入轴Ⅰ6驱动,从动齿轮24分别设于供油腔内。3个从动齿轮24分别与主动齿轮23相结合,配合供油腔,形成三个相对独立而又共壳体22装配的供油泵,两个泵为液力变矩器1工作腔供油,另一个泵通过综合控制阀21为摩擦片制动器总成13及润滑系统供油。
本实施例的具体工作过程如下:
动力流:
动力经输入轴Ⅰ6驱动泵轮7,泵轮7推动工作油循环,机械能转化为工作油动能;当具有液体动能的工作油流经涡轮8时,液流冲击涡轮8叶片,使之与泵轮7同向旋转,工作油动能又转化为机械能;释放动能后的工作油由涡轮8、固定导轮叶片9、可调导轮叶片10再次流入泵轮7,开始下一次循环;由此工作油建立了泵轮7、涡轮8、固定导轮叶片9、可调导轮叶片10间周而复始的循环,由此输入、输出间在没有任何机械连接的情况下实现了能量的柔性传递。
动力经涡轮8、涡轮轴11驱动行星减速机构2的太阳轮12;当多片式湿式摩擦片制动器总成13闭锁时,齿圈15制动,动力经由行星架14输出,最终动力经由减速机构Ⅱ3传递至被驱动设备;当多片式湿式摩擦片制动器总成13解锁时,齿圈15自由旋转,动力无输出,传动装置处于空档状态。
控制流:
电动执行器4经由丝杠连杆机构16驱动同步环17;同步环17经由拨叉18驱动可调导轮叶片10回转。对应可调导轮叶片10转动的角度不同,变矩器有不同的特性。通过可调导轮叶的转动,改变了叶型的安装角及其流道面积,从而改变变矩器的能容,达到调节涡轮8转速的目的,最终实现无级变速的控制。
工作油油流
工作油经由滤油器20流入三联供油泵19;其中两个泵向变矩器工作腔供油,工作油经由变矩器工作腔、外置机油冷却器后流回油箱;另外一个单泵向高压控制系统供油,工作油由泵出口经由箱体5内置油路流经综合控制阀21;
在综合控制阀21中,由于溢流阀的“定压”作用,工作油流经溢流阀阀芯26时被分为"高压"、"低压"两个油路;其中低压油经箱体5内置管路被送至润滑系统;高压油经由换档阀阀芯27被送至多片式湿式摩擦片制动器总成13,多片式湿式摩擦片制动器总的闭锁、解锁由电磁阀28负责控制;电磁开关阀接受中央控制器的开关信号,得电,为摩擦片制动器总成13供油,使摩擦片与齿圈15因摩擦力而连接,传动装置处于动力输出状态;电磁开关阀在中央控制器的信号控制下断电,摩擦片制动器总成13的摩擦片与齿圈15脱离接触,传动装置处于"空档"状态;部分工作油(低压油)经由溢流阀向传动装置润滑系统供油并最终流回油箱。
对所公开的实施例的上述说明,使本领域专业技术人员能够实现或使用本实用新型。对实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本实用新型的精神或范围的情况下,在其它实施例中实现,未予以详细说明和局部放大呈现的部分,为现有技术,在此不进行赘述。因此,本实用新型将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和特点相一致的最宽的范围。
Claims (4)
1.一种用于压裂柱塞泵的复合传动装置,其特征在于,包括:箱体(5)、液力变矩器(1)、行星减速机构(2)、摩擦片制动器总成(13)、综合控制阀(21)、减速机构Ⅱ(3)、电动执行器(4);
其中,所述液力变矩器(1)包括输入轴Ⅰ(6)、三联供油泵(19)、同步环(17)、导轮、涡轮(8)、涡轮轴(11)、泵轮(7);所述输入轴Ⅰ(6)为整个传动装置的输入轴;所述三联供油泵(19)设于液力变矩器(1)输入端端面,两个泵连通液力变矩器(1)工作腔,另一个泵通过综合控制阀(21)连通摩擦片制动器总成(13)供油口;所述导轮为叶片可调式,包括固定导轮叶片(9)、可调导轮叶片(10);所述同步环(17)安装于三联供油泵(19)外缘且能够绕三联供油泵(19)回转;
所述行星减速机构(2)的太阳轮(12)同轴连接并受驱动于所述涡轮轴(11),齿圈(15)与摩擦片制动器总成(13)中的摩擦片在液压控制下接触和分离;
所述行星减速机构(2)的行星架(14)连接并驱动减速机构Ⅱ(3)的输入轴Ⅱ;减速机构Ⅱ(3)的输出轴为整个传动装置的输出轴;
所述综合控制阀(21)安装于摩擦片制动器总成(13)供油口处,包括阀体(25)、溢流阀阀芯、电磁开关阀,溢流阀阀芯与电磁开关阀并联设置于综合控制阀(21)进油口处;所述溢流阀阀芯的出口经箱体(5)内置管路连通润滑系统;
所述电动执行器(4)为多回转智能型电动执行器(4),经由丝杠连杆机构(16)驱动所述同步环(17);所述同步环(17)连接多组拨叉(18);每组拨叉(18)带动1个可调导轮叶片(10)绕自身轴线回转;全部可调导轮叶片(10)的回转为同步动作。
2.根据权利要求1所述的用于压裂柱塞泵的复合传动装置,其特征在于,所述摩擦片制动器总成(13)为多片式湿式摩擦片制动器总成(13)。
3.根据权利要求1所述的用于压裂柱塞泵的复合传动装置,其特征在于,所述减速机构Ⅱ(3)为齿轮式定轴单级减速机构。
4.根据权利要求1所述的用于压裂柱塞泵的复合传动装置,其特征在于,所述三联供油泵(19)为星形布置,包括壳体(22)、主动齿轮(23)、3个从动齿轮(24);其中,壳体(22)设有进油通道、3个供油腔,主动齿轮(23)同轴并受驱动于所述输入轴Ⅰ(6),从动齿轮(24)分别设于供油腔内。
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