WO2021258649A1 - 一种旋挖钻机综合性能测试与调试试验装置及试验方法 - Google Patents

一种旋挖钻机综合性能测试与调试试验装置及试验方法 Download PDF

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WO2021258649A1
WO2021258649A1 PCT/CN2020/133620 CN2020133620W WO2021258649A1 WO 2021258649 A1 WO2021258649 A1 WO 2021258649A1 CN 2020133620 W CN2020133620 W CN 2020133620W WO 2021258649 A1 WO2021258649 A1 WO 2021258649A1
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WIPO (PCT)
Prior art keywords
rotary drilling
torque
drilling rig
dynamometer
hydraulic
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PCT/CN2020/133620
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English (en)
French (fr)
Inventor
李俊
吕岩
刘强
平德纯
韩立华
常通
周洁
张刚
陈慧
穆亚清
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徐州徐工基础工程机械有限公司
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Priority to US18/012,654 priority Critical patent/US20230251166A1/en
Publication of WO2021258649A1 publication Critical patent/WO2021258649A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G01M13/025—Test-benches with rotational drive means and loading means; Load or drive simulation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M99/00—Subject matter not provided for in other groups of this subclass
    • G01M99/005—Testing of complete machines, e.g. washing-machines or mobile phones
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M99/00—Subject matter not provided for in other groups of this subclass
    • G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B3/00—Rotary drilling
    • E21B3/02—Surface drives for rotary drilling
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D21/00—Measuring or testing not otherwise provided for
    • G01D21/02—Measuring two or more variables by means not covered by a single other subclass
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M99/00—Subject matter not provided for in other groups of this subclass
    • G01M99/007—Subject matter not provided for in other groups of this subclass by applying a load, e.g. for resistance or wear testing

Definitions

  • the invention relates to the field of rotary drilling rigs, in particular to a comprehensive performance testing and debugging test device for rotary drilling rigs based on an electric power measurement and feeder network system.
  • Rotary drilling rig is a construction machine suitable for drilling operations in building foundation engineering. It is widely used in drilling construction of various strata structures such as silt, clay, silt, gravel, silt pebbles, rocks, etc. It is extremely suitable for working conditions. complex.
  • Drilling and debugging need to occupy ground space, and the torque value can only reach 20% of the design value, the debugging effect is not ideal, and it is impossible to measure whether the technical parameters can meet the design requirements.
  • the existing comprehensive hydraulic dynamometer test bench provides a new debugging method for the debugging test, which can detect the torque, speed, power of the power head and the lifting force and pressure of the drill pipe on-line.
  • the torque load is provided by the water eddy current dynamometer, the load is relatively stable, and the loading speed is slow. It cannot simulate the sudden change in the load caused by the change of the ground in the actual working condition. There is a certain gap between the provided debugging environment and the actual working condition.
  • the pressure of the main pump and the auxiliary pump need to be monitored during the debugging process.
  • New product parameter verification and calibration require engine performance test and hydraulic power matching test, real-time monitoring and recording of power head torque, power head speed, main pump pressure, auxiliary pump pressure, engine speed, engine output power, engine output torque, engine Main engine parameters such as fuel consumption, as well as fitting characteristic curves of related parameters.
  • a test equipment that is very sensitive to load changes, has more precise control, can simulate actual working conditions, and has stronger comprehensive data analysis capabilities.
  • the present invention provides a comprehensive performance test and debugging test device for a rotary drilling rig.
  • a comprehensive performance test and debugging test device for a rotary drilling rig including:
  • Torque transmission gearbox which is fixed on the gearbox anchor plate through the gearbox adapter plate;
  • a speed-increasing corner gearbox which is installed on the torque transmission gearbox, and is connected to the dynamometer through a drive shaft, a torque sensor, and a motor coupling in turn;
  • the driving sleeve is installed in the connecting shaft of the torque transmission gearbox, and the lower end is connected to the hydraulic load cylinder through the slewing support I, the slewing support, and the tension pressure sensor, and the hydraulic load cylinder is connected to the hydraulic station through the hydraulic pipeline;
  • the pull pressure sensor and the load cylinder pressure control valve in the hydraulic station are connected to the computer software control system; the torque sensor is connected to the computer software control system; the dynamometer is connected in parallel with the power grid of the power distribution room and the water-cooled resistance box.
  • the number of the dynamometer motors is two, and the two dynamometer motors are respectively connected to drive through a motor coupling, a torque sensor, a transmission shaft, and a speed-increasing corner gear box; the two dynamometer motors are both installed on the motor base ,
  • the motor base is installed on the anchor plate of the motor base pre-buried in the foundation, and the anchor bolts are used to connect and fasten.
  • hydraulic load cylinder and the cylinder support are connected by a pin, and the cylinder support is fixed on an anchor plate of the cylinder support pre-buried in the foundation.
  • a guide mechanism is installed on both sides of the rotary support;
  • the guide mechanism includes a guide anchor plate, a guide block, a guide block support, and an adjustment pad;
  • the guide anchor plate is embedded in the foundation wall in advance, And the guide anchor plates on both sides are parallel;
  • the adjustment pad is assembled on the guide anchor plate, and the guide key is fastened to the adjustment pad;
  • each side of the rotary support is equipped with a guide block support and a guide block, There is a key groove on the guide block, and the key groove is matched with the guide key on the adjusting pad.
  • a cooling system which includes a cooling water tank, a pipeline, and a water pump; the cooling water tank is connected to the water pump, the water-cooled resistance box, the hydraulic station, and the gear oil pump station through the pipeline.
  • the torque transmission gearbox and the speed increasing corner gearbox are respectively connected to the gear oil pump station; the oil inlet temperature sensor, the oil outlet temperature sensor, the oil outlet pressure sensor and the computer software system of the gear oil pump station Connected.
  • the square head of the rotary drilling drill pipe is connected to the driving sleeve, and the torque is transmitted to the connecting shaft through the driving sleeve.
  • the connecting shaft is connected with a slewing bearing II. Speed corner gearbox.
  • the data acquisition system is connected to the ECU of the main machine of the rotary drilling rig to detect real-time host parameters of different types of rotary drilling rigs under working conditions.
  • the dynamometer motor is connected to the water-cooled resistance box and the power grid through a frequency converter, and the computer system and the frequency converter control the flow of electric energy generated by the dynamometer motor, so that the preset percentage of electricity is reversed to the grid and the remaining percentage of electricity passes through the water-cooled resistance box.
  • the water in the water supply tank is heated and consumed, and the hot water is used to wash the vehicle.
  • test method A comprehensive performance test and debugging test method for rotary drilling rigs, the test method is as follows:
  • the square head of the rotary drilling drill pipe is connected to the driving sleeve, and the torque is transmitted to the connecting shaft through the driving sleeve.
  • the connecting shaft is connected with a slewing bearing II.
  • the slewing bearing II meshes with the pinion, and then the power is transmitted to the speed-increasing corner through the pinion.
  • Gearbox, speed-increasing angle gearbox transmits torque to the dynamometer through the drive shaft, torque sensor, and motor coupling.
  • the computer receives the torque signal from the torque sensor and directly controls the dynamometer through the software to control the load, thereby realizing the adjustment Machine torque loading test;
  • the drill rod transmits the pressure and lifting force to the hydraulic load cylinder through the drive sleeve, slewing support I, slewing support, and tension pressure sensor.
  • the pressure load and lifting load of the hydraulic load cylinder are set and controlled by the computer to realize drilling. Rod lifting and pressure test;
  • the data acquisition system reserves one CAN communication, which is connected to the main engine ECU of the rotary drilling rig, so as to detect various main engine parameters in the working state of different types of rotary drilling rigs in real time.
  • Each parameter automatically generates the corresponding characteristic curve for the designer's data statistics and analysis, and the generator generates two purposes: 1. Boil hot water, used to clean the vehicle 2. Return to the company's grid for daily use in the plant area, saving power, each test After that, the power generation can be recorded cumulatively on the display of the inverter.
  • the test bench can carry out fully automatic simulation of actual working conditions load torque loading test according to the load spectrum.
  • automatic simulation loading test real-time monitoring of rotary drilling rig power head torque, power head speed, power, main pump pressure, auxiliary pump pressure, power head forward pressure, engine speed, engine torque and hydraulic oil temperature under different load torques
  • Various host parameters, fitting characteristic curves, and verifying whether each parameter value meets the acceptance requirements the domestic first to use an alternator as a load, the load control sensitivity is high, which can reach the millisecond level, and it can provide high-frequency alternating load and sudden load.
  • the test bench is designed with a new rotary and pressurized guiding composite mechanism to meet the requirements of the acceptance criteria when the rotary drill can be used for lifting and pressurizing under different torque loads.
  • the dynamometer that provides the load for the torque loading test is essentially a generator.
  • the fuel energy is converted into mechanical energy through the engine, hydraulic system, mechanical transmission system, etc., and then the dynamometer is driven
  • the motor generates electricity, and the generated electricity can be freely controlled by the operating system in any proportion of its flow. A certain proportion is used for heating the water storage tank and used for washing vehicles. The remaining proportion of the electricity is returned to the company's grid for the company's daily production needs.
  • test bench meets the loading and debugging requirements of simulated actual working conditions, and at the same time solves the problem that the energy consumed by the rotary drilling rig cannot be recycled and reused in the traditional drilling debugging and hydraulic dynamometer test bench debugging, creating a new power feeder network technology Application areas.
  • test bench can be loaded manually by inputting the torque value.
  • designers are used to test the corresponding relationship between power head speed, power head power, main pump pressure, and auxiliary pump pressure at a given torque.
  • the test bench control software can output the characteristic curve of each parameter for Designer data statistics and analysis.
  • the test bench can collect parameters such as engine speed, engine torque, main pump pressure, main pump displacement, power head speed and other parameters under different torque and pressure conditions, and automatically fit the output characteristic curves of the engine, pump and motor under system working conditions, and pass Comparing with the characteristic curve given by the manufacturer, it can detect whether the hydraulic system of the whole machine matches with the selection of components. At the same time, the efficiency of hydraulic transmission can be obtained, which has important guiding significance for optimizing product design and improving product performance.
  • the test bench can measure the maximum output torque of the rotary drilling drill, the maximum lifting force of the main roll, the maximum lifting force and maximum pressure of the pressurized winch, the maximum pressurizing pressure and the maximum lifting force of the pressurized cylinder, and adjust the accurate parameters for the designer. Optimize product design, improve product quality and performance, and provide more accurate data support.
  • Figure 1 is the connection diagram of the comprehensive performance test and debugging test device of the rotary drilling rig
  • Figure 2 is a top view of the comprehensive performance test and debugging test device of the rotary drilling rig
  • Figure 3 is an enlarged view of the guide mechanism.
  • a comprehensive performance test and debugging test device for a rotary drilling rig includes a dynamometer motor 2, a torque transmission gear box 10, a speed increasing corner gear box 6 and a drive sleeve 8.
  • the dynamometer motor 2 Set on the foundation;
  • the torque transmission gearbox 10 is fixed on the gearbox anchor plate 13 through the gearbox adapter plate 12, and the gearbox anchor plate 13 is embedded in the foundation;
  • the speed increasing corner gearbox 6 is installed on the torque transmission gearbox 10, the speed increasing corner gearbox 6 is connected to the dynamometer 2 through the transmission shaft 5, the torque sensor 4, and the motor coupling 3 in turn;
  • the drive sleeve 8 is installed in the connecting shaft 9 of the torque transmission gearbox 10, and the drive sleeve 8
  • the lower end is connected to the hydraulic load cylinder 18 through the slewing support I14, the slewing support 15, and the tension pressure sensor 17.
  • the slewing support 15 is fixed in the foundation, and the hydraulic load cylinder 18 is connected to the hydraulic station through the hydraulic pipeline; among them, the tension pressure sensor 17 and the load cylinder pressure control valve in the hydraulic station is connected to the computer software control system; the torque sensor 4 is connected to the computer software control system; the dynamometer 2 is connected in parallel with the power grid of the power distribution room and the water-cooled resistance box.
  • the number of dynamometer 2 is two.
  • the two dynamometer motors are respectively connected and driven by the motor coupling 3, torque sensor 4, transmission shaft 5 and speed increasing corner gear box 6; both dynamometer motors 2 are installed in the motor On the base 1, the motor base 1 is installed on the anchor plate of the motor base pre-buried in the foundation, and is connected and fixed with anchor bolts.
  • the hydraulic load cylinder 18 and the cylinder support 19 are connected by a pin, and the cylinder support 19 is fixed on the cylinder support anchor plate 20 pre-buried in the foundation.
  • a guide mechanism 16 is installed on each side of the rotary support 15. Due to the action of the slewing bearing I14 and the guiding mechanism 16, the torque loading test and the drill pipe lifting pressure test can be carried out at the same time.
  • a guide mechanism 16 is installed on each side of the rotary support 15;
  • the guide mechanism 16 includes a guide anchor plate 161, a guide block 162, a guide block support 163, and an adjustment pad 164;
  • a guide anchor plate 161 and anchor bolts are pre-embedded on the foundation wall, and the guide anchor plates 161 on both sides are parallel;
  • the adjustment pad 164 is assembled on the guide anchor plate 161 and fastened with nuts, and the guide key 165 is fastened with bolts to the adjustment On the backing plate 164;
  • a guide block support 163 and a guide block 162 are mounted on both sides of the rotating support 15.
  • the guide block 162 has a key groove, and the key groove is matched with the guide key 165 on the adjustment backing plate 164.
  • the test device also includes a cooling system, which includes a cooling water tank, pipeline and water pump; the cooling water tank is connected to the water pump, water-cooled resistance box, hydraulic station, and gear oil pump station through the pipeline.
  • the torque transmission gear box 10 and the speed increasing corner gear box 6 are respectively connected to the gear oil pumping station; the oil inlet temperature sensor, the oil outlet temperature sensor, and the oil outlet pressure sensor of the gear oil pump station are connected with the computer software system.
  • the square head of the rotary drilling drill pipe is connected to the driving sleeve 8, and the torque is transmitted to the connecting shaft 9 through the driving sleeve 8.
  • the connecting shaft 9 is connected to the slewing support II11, the slewing support II11 and the pinion 7 meshes, and then the power is transmitted to the speed-increasing corner gear box 6 through the pinion 7 again.
  • each sensor is connected to the ECU of the rotary drilling rig host computer to detect the host parameters of the rotary drilling rig of different models in real time.
  • test method is as follows:
  • the square head of the rotary drilling drill pipe is connected to the driving sleeve 8, and the torque is transmitted to the connecting shaft 9 through the driving sleeve 8.
  • the connecting shaft 9 is connected to the slewing support II11.
  • the power is transmitted to the speed-increasing angle gearbox 6, the speed-increasing angle gearbox 6 transmits the torque to the dynamometer 2 through the transmission shaft 5, the torque sensor 4, and the motor coupling 3.
  • the computer receives the torque signal from the torque sensor 4 and passes the software Directly control the dynamometer motor to control the load size, thus realizing the torque loading test of the whole machine.
  • the drill rod transmits the pressure and lifting force to the hydraulic load cylinder 18 through the drive sleeve 8, the slewing support I14, the slewing support 15, and the tension pressure sensor 17.
  • the pressurization load and the lifting load of the hydraulic load cylinder 18 are set by the computer And control, realize the drill rod lifting and pressurization test, and due to the action of the slewing bearing I14 and the guiding mechanism 16, the torque loading test and the drill rod lifting pressurization test can be carried out at the same time.
  • the data acquisition system reserves one CAN communication, which is connected to the main ECU of the rotary drilling rig to detect in real time the main pump pressure, auxiliary pump pressure, power head forward pressure, power head reverse pressure, Engine torque, engine speed, engine fuel consumption, engine water temperature, engine oil pressure, hydraulic oil temperature, engine fuel consumption and other host parameters, and finally realize functions including torque loading, drill pipe tension pressure, integrated data monitoring and theoretical verification of the whole machine operation, etc.
  • Comprehensive performance test and data analysis test By analyzing various technical parameters, it provides a reliable scientific basis for optimizing product design, improving product quality and performance, and developing high-quality, high-standard rotary drilling rigs.
  • the dynamometer motor 2 In the torque loading test, the dynamometer motor 2 is not only a load for the system, but it is also a generator, and a large amount of electrical energy will be generated during the test.
  • the dynamometer motor 2 is connected to the water-cooled resistance box and the power grid through the frequency converter.
  • the computer system and the frequency converter can control the flow of electric energy generated by the dynamometer motor, so that a certain percentage of the electricity is reversed to the grid and the remaining percentage of electricity is fed to the water tank through the water-cooled resistance box.
  • the water is used for heating and consumption, and the hot water is used to wash the vehicle, which has the characteristics of energy recovery and reuse, energy saving and environmental protection.
  • the present invention has the following effects:
  • the test bench can carry out fully automatic simulation of actual working conditions load torque loading test according to the load spectrum.
  • automatic simulation loading test real-time monitoring of rotary drilling rig power head torque, power head speed, power, main pump pressure, auxiliary pump pressure, power head forward pressure, engine speed, engine torque and hydraulic oil temperature under different load torques
  • Various host parameters, fitting characteristic curves, and verifying whether each parameter value meets the acceptance requirements the domestic first to use an alternator as a load, the load control sensitivity is high, which can reach the millisecond level, and it can provide high-frequency alternating load and sudden load.
  • the test bench is designed with a new rotary and pressurized guiding composite mechanism to meet the requirements of the acceptance criteria when the rotary drill can be used for lifting and pressurizing under different torque loads.
  • the dynamometer that provides the load for the torque loading test is essentially a generator.
  • the fuel energy is converted into mechanical energy through the engine, hydraulic system, mechanical transmission system, etc., and then the dynamometer is driven
  • the motor generates electricity, and the generated electricity can be freely controlled by the operating system in any proportion of its flow. A certain proportion is used for heating the water storage tank and used for washing vehicles. The remaining proportion of the electricity is returned to the company's grid for the company's daily production needs.
  • test bench meets the loading and debugging requirements of simulated actual working conditions, and at the same time solves the problem that the energy consumed by the rotary drilling rig cannot be recycled and reused in the traditional drilling debugging and hydraulic dynamometer test bench debugging, creating a new power feeder network technology Application areas.
  • test bench can be loaded manually by inputting the torque value.
  • designers are used to test the corresponding relationship between power head speed, power head power, main pump pressure, and auxiliary pump pressure at a given torque.
  • the test bench control software can output the characteristic curve of each parameter for Designer data statistics and analysis.
  • the test bench can collect parameters such as engine speed, engine torque, main pump pressure, main pump displacement, power head speed and other parameters under different torque and pressure conditions, and automatically fit the output characteristic curves of the engine, pump and motor under system working conditions, and pass Comparing with the characteristic curve given by the manufacturer, it can detect whether the hydraulic system of the whole machine matches with the selection of components. At the same time, the efficiency of hydraulic transmission can be obtained, which has important guiding significance for optimizing product design and improving product performance.
  • the test bench can measure the maximum output torque of the rotary drilling drill, the maximum lifting force of the main roll, the maximum lifting force and maximum pressure of the pressurized winch, the maximum pressurizing pressure and the maximum lifting force of the pressurized cylinder, and adjust the accurate parameters for the designer. Optimize product design, improve product quality and performance, and provide more accurate data support.

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Abstract

一种旋挖钻机综合性能测试与调试试验装置及试验方法，试验装置中的测功电机（2）设置在地基上；传扭齿轮箱（10）通过齿轮箱转接板（12）固定在齿轮箱锚固板（13）上；增速转角齿轮箱（6）安装在传扭齿轮箱（10）上，增速转角齿轮箱（6）又依次通过传动轴（5）、扭矩传感器（4）、电机联轴器（3）与测功电机（2）相连；驱动套（8）装入传扭齿轮箱（10）的连接轴（9）中，驱动套（8）下端通过回转支承Ⅰ（14）、回转支座（15）、拉压力传感器（17）与液压负载油缸（18）相连，回转支座（15）固定在地基中，液压负载油缸（18）通过液压管路连接至液压站；其中，拉压力传感器（17）和液压站中负载油缸压力控制阀连接至计算机软件控制系统；扭矩传感器（4）与计算机软件控制系统相连；测功电机（2）与配电室电网和水冷电阻箱并联。使用该装置的控制能够更精确，并且该装置能模拟实际工况且综合数据分析能力更强。

Description

一种旋挖钻机综合性能测试与调试试验装置及试验方法 技术领域
本发明涉及旋挖钻机领域，具体涉及一种基于电力测功含馈网系统的旋挖钻机综合性能测试与调试试验装置。
背景技术
旋挖钻机是一种适合建筑基础工程中成孔作业的施工机械，在多种地层结构如粉土、粘土、泥砂、砾石、淤泥卵石、岩石等钻孔施工中广泛应用，面对工况极其复杂。
目前旋挖钻机下线调试主要有两种手段：钻孔调试和综合试验台调试。打孔调试需要占用地面空间，并且扭矩值只能达到设计值的20％，调试效果不理想，无法衡量技术参数能否满足设计要求。
现有的水力测功综合试验台为调试试验提供了全新的调试方法，可在线检测动力头扭矩、转速、功率以及钻杆的提升力和加压力等参数。但是其扭矩负载由水涡流测功机提供，负载相对平稳，加载速度慢，无法模拟实际工况中由于地层变化产生的载荷突变，所提供调试环境与实际工况有一定差距。
目前我们对整机调试又提出了更高的要求，除了能满足按实际工况加载(载荷变化速度快，可自动加载高频交变载荷)，调试过程中还需监测主泵压力、副泵压力、动力头正转压力、液压油温度、发动机水温、发动机转速、发动机扭矩和发动机油耗等参数，实时监测整机在模拟实际工况作业中整机状态，有无异常，是否满足验收准则要求。
除了需满足更高要求的调试要求，新产品在开发设计阶段也需要一台综合性能测试装置。新产品参数验证和校准需做发动机性能试验以及液压动力匹配试验验，实时监测并记录动力头扭矩、动力头转速、主泵压力、副泵压力、发动机转速、发动机输出功率、发动机输出扭矩、发动机油耗等主机参数，以及拟合相关参数特性曲线。综上，需要一台负载变化非常灵敏、控制更精确、能模拟实际工况且综合数据分析能力更强的试验设备。
发明内容
根据现有技术的不足，本发明提供一种旋挖钻机综合性能测试与调试试验装置。
本发明按以下技术方案实现：
一种旋挖钻机综合性能测试与调试试验装置，包括：
测功电机，其设置在地基上；
传扭齿轮箱，其通过齿轮箱转接板固定在齿轮箱锚固板上；
增速转角齿轮箱，其安装在所述传扭齿轮箱上，又依次通过传动轴、扭矩传感器、电机联轴器与测功电机相连；
驱动套，其装入所述传扭齿轮箱的连接轴中，下端通过回转支承Ⅰ、回转支座、拉压力传感器与液压负载油缸相连，液压负载油缸通过液压管路连接至液压站；
其中，所述拉压力传感器和液压站中负载油缸压力控制阀连接至计算软件机控制系统；所述扭矩传感器与计算机软件控制系统相连；测功电机与配电室电网和水冷电阻箱并联。
进一步，所述测功电机的数量为两个，两个测功电机分别通过电机联轴器、扭矩传感器、传动轴与增速转角齿轮箱连接传动；两个测功电机均安装在电机底座上，电机底座装在预埋在地基里的电机底座锚固板上，用地脚螺栓连接紧固。
进一步，所述液压负载油缸与油缸支座通过销轴连接，油缸支座固定在预埋在地基里的油缸支座锚固板上。
进一步，所述回转支座两侧各装有一个导向机构；所述导向机构包括导向锚固板、导向块、导向块支座、调整垫板；所述导向锚固板预埋在基础墙面上，且两侧的导向锚固板相平行；所述调整垫板装配在导向锚固板上，所述导向键紧固在调整垫板上；回转支座两侧各装配一个导向块支座和导向块，导向块上有键槽，键槽与调整垫板上的导向键配合。
进一步，还包括冷却系统，所述冷却系统包括冷却水箱、管路和水泵；所述冷却水箱通过管路与水泵、水冷电阻箱、液压站、齿轮油泵站相连。
进一步，还包括润滑系统，所述传扭齿轮箱、增速转角齿轮箱分别与齿轮油泵站相连；所述齿轮油泵站的进油温度传感器、出油温度传感器、出油压力传感器与计算机软件系统相连。
进一步，旋挖钻钻杆方头接入驱动套，通过驱动套将扭矩传递到连接轴，连接轴上接回转支承Ⅱ，回转支承Ⅱ与小齿轮啮合，再通过小齿轮再将动力传递到增速转角齿轮箱。
进一步，数据采集系统与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下主机参数。
进一步，所述测功电机通过变频器与水冷电阻箱和电网相连，由计算机系统和变频器控制测功电机产生电能的流向，使预设百分比的电量反网利用、剩余百分比电量通过水冷电阻箱给水箱中得水加热消耗，热水用来清洗车辆。
一种旋挖钻机综合性能测试与调试试验方法，该试验方法如下：
旋挖钻钻杆方头接入驱动套，通过驱动套将扭矩传递到连接轴，连接轴上接回转支承Ⅱ，回转支承Ⅱ与小齿轮啮合，再通过小齿轮再将动力传递到增速转角齿轮箱，增速转角齿轮箱通 过传动轴、扭矩传感器、电机联轴器将扭矩传递至测功电机，计算机接收扭矩传感器中扭矩信号并通过软件直接控制测功电机控制负载大小，由此实现整机扭矩加载试验；
此外，钻杆将加压力和提升力通过驱动套、回转支承Ⅰ、回转支座、拉压力传感器传递至液压负载油缸，液压负载油缸的加压负载和提升负载由计算机设定并控制，实现钻杆提升和加压试验；
数据采集系统预留一路CAN通讯，与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下各项主机参数。
各参数自动生成相应特性曲线，供设计人员数据统计和分析，发电机发电两方面用途：1、烧热水，用于清洗车辆2、返回公司电网，供厂区日常使用，节省电能，每次试验完，变频器的显示器上可累计记录发电量。
本发明有益效果：
1、试验台可按照荷谱进行全自动模拟实际工况载扭矩加载试验。自动模拟加载试验过程中，不同负载扭矩下实时监测旋挖钻机动力头扭矩、动力头转速、功率、主泵压力、副泵压力、动力头正转压力、发动机转速、发动机扭矩和液压油温等各项主机参数，拟合特性曲线，检验各参数值是否满足验收要求；国内首创使用交流发电机作为负载，载荷控制灵敏度高，可达到毫秒级，可提供高频交变载荷和突变载荷，可实时监测在负载扭矩值突变时，液压系统抗冲击能力和整机稳定性。
旋挖钻在施工过程中，主卷提升力，动力头加压油缸的加压力和提升力、加压卷扬的加压力和提升力等参数大小对施工效率起到决定性作用。试验台设计了新的回转和加压导向复合机构，满足旋挖钻调试中旋转和加压同步进行，检测旋挖钻可在不同扭矩负载下做提升力和加压力是否满足验收准则要求。
2、开发了电力馈网技术新的应用领域，能量可回收。为扭矩加载试验提供负载的测功机实质是发电机，模拟实际工况载荷谱进行全自动扭矩加载试验过程中，燃油能量通过发动机、液压系统、机械传动系统等转换成机械能，进而驱动测功电机产生电能，产生的电能可以通过操作系统按任意比例自由支配其流向，一定的比例用于储水箱加热，用于清洗车辆，其余比例的电能返回公司电网，用于公司日常生产需求。试验台满足模拟实际工况加载调试需求的同时，解决了传统打孔调试和水力测功机试验台调试中，旋挖钻机消耗燃油的能量无法回收再利用的难题，开创了电力馈网技术新的应用领域。
3、为新产品开发设计提供高端试验平台。试验台可以手动输入扭矩值进行加载。设计人员在新产品开发设计过程中，用于测试在给定扭矩时，动力头转速、动力头功率、主泵压 力、副泵压力等对应关系，试验台控制软件可输出各参数特性曲线，供设计人员数据统计和分析。
试验台可采集不同扭矩和压力工况下的发动机转速、发动机扭矩、主泵压力、主泵排量、动力头转速等参数，自动拟合系统工作状态下发动机、泵和马达输出特性曲线，通过与厂家给定的特性曲线作对比，检测整机液压系统是否与部件选型相匹配，同时还可得出液压传动效率，为优化产品设计、提升产品性能有着重要的指导意义。
试验台可测得旋挖钻的最大输出扭矩、主卷最大提升力、加压卷扬最大提升力和最大加压力、加压油缸最大加压力和最大提升力，为设计人员调整准确参数，给优化产品设计，提高产品质量和性能，提供更准确的数据支撑。
4、钻杆可靠性研究试验。在旋挖钻机钻杆不同位置贴上应力、应变感应贴片，旋挖钻机按模拟实际工况载荷谱加载过程中实时检测并记录每个贴片位置的应力和应变，分析施工过程中钻杆应力分布情况，为研究可靠性更高、耐久性更强的钻杆、解决钻杆开裂问题提供关键的数据支持。
附图说明
构成本申请的一部分的说明书附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：
图1为旋挖钻机综合性能测试与调试试验装置连接图；
图2为旋挖钻机综合性能测试与调试试验装置俯视图；
图3为导向机构放大图。
1-电机底座，2-测功电机，3-电机联轴器，4-扭矩传感器，5-传动轴，6-增速转角齿轮箱，7-小齿轮，8-驱动套，9-连接轴，10-传扭齿轮箱，11-回转支承Ⅱ，12-齿轮箱转接板，13-齿轮箱锚固板，14-回转支承Ⅰ，15-回转支座，16-导向机构，17-拉压力传感器，18-液压负载油缸，19-油缸支座，20-油缸支座锚固板，161-导向锚固板，162-导向块，163-导向块支座，164-调整垫板，165-导向键。
具体实施方式
为使本发明实施的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行更加详细的描述。在附图中，自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。所描述的实施例是本发明一部分实施例，而不是全部的实施例。下面通过参考附图描述的实施例是示例性的，旨在用于解释本发明，而不能理解为对本发明的限制。基于本发明中的实施例，本领域普通技术人员在没 有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。下面结合附图对本发明的实施例进行详细说明。
如图1、图2所示，一种旋挖钻机综合性能测试与调试试验装置，包括测功电机2、传扭齿轮箱10、增速转角齿轮箱6和驱动套8；其中，测功电机2设置在地基上；传扭齿轮箱10通过齿轮箱转接板12固定在齿轮箱锚固板13上，齿轮箱锚固板13预埋在地基中；增速转角齿轮箱6安装在传扭齿轮箱10上，增速转角齿轮箱6又依次通过传动轴5、扭矩传感器4、电机联轴器3与测功电机2相连；驱动套8装入传扭齿轮箱10的连接轴9中，驱动套8下端通过回转支承Ⅰ14、回转支座15、拉压力传感器17与液压负载油缸18相连，回转支座15固定在地基中，液压负载油缸18通过液压管路连接至液压站；其中，拉压力传感器17和液压站中负载油缸压力控制阀连接至计算软件机控制系统；扭矩传感器4与计算机软件控制系统相连；测功电机2与配电室电网和水冷电阻箱并联。
以下给出上述实施例中关于测功电机连接一优选实施例：
测功电机2的数量为两个，两个测功电机分别通过电机联轴器3、扭矩传感器4、传动轴5与增速转角齿轮箱6连接传动；两个测功电机2均安装在电机底座1上，电机底座1装在预埋在地基里的电机底座锚固板上，用地脚螺栓连接固定。
以下给出上述实施例中关于液压负载油缸连接一优选实施例：
液压负载油缸18与油缸支座19通过销轴连接，油缸支座19固定在预埋在地基里的油缸支座锚固板20上。
进一步方案，回转支座15两侧各装有一个导向机构16。由于回转支承Ⅰ14和导向机构16作用，使得扭矩加载试验和钻杆提升加压试验可同时进行。
具体的，如图3所示，回转支座15两侧各装有一个导向机构16；导向机构16包括导向锚固板161、导向块162、导向块支座163、调整垫板164；导向锚固板161和地脚螺栓预埋在基础墙面上，且两侧的导向锚固板161相平行；调整垫板164装配在导向锚固板161上，用螺母紧固，导向键165用螺栓紧固在调整垫板164上；回转支座15两侧各装配一个导向块支座163和导向块162，导向块162上有键槽，键槽与调整垫板164上的导向键165配合。
更进一步方案：试验装置还包括冷却系统，冷却系统包括冷却水箱、管路和水泵；冷却水箱通过管路与水泵、水冷电阻箱、液压站、齿轮油泵站相连。其中，传扭齿轮箱10、增速转角齿轮箱6分别与齿轮油泵站相连；齿轮油泵站的进油温度传感器、出油温度传感器、出油压力传感器与计算机软件系统相连。
继续参照图1、图2所示，旋挖钻钻杆方头接入驱动套8，通过驱动套8将扭矩传递 到连接轴9，连接轴9上接回转支承Ⅱ11，回转支承Ⅱ11与小齿轮7啮合，再通过小齿轮7再将动力传递到增速转角齿轮箱6。
需要说明的是，各个传感器采集的数据与与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下主机参数。
以下给出一种旋挖钻机综合性能测试与调试试验方法，该试验方法如下：
旋挖钻钻杆方头接入驱动套8，通过驱动套8将扭矩传递到连接轴9，连接轴9上接回转支承Ⅱ11，回转支承Ⅱ11与小齿轮7啮合，再通过小齿轮7再将动力传递到增速转角齿轮箱6，增速转角齿轮箱6通过传动轴5、扭矩传感器4、电机联轴器3将扭矩传递至测功电机2，计算机接收扭矩传感器4中扭矩信号并通过软件直接控制测功电机控制负载大小，由此实现整机扭矩加载试验。此外，钻杆将加压力和提升力通过驱动套8、回转支承Ⅰ14、回转支座15、拉压力传感器17传递至液压负载油缸18，液压负载油缸18的加压负载和提升负载由计算机设定并控制，实现钻杆提升和加压试验，并且由于回转支承Ⅰ14和导向机构16作用，扭矩加载试验和钻杆提升加压试验可同时进行。再者，数据采集系统预留一路CAN通讯，与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下主泵压力、副泵压力、动力头正转压力、动力头反转压力、发动机扭矩、发动机转速、发动机油耗、发动机水温、机油压力、液压油温、发动机油耗等各项主机参数，最终实现包含扭矩加载、钻杆拉压力及整机运行综合数据监测及理论验证等功能的综合性能测试及数据分析试验。通过分析各项技术参数，给优化产品设计、提高产品质量和性能，开发高质量、高标准的旋挖钻机提供了可靠的科学依据。
扭矩加载试验中测功电机2除了为系统提供负载外，本身还是发电机，实验过程中会产生大量电能。测功电机2通过变频器与水冷电阻箱和电网相连，可由计算机系统和变频器控制测功电机产生电能的流向，使某一百分比的电量反网利用、剩余百分比电量通过水冷电阻箱给水箱中得水加热消耗，热水用来清洗车辆，具有能量回收再利用、节能环保的特点。
综上，本发明与现有技术相比具有以下效果：
1、试验台可按照荷谱进行全自动模拟实际工况载扭矩加载试验。自动模拟加载试验过程中，不同负载扭矩下实时监测旋挖钻机动力头扭矩、动力头转速、功率、主泵压力、副泵压力、动力头正转压力、发动机转速、发动机扭矩和液压油温等各项主机参数，拟合特性曲线，检验各参数值是否满足验收要求；国内首创使用交流发电机作为负载，载荷控制灵敏度高，可达到毫秒级，可提供高频交变载荷和突变载荷，可实时监测在负载扭矩值突变时，液压系统抗冲击能力和整机稳定性。
旋挖钻在施工过程中，主卷提升力，动力头加压油缸的加压力和提升力、加压卷扬的加压力和提升力等参数大小对施工效率起到决定性作用。试验台设计了新的回转和加压导向复合机构，满足旋挖钻调试中旋转和加压同步进行，检测旋挖钻可在不同扭矩负载下做提升力和加压力是否满足验收准则要求。
2、开发了电力馈网技术新的应用领域，能量可回收。为扭矩加载试验提供负载的测功机实质是发电机，模拟实际工况载荷谱进行全自动扭矩加载试验过程中，燃油能量通过发动机、液压系统、机械传动系统等转换成机械能，进而驱动测功电机产生电能，产生的电能可以通过操作系统按任意比例自由支配其流向，一定的比例用于储水箱加热，用于清洗车辆，其余比例的电能返回公司电网，用于公司日常生产需求。试验台满足模拟实际工况加载调试需求的同时，解决了传统打孔调试和水力测功机试验台调试中，旋挖钻机消耗燃油的能量无法回收再利用的难题，开创了电力馈网技术新的应用领域。
3、为新产品开发设计提供高端试验平台。试验台可以手动输入扭矩值进行加载。设计人员在新产品开发设计过程中，用于测试在给定扭矩时，动力头转速、动力头功率、主泵压力、副泵压力等对应关系，试验台控制软件可输出各参数特性曲线，供设计人员数据统计和分析。
试验台可采集不同扭矩和压力工况下的发动机转速、发动机扭矩、主泵压力、主泵排量、动力头转速等参数，自动拟合系统工作状态下发动机、泵和马达输出特性曲线，通过与厂家给定的特性曲线作对比，检测整机液压系统是否与部件选型相匹配，同时还可得出液压传动效率，为优化产品设计、提升产品性能有着重要的指导意义。
试验台可测得旋挖钻的最大输出扭矩、主卷最大提升力、加压卷扬最大提升力和最大加压力、加压油缸最大加压力和最大提升力，为设计人员调整准确参数，给优化产品设计，提高产品质量和性能，提供更准确的数据支撑。
4、钻杆可靠性研究试验。在旋挖钻机钻杆不同位置贴上应力、应变感应贴片，旋挖钻机按模拟实际工况载荷谱加载过程中实时检测并记录每个贴片位置的应力和应变，分析施工过程中钻杆应力分布情况，为研究可靠性更高、耐久性更强的钻杆、解决钻杆开裂问题提供关键的数据支持。
最后应当说明的是:以上实施例仅用以说明本发明的技术方案而非对其限制；尽管参照较佳实施例对本发明进行了详细的说明，所属领域的普通技术人员应当理解：依然可以对本发明的具体实施方式进行修改或者对部分技术特征进行等同替换；而不脱离本发明技术方案的精神，其均应涵盖在本发明请求保护的技术方案范围当中。

Claims (10)

  1. 一种旋挖钻机综合性能测试与调试试验装置，其特征在于，包括：
    测功电机，其设置在地基上；
    传扭齿轮箱，其通过齿轮箱转接板固定在齿轮箱锚固板上；
    增速转角齿轮箱，其安装在所述传扭齿轮箱上，又依次通过传动轴、扭矩传感器、电机联轴器与测功电机相连；
    驱动套，其装入所述传扭齿轮箱的连接轴中，下端通过回转支承Ⅰ、回转支座、拉压力传感器与液压负载油缸相连，液压负载油缸通过液压管路连接至液压站；
    其中，所述拉压力传感器和液压站中负载油缸压力控制阀连接至计算软件机控制系统；所述扭矩传感器与计算机软件控制系统相连；测功电机与配电室电网和水冷电阻箱并联。
  2. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：所述测功电机的数量为两个，两个测功电机分别通过电机联轴器、扭矩传感器、传动轴与增速转角齿轮箱连接传动；
    两个测功电机均安装在电机底座上，电机底座装在预埋在地基里的电机底座锚固板上，用地脚螺栓连接紧固。
  3. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：所述液压负载油缸与油缸支座通过销轴连接，油缸支座固定在预埋在地基里的油缸支座锚固板上。
  4. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：所述回转支座两侧各装有一个导向机构；
    所述导向机构包括导向锚固板、导向块、导向块支座、调整垫板；
    所述导向锚固板预埋在基础墙面上，且两侧的导向锚固板相平行；
    所述调整垫板装配在导向锚固板上，所述导向键紧固在调整垫板上；
    回转支座两侧各装配一个导向块支座和导向块，导向块上有键槽，键槽与调整垫板上的导向键配合。
  5. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：还包括润滑系统，所述润滑系统包括齿轮油泵站，所述齿轮油泵站分别与传扭齿轮箱、增速转角齿轮箱相连；
    所述齿轮油泵站的进油温度传感器、出油温度传感器、出油压力传感器通过试验台数据采集系统与计算机软件系统相连。
  6. 根据权利要求5所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：试验台 数据采系统与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下主机参数。
  7. 根据权利要求5所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：还包括冷却系统，所述冷却系统包括冷却水箱、管路和水泵；
    所述冷却水箱通过管路与水泵、液压站、齿轮油泵站相连。
  8. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：旋挖钻钻杆方头接入驱动套，通过驱动套将扭矩传递到连接轴，连接轴上接回转支承Ⅱ，回转支承Ⅱ与小齿轮啮合，再通过小齿轮再将动力传递到增速转角齿轮箱。
  9. 根据权利要求1所述的一种旋挖钻机综合性能测试与调试试验装置，其特征在于：所述测功电机通过变频器与水冷电阻箱和电网相连，由计算机系统和变频器控制测功电机产生电能的流向，使预设百分比的电量反网利用、剩余百分比电量通过水冷电阻箱给储水箱中的水加热消耗，热水用来清洗车辆。
  10. 一种旋挖钻机综合性能测试与调试试验方法，其特征在于：
    旋挖钻钻杆方头接入驱动套，通过驱动套将扭矩传递到连接轴，连接轴上接回转支承Ⅱ，回转支承Ⅱ与小齿轮啮合，再通过小齿轮将动力传递到增速转角齿轮箱，增速转角齿轮箱通过传动轴、扭矩传感器、电机联轴器将扭矩传递至测功电机，计算机接收扭矩传感器中扭矩信号并通过软件直接控制测功电机控制负载大小，由此实现整机扭矩加载试验；
    此外，钻杆将加压力和提升力通过驱动套、回转支承Ⅰ、回转支座、拉压力传感器传递至液压负载油缸，液压负载油缸的加压负载和提升负载由计算机设定并控制，实现钻杆提升和加压试验；
    数据采集系统预留一路CAN通讯，与旋挖钻机主机ECU相连，实时检测不同型号旋挖钻机工作状态下各项主机参数。
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