CN109869294A - 一种超大功率五缸柱塞泵 - Google Patents
一种超大功率五缸柱塞泵 Download PDFInfo
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- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
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- F04B9/02—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical
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- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B9/00—Piston machines or pumps characterised by the driving or driven means to or from their working members
- F04B9/02—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical
- F04B9/04—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical the means being cams, eccentrics or pin-and-slot mechanisms
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Abstract
本发明公开了一种超大功率五缸柱塞泵,包括动力端总成、液力端总成和减速箱总成,动力端总成采用分段式结构设计,包括曲轴箱体、十字头箱体和间隔架,十字头箱体的一端与曲轴箱体连接,十字头箱体的另一端与间隔架连接,液力端总成设在间隔架一端,通过螺栓依次穿过间隔架、十字头箱体与曲轴箱体连接,减速箱总成与曲轴箱体连接,曲轴箱体内的曲轴采用合金钢锻造而成,包括六个轴颈和五个曲拐,相邻两个轴颈之间设一个曲拐,曲拐与曲轴的旋转中心距离为110至160mm。有益效果:一种超大功率五缸柱塞泵,其额定输入功率为5000hp,以解决电驱压裂中大功率电机无法匹配相应规格柱塞泵的问题,同时也解决了油气田井场条件受限,压裂设备匹配多的矛盾。
Description
技术领域
本发明涉及油气钻采设备的领域,具体涉及一种超大功率五缸柱塞泵。
背景技术
随着油气田超高压、超深井、水平井的不断开发,其作业工况也越来越恶劣,要求高压力、大排量作业,因此对柱塞泵的要求也越来越高,单台压裂设备可以输出高压力、大排量,这样就要求柱塞泵可以大功率、高压力输出;特别是在非常规油气作业——页岩气作业,其作业工况恶劣,需要长时间、大排量、高压力作业,而且作业频次越频繁,因此对压裂设备要求越来越高,而柱塞泵又是压裂设备中的核心部件,因此对柱塞泵的要求也越来越高;近几年新兴电驱压裂作业,采用电机驱动,电机可以选择很大功率,例如:额定功率可以达到3000KW、4000kw、5000kw、6000kw等,但柱塞泵还没有这么大规格的,目前市场上常见的压裂泵主要有2800HP五缸柱塞泵、3000HP三缸柱塞泵、3300HP五缸柱塞泵、4000HP三缸柱塞泵;2800HP五缸柱塞泵主要配置在2500型压裂车上,目前2500型压裂车是压裂作业中最常用、做多的压裂设备;其缺点是在高压力作业下,单机设备排量低;在页岩气作业中需要十几台压裂车同时作业才能满足作业工艺中总排量的要求,这么多台车的同时作业,会占用很大的井场面积,与油气田井场条件受限的矛盾尤为突出;4000HP三缸柱塞泵是配置在3100HP压裂车上,但4000HP柱塞泵是三缸泵其排量比2800HP五缸泵低很多,在相同柱塞规格、相同冲刺下其排量只是2800HP五缸泵的82.54%;如果将2800HP柱塞泵和4000HP柱塞泵配置到电驱压裂设备上,体现不出电驱压裂的优势,相当于大马拉小车,因此急需开发一款大功率的柱塞泵来匹配新兴的电驱压裂设备。
发明内容
本发明的目的克服现有技术的不足,提供一种超大功率五缸柱塞泵,其额定输入功率为5000hp,以解决电驱压裂中大功率电机无法匹配相应规格柱塞泵的问题,同时也解决了油气田井场条件受限,压裂设备匹配多的矛盾。
本发明的目的是通过以下技术措施达到的:一种超大功率五缸柱塞泵,包括动力端总成、液力端总成和减速箱总成,所述动力端总成采用分段式结构设计,包括曲轴箱体、十字头箱体和间隔架,所述十字头箱体的一端与曲轴箱体通过螺栓连接,所述十字头箱体的另一端与间隔架通过螺栓连接,液力端总成设在间隔架一端,通过螺栓依次穿过间隔架、十字头箱体与曲轴箱体连接,减速箱总成通过螺栓与曲轴箱体连接,所述曲轴箱体内的曲轴采用合金钢锻造而成,包括六个轴颈和五个曲拐,相邻两个轴颈之间设一个曲拐,所述曲拐与曲轴的旋转中心距离为110至160mm。
进一步地,所述减速箱总成的输入角度可以根据输入要求进行调整。
进一步地,所述减速箱总成包括行星减速箱和平行级减速箱;所述平行级减速箱和行星级减速箱均为斜齿轮传动;所述行星减速箱包括一个太阳轮、四个行星齿轮和一个齿轮圈,四个行星齿轮组成行星齿轮机构,太阳轮位于行星齿轮机构中心,行星齿轮和相邻的太阳轮、齿轮圈处于常啮合状态;所述平行级减速箱包括小齿轮和大齿轮,小齿轮与输入端相连,大齿轮与行星减速箱太阳轮同轴,其传动比为6.5:1—15:1。
进一步地,所述间隔架上设有拱形结构支撑柱。
进一步地,所述十字头箱体内设有十字头机构,在曲轴箱体与十字头箱体内设有连杆机构,连杆机构一端与曲轴连接,连杆机构另一端与十字头机构连接,连杆机构包括连杆盖、连杆轴瓦和连杆体,连杆盖与连杆体通过螺栓连接,连杆轴瓦位于连杆盖与连杆体连接形成的圆柱形空间内,连杆轴瓦两侧为翻边结构,宽边结构宽径比大。
与现有技术相比,本发明的有益效果是:
1、一种超大功率五缸柱塞泵其制动功率为5000hp,最大输出功率可达4500hp,相当于2台2500泵的总和,大功率、大排量设计,可适用于各种复杂作业工况,并可减少现场作业所需设备,节约现场作业场地,降低设备成本。
2、分段式设计使动力端总成整体结构紧凑、加工制造更为容易,整泵的装配和后期维护也更为方便;通过选用高强度钢板和合理的结构设计保证各箱体的强度和刚度要求,如间隔架支撑柱设计为拱形结构,提高支撑强度,满足动力端总成在高负荷强度和刚度下使用要求,同时分段式结构设计方便后期的装配和维修,同时也降低了加工成本,降低了曲轴箱体的重量。
3、采用10in长冲程设计和五缸结构设计,具有如下设计优点:10in长冲程设计可实现大排量的作业需求,同时降低泵的冲次,提高各零部件的使用寿命;采用五缸结构设计增加了柱塞泵输出排量,同时与三缸泵相比,五缸泵作业平稳无振动,可以减少整泵的振动,延长使用寿命。
4、减速箱总成采用行星级减速箱和平行级减速箱配合使用,利于获得大的传动比,传动比可以达到6.5:1—15:1,大速比可以降低输入扭矩,提高减速箱的使用寿命,为满足涡轮发动机驱动和电机驱动的匹配提供了有效保障;大的减速比可以降低柱塞泵的冲次,降低各旋转零部件的疲劳循环次数,可以延长各零部件的使用寿命;同时减速箱的输入角度可以根据输入要求进行调整,可以满足多角度调整,适应多种安装需求。
5、曲轴曲拐的尺寸增大,保证柱塞泵可以输出更高的压力。
6、连杆轴瓦两侧为翻边结构,翻边结构宽径比大,能够实现较高的承载能力,而且定位效果好。
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为本发明结构示意图。
图2为本发明动力端总成结构示意图。
图3为本发明减速箱总成示意图。
图4为本发明剖视图。
图5为本发明连杆机构与十字头机构的连接结构示意图。
图6为本发明曲轴结构示意图。
图7为本发明连杆轴瓦结构示意图。
图8为本发明平行级减速箱结构示意图。
图9为本发明行星减速箱结构示意图。
其中,1动力端总成,2液力端总成,3减速箱总成,4曲轴箱体,5十字头箱体,6间隔架,7曲轴,8轴颈,9曲拐,10圆柱滚子轴,11阀箱,12柱塞,13轴承座,14前端板,15盖板,16支腿,17滑轨,18支撑柱,19连杆盖,20连杆轴瓦,21连杆体,22十字头,23十字头压盖,24十字头连接螺钉,25十字头导板,26导板螺栓,27拉杆,28卡箍,29行星减速箱,30平行级减速箱,31翻边结构,32大齿轮,33小齿轮,34行星齿轮,35齿轮圈,36太阳轮。
具体实施方式
实施例,如图1至9所示,一种超大功率五缸柱塞泵,包括动力端总成1、液力端总成2和减速箱总成3,所述动力端总成1采用分段式结构设计,分段式设计使动力端总成1整体结构紧凑、加工制造更为容易,整泵的装配和后期维护也更为方便,同时也降低了加工成本。动力端总成1包括曲轴箱体4、十字头箱体5和间隔架6,所述十字头箱体5的一端与曲轴箱体4通过六角头螺栓连接,所述十字头箱体5的另一端与间隔架6通过螺栓连接,液力端总成2设在间隔架6一端,通过螺栓依次穿过间隔架6、十字头箱体5与曲轴箱体4连接,减速箱总成3通过螺栓与曲轴箱体4连接,所述曲轴箱体4内的曲轴7采用合金钢锻造而成,包括六个轴颈8和五个曲拐9,相邻两个轴颈8之间设一个曲拐9,即五缸结构设计,采用五缸结构设计增加了柱塞泵输出排量,同时与三缸泵相比,五缸泵作业平稳无振动,可以减少整泵的振动,延长使用寿命;所述曲拐9与曲轴7的旋转中心距离为110至160mm,保证柱塞泵可以输出更高的压力,即为长冲程提供技术支持,其冲程可达到10in,可实现大排量的作业需求,同时降低泵的冲次,提高各零部件的使用寿命。
液力端总成2包括阀箱11和柱塞12,柱塞12设在阀箱11内,曲轴箱体4采用钢板焊接而成,主要是将六个轴承座13和前端板14、盖板15、支腿16等组合后焊接到一起,焊接完成后对轴承座13及前端板14进行精加工而成。十字头箱体5采用钢板焊接而成,十字头箱体5上固定有圆弧形滑轨17,圆弧形滑轨17采用合金钢锻造而成;间隔架6上具有拱形结构支撑柱18,提高支撑强度;十字头箱体5及间隔架6上留有通孔,液力端阀箱11通过螺栓依次穿过间隔架6、十字头箱体5与曲轴箱体4连接。轴颈8上安装圆柱滚子轴10,圆柱滚子轴10外圈安装在轴承座13上。
所述十字头箱体5内设有十字头机构,在曲轴箱体4与十字头箱体5内设有连杆机构,连杆机构一端与曲轴7连接,连杆机构另一端与十字头机构连接,连杆机构包括连杆盖19、连杆轴瓦20和连杆体21,连杆盖19与连杆体21通过螺栓连接,连杆轴瓦20位于连杆盖19与连杆体21连接形成的圆柱形空间内,连杆轴瓦20两侧为翻边结构31,宽边结构宽径比大,能够实现较高的承载能力,而且定位效果好。十字头机构包括十字头22、十字头压盖23、十字头连接螺钉24、十字头导板25、导板螺栓26,连杆体21、连杆盖19、十字头22和十字头压盖23采用合金钢锻造而成,连杆机构一端与曲拐9连接,另一端通过十字头压盖23与十字头22连接;十字头导板25通过导板螺栓26固定于十字头22上,十字头导板25为圆弧形,表面有油槽;十字头22通过拉杆27和卡箍28与液力端总成2的柱塞12连接,进一步的,十字头22与拉杆27之间通过螺钉连接。
所述减速箱总成输出端与曲轴7连接,减速箱总成包括行星减速箱29和平行级减速箱30,所述平行级减速箱30和行星级减速箱29均为斜齿轮传动,所述行星减速箱29包括一个太阳轮36、四个行星齿轮34和一个齿轮圈35,四个行星齿轮34组成行星齿轮机构,太阳轮36位于行星齿轮机构中心,行星齿轮34和相邻的太阳轮36、齿轮圈35处于常啮合状态;所述平行级减速箱30包括大齿轮32和小齿轮33,小齿轮33与输入端相连,大齿轮32与行星减速箱29太阳轮36同轴;输入端输入转速,经小齿轮33传递给大齿轮32实现一级减速,通过大齿轮32传递给太阳轮36,太阳轮36传递到行星齿轮34实现二级减速,从而获得大传动比,其传动比可以达到6.5:1—15:1;行星级减速箱29采用四个均匀分布的行星齿轮34同时传递运动和动力,四个行星轮34因公转而产生的离心惯性力与齿廓间反作用力的径向分力相互平衡抵消,使主轴受力减小,实现大功率传递。大速比可以降低输入扭矩,提高减速箱的使用寿命,为满足涡轮发动机驱动和电机驱动的匹配提供了有效保障;大的减速比可以降低柱塞泵的冲次,降低各旋转零部件的疲劳循环次数,可以延长各零部件的使用寿命;同时减速箱总成的输入角度可以根据输入要求进行调整,可以满足多角度调整,适应多种安装需求。
减速箱总成3带动曲轴7转动,曲轴7在轴承座13支撑的轴承内转动,曲轴7带动连杆体21,连杆体21通过带动十字头22,十字头22在十字头箱体5的圆弧形滑轨17内部往复运动,十字头22通过拉杆27带动柱塞12在液力端总成2的阀箱11内部作往复运动,进行液体的吸入与排出工作。
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 (5)
1.一种超大功率五缸柱塞泵,包括动力端总成、液力端总成和减速箱总成,其特征在于:所述动力端总成采用分段式结构设计,包括曲轴箱体、十字头箱体和间隔架,所述十字头箱体的一端与曲轴箱体通过螺栓连接,所述十字头箱体的另一端与间隔架通过螺栓连接,液力端总成设在间隔架一端,通过螺栓依次穿过间隔架、十字头箱体与曲轴箱体连接,减速箱总成通过螺栓与曲轴箱体连接,所述曲轴箱体内的曲轴采用合金钢锻造而成,包括六个轴颈和五个曲拐,相邻两个轴颈之间设一个曲拐,所述曲拐与曲轴的旋转中心距离为110至160mm。
2.根据权利要求1所述的超大功率五缸柱塞泵,其特征在于:所述减速箱总成的输入角度可以根据输入要求进行调整。
3.根据权利要求1所述的超大功率五缸柱塞泵,其特征在于:所述减速箱总成包括行星减速箱和平行级减速箱;所述平行级减速箱和行星级减速箱均为斜齿轮传动;所述行星减速箱包括一个太阳轮、四个行星齿轮和一个齿轮圈,四个行星齿轮组成行星齿轮机构,太阳轮位于行星齿轮机构中心,行星齿轮和相邻的太阳轮、齿轮圈处于常啮合状态;所述平行级减速箱包括小齿轮和大齿轮,小齿轮与输入端相连,大齿轮与行星减速箱太阳轮同轴,其传动比为6.5:1—15:1。
4.根据权利要求1所述的超大功率五缸柱塞泵,其特征在于:所述间隔架上设有拱形结构支撑柱。
5.根据权利要求1所述的超大功率五缸柱塞泵,其特征在于:所述十字头箱体内设有十字头机构,在曲轴箱体与十字头箱体内设有连杆机构,连杆机构一端与曲轴连接,连杆机构另一端与十字头机构连接,连杆机构包括连杆盖、连杆轴瓦和连杆体,连杆盖与连杆体通过螺栓连接,连杆轴瓦位于连杆盖与连杆体连接形成的圆柱形空间内,连杆轴瓦两侧为翻边结构,宽边结构宽径比大。
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