CN210770133U - 一种整体式动力端结构的五缸柱塞泵 - Google Patents
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Abstract
本实用新型公开了提供一种整体式动力端结构的五缸柱塞泵，对五缸柱塞泵动力端总成中的曲轴箱体和十字头箱体采用整体焊接结构，使得动力端总成的结构强度更高，支撑稳定性更好，可减少整泵振动。缸间距为13‑14英寸，增大了连杆、十字头和轴瓦的承载面积，为五缸柱塞泵大功率的输出提供保障，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。11英寸的长冲程设计可更好地实现大排量的作业需求，提高作业效率。对曲轴箱体、十字头箱体和液力端总成的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。
Description
技术领域
本实用新型涉及柱塞泵技术领域，具体涉及一种整体式动力端结构的五缸柱塞泵。
背景技术
随着非常规油气、页岩油气的进一步开发，压裂作业对压力和排量的要求在不断提高，不仅作业压力随着水平井深度的增加在不断增大，而且单段井所需求的排量也越来越高，这就使得压裂施工规模越来越大，恶劣的作业工况也对压裂设备尤其是对柱塞泵提出了更高的要求。目前在页岩油气开发过程中，作业压力普遍达到80-90MPa甚至更高，单段作业排量也普遍在1800m3-2000m3甚至以上，柱塞泵不仅要能够满足高压力、大排量的持续作业，还要保证连续高负荷作业下的质量稳定性，减少停泵时间和检修时间。目前市场上应用最广的压裂车是2500型压裂车，配备2800hp柱塞泵，其他常用的压裂泵型有2500hp泵、3300hp泵、4000hp泵等，以2800hp泵为例，因功率限制，在高压力作业时的单泵排量较低，一个单段排量需求在14-16m3/min的页岩气井场，共需要接近20台的压裂车同时作业才能满足压裂作业总排量的要求，这就会占用很大的井场面积，增大了狭小的油气田井场设备布置的困难，此外，常规柱塞泵在面临越来越恶劣的作业工况，长时间处于高负荷作业，出现问题的频率也不断增大，增加了维护和检修的成本。近几年电驱压裂作业兴起，采用电机驱动也解决了柴油发动机功率受限的问题，更适合驱动大功率柱塞泵。
而随着柱塞泵功率的提升，对柱塞泵本身的运行稳定性也提出了更高的要求，尤其是柱塞泵的动力端结构的强度，支撑稳定性等要求更高。
实用新型内容
本实用新型的目的克服现有技术的不足，提供一种整体式动力端结构的五缸柱塞泵，对五缸柱塞泵动力端总成中的曲轴箱体和十字头箱体采用整体焊接结构，使得动力端总成的结构强度更高，支撑稳定性更好，可减少整泵振动。缸间距为13-14英寸，为五缸柱塞泵大功率的输出提供保障，具体的五缸柱塞泵的功率可以达到7000hp，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。11英寸的长冲程设计可更好地实现大排量的作业需求，提高作业效率。对曲轴箱体、十字头箱体和液力端总成的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。五缸柱塞泵采用行星级减速箱和平行级减速箱的二级减速有利于获得大的减速比，增大减速比可以降低输入扭矩，提高减速箱的使用寿命，更好地匹配发动机和电机选型；增大减速比还可以有效降低五缸柱塞泵的冲次，延长各零部件的使用寿命。
本实用新型是通过以下技术方案实现的：一种整体式动力端结构的五缸柱塞泵，包括动力端总成，液力端总成和减速箱总成，所述动力端总成的一端与液力端总成连接，所述动力端总成另一端与减速箱总成连接，所述动力端总成包括曲轴箱体，十字头箱体和间隔架，所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体，动力端壳体与间隔架连接，所述动力端壳体包括立板，轴承座，前端板，后盖板，底板，支撑板和上盖板，所述立板的数量为6个，轴承座的数量为6个，一个立板对应连接一个轴承座，6个立板平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板，在所述动力端腔体的顶部安装上盖板，在所述动力端腔体的前端安装前端板，在所述动力端腔体的后端安装后盖板，在相邻两个平行设置的立板之间设支撑板。
进一步地，所述曲轴箱体的底部设曲轴支撑体，所述曲轴支撑体用于支承曲轴箱体。
进一步地，所述十字头箱体的底部设十字头支撑体，所述十字头支撑体用于支承十字头箱体。
进一步地，所述间隔架的底部设液力支撑体，所述液力支撑体用于支承液力端总成。
进一步地，所述曲轴箱体内设有曲轴，所述曲轴采用合金钢整体锻造而成，所述曲轴包括六个轴颈和五个曲拐，在相邻两个轴颈之间设一个曲拐，所述五缸柱塞泵的缸间距为13-14英寸。
进一步地，在所述曲轴内设有花键，所述减速箱总成与曲轴花键连接。
进一步地，所述十字头箱体内设十字头总成，在曲轴箱体和十字头箱体之间设连杆总成，在曲轴箱体内设曲轴，连杆总成的一端通过连杆轴瓦与曲轴连接，连杆总成的另一端通过十字头轴瓦与十字头总成连接，连杆轴瓦和十字头轴瓦均为带合金镀层的钢背轴瓦。
进一步地，所述整体式动力端结构的五缸柱塞泵的冲程为11英寸。
进一步地，所述减速箱总成包括行星级减速箱和平行级减速箱，行星级减速箱的一端与动力端总成连接，行星级减速箱的另一端与平行级减速箱连接，通过行星级减速箱和平行级减速箱实现减速箱总成的二级减速，其减速比为8:1-15:1。
与现有技术相比，本实用新型的有益效果是：1、对五缸柱塞泵动力端总成中的曲轴箱体和十字头箱体采用整体焊接结构，使得动力端总成的结构强度更高，支撑稳定性更好，可减少整泵振动。2、缸间距为13-14英寸，增大了连杆、十字头和轴瓦的承载面积，为五缸柱塞泵大功率的输出提供保障，具体的五缸柱塞泵的功率可以达到7000hp，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。3、11英寸的长冲程设计可更好地实现大排量的作业需求，提高作业效率。4、对曲轴箱体、十字头箱体和液力端总成的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。5、五缸柱塞泵采用行星级减速箱和平行级减速箱的二级减速有利于获得大的减速比，增大减速比可以降低输入扭矩，提高减速箱的使用寿命，更好地匹配发动机和电机选型；增大减速比还可以有效降低五缸柱塞泵的冲次，延长各零部件的使用寿命。
下面结合附图和具体实施方式对本实用新型作详细说明。
附图说明
图1是五缸柱塞泵的结构示意图。
图2是动力端总成的结构示意图。
图3是动力端壳体的结构示意图。
图4是减速箱总成的结构示意图。
图5是行星级减速箱的剖视图。
图6是平行级减速箱的剖面图。
图7是曲轴的结构示意图。
图8是连杆总成与十字头总成连接的结构示意图。
其中，1.动力端总成，2.减速箱总成，3.液力端总成，4.驱动法兰，5.动力端壳体，6.曲轴，7.轴承，8.连杆轴瓦，9.连杆体，10.滑轨，11.十字头，12.十字头轴瓦，13.拉杆，14.间隔架，15.长螺杆，16.螺母，17.卡箍，18.柱塞，19.阀箱，20.曲轴支撑体，21.十字头支撑体，22.液力支撑体，23.后盖板，24.立板，25.轴承座，26.底板，27.支撑板，28.前端板，29.上盖板，30.平行级减速箱，31.行星级减速箱，32.内齿圈，33.行星轮，34.太阳轮，35.行星架，36.大齿轮，37.小齿轮，38.花键，39.连杆盖，40.连杆螺栓，41.十字头压盖，42.导板，43.螺钉。
具体实施方式
实施例，如图1至8所示，一种整体式动力端结构的五缸柱塞泵，包括动力端总成1，液力端总成3和减速箱总成2，所述动力端总成1的一端与液力端总成3连接，所述动力端总成1另一端与减速箱总成2连接，所述动力端总成1包括曲轴箱体，十字头箱体和间隔架14，所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体5，动力端壳体5与间隔架14连接，所述动力端壳体5包括立板24，轴承座25，前端板28，后盖板23，底板26，支撑板27和上盖板29，所述立板24的数量为6个，轴承座25的数量为6个，一个立板24对应连接一个轴承座25，6个立板24平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板26，在所述动力端腔体的顶部安装上盖板29，在所述动力端腔体的前端安装前端板28，在所述动力端腔体的后端安装后盖板23，在相邻两个平行设置的立板24之间设支撑板27。对五缸柱塞泵动力端总成1中的曲轴箱体和十字头箱体采用整体焊接结构，使得动力端总成1的结构强度更高，支撑稳定性更好，可有效减少动力端壳体5承载变形，可减少整泵振动，提高五缸柱塞泵运行稳定性。
所述曲轴箱体的底部设曲轴支撑体20，所述曲轴支撑体20用于支承曲轴箱体。所述十字头箱体的底部设十字头支撑体21，所述十字头支撑体21用于支承十字头箱体。所述间隔架14的底部设液力支撑体22，所述液力支撑体22用于支承液力端总成3。五缸柱塞泵采用多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。
所述曲轴箱体内设有曲轴6和轴承7，所述曲轴6采用合金钢整体锻造而成，所述曲轴6包括六个轴颈和五个曲拐，在相邻两个轴颈之间设一个曲拐，所述五缸柱塞泵的缸间距为13-14英寸。增大缸间距设计，有利于增大曲轴6与连杆轴瓦8、十字头11与滑轨10的接触面积，提高支撑强度。为五缸柱塞泵大功率的输出提供保障，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。轴承7有6个，6个轴承7安装在六个轴颈上，同时轴承7外圈装配在动力端壳体5的6个轴承座25上，可在轴承座25内实现回转运动。
在所述曲轴6内设有花键38，所述减速箱总成2通过螺栓与动力端壳体5连接，所述减速箱总成2上设有外花键，外花键与花键38连接，用于动力输出，减速箱总成2的安装角度可根据输入要求进行调整。减速箱总成2外设有驱动法兰4，通过驱动法兰4外接动力源，实现动力输入。
所述十字头箱体内设十字头总成，在曲轴箱体和十字头箱体之间设连杆总成，在曲轴箱体内设曲轴6，连杆总成的一端通过连杆轴瓦8与曲轴6连接，连杆总成的另一端通过十字头轴瓦12与十字头总成连接，可实现往复摆动，十字头总成的另一端与拉杆13连接。拉杆13为空心结构。连杆轴瓦8和十字头轴瓦12均为带合金镀层的钢背轴瓦。宽径比大、支撑强度高。
在动力端壳体5内的支撑板27上固定有滑轨10，滑轨10有2个，2个滑轨10形成半圆形空间，十字头11安装在半圆形空间内，可以实现往复直线运动。
十字头总成为分体式结构设计，包括十字头压盖41和十字头11，十字头压盖41和十字头11连接，便于同连杆总成的装配和拆卸。
连杆总成包括连杆盖39和连杆体9，连杆盖39和连杆体9采用整体式锻造后切割而成，强度高，连杆盖39和连杆体9通过螺栓进行连接，具体的，连杆体9的一端通过连杆盖39、连杆螺栓40和连杆轴瓦8与曲拐连接，连杆体9的另一端通过十字头压盖41和十字头轴瓦12与十字头11连接。在十字头11的上下两端通过螺钉43分别固定有导板42，导板42为铜合金材质，与滑轨10直接接触，进行相对运动。
曲轴6、连杆体9、十字头11上均设计有润滑油路，用于实现给轴承7、连杆轴瓦8、十字头轴瓦12的润滑。
液力端总成3包括阀箱19、柱塞18、卡箍17等，液力端总成3通过卡箍17将柱塞18和拉杆13连接在一起，并利用长螺杆15、螺母16将其固定在间隔架14上，长螺杆15通过螺纹连接在动力端壳体5上。
所述整体式动力端结构的五缸柱塞泵的冲程为11英寸。长冲程设计非常适合当前页岩气压裂拉链式作业需求，减少井场设备数量，提高作业效率和经济性。
所述减速箱总成2包括行星级减速箱31和平行级减速箱30，行星级减速箱31的一端与动力端总成1连接，行星级减速箱31的另一端与平行级减速箱30连接，通过行星级减速箱31和平行级减速箱30实现减速箱总成2的二级减速，其减速比为8:1-15:1。平行级减速箱30包括大齿轮36和小齿轮37，进行一级减速；行星级减速箱31由内齿圈32、四个行星轮33、太阳轮34、行星架35组成行星齿轮机构，进行二级减速。太阳轮34位于行星齿轮机构中心，与行星轮33啮合，并与平行级减速箱30的大齿轮36同轴。运行时，驱动法兰4外接动力源带动输入轴转动，经小齿轮37传递给大齿轮36实现一级减速，通过大齿轮36传递给太阳轮34，太阳轮34通过行星轮33带动行星架35实现二级减速，最终将动力通过花键38传递给曲轴6。通过二级变速可获得大传动比，有效地减低输入扭矩，降低泵的冲次。
工作原理：外部动力或转速通过驱动法兰4带动减速箱总成2转动，经二级变速将动力和扭矩通过花键38传递给曲轴6，曲轴6和轴承7在动力端壳体5内转动，带动连杆体9、十字头11、拉杆13运动，将曲轴6的旋转运动转变为拉杆13的往复直线运动，拉杆13通过卡箍17带动柱塞18在阀箱19内进行往复运动，从而实现低压液体的吸入和高压液体的排出，实现液体的泵送。
本行业的技术人员应该了解，本实用新型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实用新型的原理，在不脱离本实用新型精神和范围的前提下，本实用新型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实用新型范围内。本实用新型要求保护范围由所附的权利要求书及其等效物界定。
Claims (9)
1.一种整体式动力端结构的五缸柱塞泵，包括动力端总成，液力端总成和减速箱总成，所述动力端总成的一端与液力端总成连接，所述动力端总成另一端与减速箱总成连接，其特征在于：所述动力端总成包括曲轴箱体，十字头箱体和间隔架，所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体，动力端壳体与间隔架连接，所述动力端壳体包括立板，轴承座，前端板，后盖板，底板，支撑板和上盖板，所述立板的数量为6个，轴承座的数量为6个，一个立板对应连接一个轴承座，6个立板平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板，在所述动力端腔体的顶部安装上盖板，在所述动力端腔体的前端安装前端板，在所述动力端腔体的后端安装后盖板，在相邻两个平行设置的立板之间设支撑板。
2.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述曲轴箱体的底部设曲轴支撑体，所述曲轴支撑体用于支承曲轴箱体。
3.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述十字头箱体的底部设十字头支撑体，所述十字头支撑体用于支承十字头箱体。
4.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述间隔架的底部设液力支撑体，所述液力支撑体用于支承液力端总成。
5.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述曲轴箱体内设有曲轴，所述曲轴采用合金钢整体锻造而成，所述曲轴包括六个轴颈和五个曲拐，在相邻两个轴颈之间设一个曲拐，所述五缸柱塞泵的缸间距为13-14英寸。
6.根据权利要求5所述的整体式动力端结构的五缸柱塞泵，其特征在于：在所述曲轴内设有花键，所述减速箱总成与曲轴花键连接。
7.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述十字头箱体内设十字头总成，在曲轴箱体和十字头箱体之间设连杆总成，在曲轴箱体内设曲轴，连杆总成的一端通过连杆轴瓦与曲轴连接，连杆总成的另一端通过十字头轴瓦与十字头总成连接，连杆轴瓦和十字头轴瓦均为带合金镀层的钢背轴瓦。
8.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述整体式动力端结构的五缸柱塞泵的冲程为11英寸。
9.根据权利要求1所述的整体式动力端结构的五缸柱塞泵，其特征在于：所述减速箱总成包括行星级减速箱和平行级减速箱，行星级减速箱的一端与动力端总成连接，行星级减速箱的另一端与平行级减速箱连接，通过行星级减速箱和平行级减速箱实现减速箱总成的二级减速，其减速比为8:1-15:1。
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