A composite natural gas compressor host no-load operation test device

Abstract

The present invention discloses a composite natural gas compressor main engine no-load mechanical operation test device, comprising a base, a main engine system, a transmission system, a drive system, a lubrication system, and an electronic control system. The main engine sub-base is divided into multiple specifications according to the machine model and is used to install different types of units. The drive device sub-base is divided into multiple specifications and is used to install different types of drive devices. The transmission system is used to connect the drive device to the corresponding main engine shaft to be tested. The lubrication system is used to provide lubricating oil to the main engine to be tested. The electronic control system is used to control the main engine system, the drive system, and the lubrication system respectively. The present invention can carry out no-load mechanical operation tests on large, medium, and small natural gas compressor main engines, and can verify the lubrication effect of the compressor main engine lubrication system and the movement of each friction pair of the motion system, thereby verifying the mechanical performance of the compressor main engine.

Description

Technical Field

[0001] The present invention relates to the technical field of natural gas compressors, and in particular to a no-load mechanical operation test device for a composite natural gas compressor host. Background Art

[0002] The natural gas compressor main unit is the core assembly of the compressor unit. Its main function is to compress gas. The compressor main unit mainly includes the body, moving parts, mid-body, cylinder and lubrication parts. API618 requires that the compressor main unit should undergo a 4-hour no-load mechanical operation test to verify the performance of the compressor main unit. When the manufacturer conducts the no-load operation test of the compressor main unit, it is necessary to comprehensively consider the ability of the test equipment to be suitable for conducting compressor main unit tests of various models. The no-load mechanical operation test mainly includes three parts: flushing, dry running, and dry running with cylinders. It can verify the lubrication effect of the compressor main unit lubrication system and the movement of each friction pair of the motion system, thereby verifying the mechanical performance of the main unit. Therefore, it is necessary to design a no-load mechanical operation test device that can adapt to various specifications of main units. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a composite natural gas compressor host no-load mechanical operation test device capable of realizing no-load mechanical operation tests of multiple compressor hosts in response to the deficiencies in the above-mentioned prior art.

[0004] The technical solution adopted by the present invention is: a composite natural gas compressor host no-load mechanical operation test device, including a base, a host system, a transmission system, a drive system, a lubrication system and an electronic control system, characterized in that: the host system includes a host sub-base mounted on the base and a host to be tested mounted on the host sub-base, the host sub-base is divided into multiple specifications according to the machine model, and is used to install different types of units, the drive system includes a drive device sub-base and a drive device mounted on the drive sub-base, the drive device sub-base is divided into multiple specifications, and is used to install different types of drive devices, the transmission system is used to connect the drive device with the corresponding host shaft to be tested, the lubrication system is used to provide lubricating oil to the host to be tested, and the electronic control system is used to control the host system, drive system, and lubrication system respectively.

[0005] According to the above technical solution, the transmission system includes a main shaft connecting member connected to the main shaft to be tested, a flywheel connected to the main shaft connecting member, a flexible long shaft connector connected to the flywheel, and a motor shaft connecting member connected to the other end of the flexible long shaft connector, and the motor shaft connecting member is connected to the test motor shaft.

[0006] According to the above technical solution, the flexible long axis connector includes a connecting shaft, half of a cross-axis universal joint structure symmetrically arranged at both ends of the connecting shaft, and a connecting disk, one end of the connecting disk is a disk-shaped structure for connecting to other parts, and the other end is half of the cross-axis universal joint structure, which together with the other half of the cross-axis universal joint structure of the connecting shaft form a complete cross-axis universal joint structure.

[0007] According to the above technical solution, the main shaft connecting part includes a sleeve and a connecting disk connected to the sleeve. The sleeve is used to fit the main shaft to be tested. The two are connected by a key. The connecting disk is arranged vertically to the sleeve, and the sleeve is connected to the flywheel.

[0008] According to the above technical solution, the motor shaft connector includes a motor sleeve and a connecting disk connected to the motor sleeve, the connecting disk is connected to the other end of the flexible long shaft connector, and the motor sleeve is interference fit with the motor shaft.

[0009] According to the above technical solution, the base is connected to the foundation through anchor bolts, and the base is installed on the foundation through an inclined base adjustment pad. The lower end of the anchor bolt is connected to the foundation through a grouting structure, and the upper end is connected to the locking nut in the base connection hole. The base connection hole is a stepped hole with a larger aperture at the top and a smaller aperture at the bottom. A spherical adjustment pad is provided at the step of the stepped hole. The spherical adjustment pad is mounted on the anchor bolt, and its upper end is pressed into the stepped hole through a locking nut.

[0010] According to the above technical solution, the base adjustment pad includes two adjustment blocks with inclined surfaces and an adjustment screw. The two adjustment blocks are matched through the inclined surfaces, and the adjustment screw is threadedly connected to one of the adjustment blocks through a thread.

[0011] According to the above technical solution, the spherical adjustment pad includes a spherical pad, a spherical bolt that cooperates with the lower end of the spherical pad through a spherical surface, a round nut that is threadedly connected to the lower part of the spherical bolt, and a positioning sleeve installed in the positioning hole of the spherical bolt, and the spherical pad is sleeved on the upper end of the positioning sleeve.

[0012] According to the above technical solution, the lubrication system is connected to the filter skid and the host to be tested through pre-buried pipelines. The lubrication system includes an oil tank, multiple oil pumps and a control valve assembly. Oil collecting tanks are set around the cover plate to collect waste oil.

[0013] According to the above technical solution, the electronic control system includes a PLC controller, a frequency converter and a control console. The main engine operation stage test procedures of "flushing", "empty running-in" and "empty running-in with cylinder" can be displayed on the console. The three stages of the test can be automatically or manually controlled at the console. The electronic control system can automatically refuel, replenish oil, drain oil and control the speed of each level and the test stage.

[0014] The beneficial effects achieved by the present invention are:

[0015] 1. The present invention can carry out no-load operation tests on large, medium and small natural gas compressor hosts, verify the lubrication effect of the compressor host lubrication system and the movement conditions of each friction pair of the motion system, and thus verify the mechanical performance of the compressor host.

[0016] 2. The transmission system is equipped with a flexible long-axis connector, which can be used to solve the problems of inconsistent center height and axial size deviation between the host and the driver, so as to achieve rapid connection and alignment of various types of hosts during host testing, and has strong applicability.

[0017] 3. By setting up adaptive floating anchor bolts, the combination of the spherical adjustment pad and the base adjustment inclined pad can eliminate the gap between the base and the foundation, ensuring the level of the base, easy adjustment and strong applicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A schematic diagram of the structure provided by an embodiment of the present invention.

[0019] Figure 2 This is a diagram of the host test placement of various models provided in the embodiments of the present invention.

[0020] Figure 3 A schematic structural diagram of an adaptive floating anchor bolt provided in an embodiment of the present invention.

[0021] Figure 4 This is a structural diagram of a base adjustment pad provided in an embodiment of the present invention.

[0022] Figure 5 This is a schematic structural diagram of a spherical adjustment pad provided by an embodiment of the present invention.

[0023] Figure 6 A structural diagram of a flexible transmission device provided in an embodiment of the present invention.

[0024] Figure 7 Schematic diagram of the structure of the flexible long axis connector in an embodiment of the present invention. DETAILED DESCRIPTION

[0025] The present invention will be further described below with reference to the accompanying drawings.

[0026] like Figure 1 、 2As shown, this embodiment provides a composite natural gas compressor host no-load operation test device, including a base 2, a host system, a transmission system 4, a drive system, a lubrication system and an electronic control system. The host system includes a host sub-base 3 mounted on the base 2 and a host to be tested mounted on the host sub-base. The host sub-base is divided into multiple specifications according to the machine model and is used to install different types of units. The drive system includes a drive device sub-base 5 and a drive device 6 mounted on the drive sub-base. The drive device sub-base 5 is divided into multiple specifications and is used to install different types of drive devices 6. The transmission system is used to connect the drive device 6 to the corresponding host shaft to be tested. The lubrication system is used to provide lubricating oil to the host to be tested. The electronic control system is used to control the host system, the drive system, and the lubrication system respectively.

[0027] The foundation 1 of the device is a reinforced concrete structure, with electrical wires, lubricating oil lines, and oil drainage pipelines pre-buried in the foundation. The foundation bearing capacity can reach 60T.

[0028] A casting base 2 with longitudinal and transverse T-slots is installed on the foundation, and the base is fixed with special self-adaptive floating anchor bolts 14 filled with concrete slurry. Figure 3 、 4 As shown in Figure 5, the base 1 is installed on the foundation 2 through the base adjustment pad 15, the lower end of the anchor bolt 4 is connected to the foundation 2 through the grouting structure 11, and the upper end is connected to the locking nut 12 in the base connection hole.

[0029] In this embodiment, the lower end of the anchor bolt is connected to the foundation 2 through the grouting structure 11, and the upper end is connected to the locking nut in the base connection hole.

[0030] In this embodiment, the base connection hole is a stepped hole with a larger diameter at the top and a smaller diameter at the bottom. A spherical adjustment pad 13 is provided at the step of the stepped hole. The spherical adjustment pad 13 is mounted on the anchor bolt 14, and its upper end is pressed into the stepped hole through the locking nut 2.

[0031] In this embodiment, Figure 4 As shown, the base adjustment pad 15 includes two adjustment blocks 1501 and 1502 with inclined surfaces and an adjusting screw 1503. The two adjustment blocks 1501 and 1502 are matched through the inclined surfaces, and the adjusting screw 1503 is threadedly connected to the upper adjustment block 1502 through a thread. The adjusting screw is screwed in or out to push the adjustment block 1502 to move forward and backward, thereby adjusting the contact between the two inclined iron inclined surfaces, and then adjusting the height of the inclined pad iron.

[0032] In this embodiment, Figure 5As shown, the spherical adjustment pad includes a spherical pad 1301, a spherical bolt 1302 that spherically engages with the lower end of the spherical pad 1301, a round nut 1303 that is threadedly connected to the lower surface of the spherical bolt 1302, and a positioning sleeve 1304 that fits within the positioning hole of the spherical bolt 1302. The spherical pad 1301 is fitted over the upper end of the positioning sleeve 1304. The upper end of the spherical pad 1301 is a flat structure used to support other workpieces to be supported and adjusted, while the lower end is a spherical structure that spherically engages with the spherical bolt 1302. The upper end of the spherical bolt 1302 is a spherical structure that spherically engages with the spherical pad 1301. The lower outer surface of the spherical bolt 1302 is threaded and connected to the round nut 1303. Four groups of adjustment blind holes are evenly distributed on the outer circular surface of the spherical bolt 1302. The spherical bolt 1302 can be rotated by inserting a crowbar or the like into the blind holes to realize the lifting and lowering of the spherical bolt 1302; the upper and lower parts of the round nut 1303 are both planar structures, the lower part contacts the foundation or other workpieces, and the upper part may directly contact the spherical bolt 1302. The inner hole of the round nut 1303 is provided with a thread, which is connected to the spherical bolt 1302 through a threaded connection. Adjustment blind holes 1307 are provided on the outer circular surface of the round nut 1303, which have the same function as the blind holes of the spherical bolt 1302; the positioning sleeve 1304 is in direct contact with the spherical pad 1301 and the spherical bolt 1302. The positioning sleeve 1304 has a micro-interference fit with the spherical pad 1301 and a clearance fit with the spherical bolt 1302. The positioning hole is a stepped hole with a smaller inner diameter at the top and a larger inner diameter at the bottom, and a radial flange is provided at the lower end of the positioning sleeve 1304. The radial flange on the lower outer surface of positioning sleeve 1304 fits within annular groove 1306 in the corresponding stepped hole within spherical bolt 1302. This prevents spherical pad 1301 from separating from spherical bolt 1302 when the spherical adjustment pad is not in use, potentially leading to loss of spherical pad 1301. During pre-installation, the length of the engaged threads of spherical bolt 1302 and round nut 1303 is adjusted by adjusting the blind adjustment holes in the spherical bolt 1302 and round nut 1303 to achieve adjustment within the height range H1-H2. The spherical contact areas of spherical pad 1301 and spherical bolt 1302 enable adaptive leveling, thereby achieving automatic adjustment within a certain range.

[0033] Adjustment is divided into two parts: 1) According to Figure 1 After the base is in place, adjust the inclined shims to make the base level, insert the anchor bolts, and inject grout; 2) After the base has been used for a period of time, if the base becomes deflected due to reasons such as foundation sinking, the spherical adjustment structure of the spherical adjustment pad will come into play. The upper concave spherical surface and the lower convex spherical surface will adaptively find the level, and the plane on the spherical adjustment pad can always be kept absolutely level. That is, the spherical structure eliminates errors such as foundation sinking, so that the base always remains level.

[0034] The main engine sub-base 3 is a welded assembly of I-beams and other profiles. It is divided into three specifications: large, medium and small according to the machine model. Each specification of the main engine sub-base is a composite structure. For example, the innermost main engine sub-base indicated by serial number 3 in the legend is the main engine sub-base of a large machine. This type of unit has two-row, four-row, six-row and other structures, and the sizes of the positioning bolts of each structure are different. Taking into account the fixing methods of various models, the main engine sub-base can realize the installation and fixation of all large, medium and small main engines. Each main engine sub-base is provided with an oil collection tank to facilitate the centralized collection and treatment of waste lubricating oil from the main engine.

[0035] The transmission system has a certain degree of flexible adjustment function, which can adapt to various structural forms of crankshaft heads and main engine center heights, that is, different types of units can be installed in place at one time without repeated adjustment and alignment. Figure 5 、 6 As shown, it includes a main engine shaft connector 17 for connecting to the main engine shaft 16 to be tested, a flywheel 18 connected to the main engine shaft connector, a flexible long shaft connector 19 connected to the flywheel, and a motor shaft connector 20 connected to the other end of the flexible long shaft connector. The motor shaft connector 20 is connected to the test motor shaft 21. This flexible long shaft connector can achieve self-adjustment of the transmission system to within 3° of main engine and motor misalignment, thus ensuring that all center height models can be accurately positioned in one go, eliminating the need to repeatedly adjust the main engine or motor height by adding or removing shims to achieve the required alignment (using conventional couplings, the main engine and motor alignment requirements are 0.05mm, approximately 0.4°).

[0036] In this embodiment, the main shaft connector 17 includes a sleeve and a connecting disk connected to the sleeve. The sleeve is used to fit the main shaft to be tested. The two are connected by a key. The connecting disk is perpendicular to the sleeve, and the sleeve is connected to the flywheel. Specifically, the inner hole size of the sleeve is slightly larger than the outer diameter of the main shaft to be wrapped, which facilitates the assembly of the sleeve on the main shaft. The sleeve and the main shaft are connected by a straight shaft with a key. Two sets of clamping bolts are used to clamp the key to provide a certain radial force. While eliminating the slight gap between the main shaft and the sleeve, the radial force and the clamping force generate friction to work, so that the sleeve drives the main shaft to rotate. The connecting disk is provided with multiple sets of hole positions. By selecting different hole positions and using two sets of bolts to connect the sleeve and different types of flywheels, a variety of flywheels can be quickly replaced.

[0037] The flywheel 18 comprises a flywheel body, which is provided with a plurality of bolt mounting holes and is connected to the main shaft connector 17 and the flexible long shaft connector 19 via a bolt group.

[0038] The flexible long-axis connector features a cross-axis integral fork universal joint structure, enabling radial adaptive adjustment. It includes a connecting disc 1901, a connecting shaft 1902, a connecting shaft 1903, and a connecting disc 1904. One end of connecting disc 1901 is a disc-shaped structure with bolt holes, allowing bolted connection to other parts. The other end forms one half of a cross-axis universal joint structure, which, together with the other half of the cross-axis universal joint structure of connecting shaft 1902, forms a complete cross-axis universal joint structure. One end of connecting shaft 1902, also forms one half of a cross-axis universal joint structure, which, together with the other half of the cross-axis universal joint structure of connecting disc 1901, forms a complete cross-axis universal joint structure. One end of connecting shaft 1902, also forms one half of a cross-axis universal joint structure, which, together with the other half of the cross-axis universal joint structure of connecting disc 1901, forms a complete cross-axis universal joint structure. The right portion of connecting shaft 1903 can be inserted into the left portion of connecting shaft 402, and the axial dimension of the device can be adjusted by adjusting the length of the inserted portion. Positioning devices are provided at the outer and inner stop points to prevent connecting shafts 1902 and 1903 from disengaging. The structures of the connecting shaft 1903 and the connecting disk 1904 are similar to those of the connecting shaft 1902 and the connecting disk 1901. The two sets of cross-axis universal joint structures can realize radial adaptive adjustment of the device.

[0039] The motor shaft connector 20 includes a motor shaft sleeve and a connecting disk connected to the motor shaft sleeve, the connecting disk is connected to the other end of the flexible long shaft connector, and the motor shaft sleeve is interference fit with the motor shaft 21.

[0040] In this embodiment, the driving system is mainly a motor, which provides power for the device and frequency conversion control; the driving device sub-base 5 is a motor sub-base 5, which has a structure similar to the main machine sub-base 2 and is used to fix the test motor.

[0041] The lubrication system provides lubricating oil to the test equipment. This circulating oil circuit requires only regular replenishment based on the liquid level indicator. The lubrication station is connected to the filter skid and the compressor unit under test via pre-buried piping. The lubrication station's main components include an oil tank (including a liquid level indicator, drain and inspection ports), a cover plate, multiple oil pumps, and valves. Oil collection troughs are located around the cover plate to collect waste oil. This lubrication station can accommodate tests for various lubrication-type units.

[0042] The main function of the filter skid 9 is to filter the circulating lubricating oil, a secondary filtration, and mainly includes filters, valves, pipelines, etc. The lubrication system is also equipped with a cooling system 10, whose main function is to cool the lubricating oil. The cooling system can be opened and closed according to actual needs (in winter when the temperature is low, the lubricating oil can enter the test system directly without cooling), and mainly includes a cooler, valves and pipelines.

[0043] The electronic control system is the control part of the entire device. The control functions such as the start and stop of the device, the frequency regulation of each motor, the selection and revision of the test stage, etc. are all realized here. It mainly includes a PLC controller, a frequency converter and a control console. The main engine operation stage test procedures of "flushing", "empty running-in", and "empty running-in with cylinder" can be displayed on the console. The three stages of the test can be automatically or manually controlled at the console. The electronic control system can automatically refuel, replenish oil, drain oil, and control the speed of each level and the test stage.

[0044] After the test unit is assembled, it is positioned on the main engine sub-base 3, where the main engine and sub-base 3 are bolted together. Bolts are also used to connect the main engine (with a sleeve mounted on the main engine crankshaft head) and the transmission system 4. The test device is activated on the console 8, and the test program is entered. Click "Start" to enter the automatic test program, or the three phases of the compressor main engine no-load operation test can be carried out in stages: "Flushing," "Run-in," and "Run-in with Cylinders." The system automatically controls oil filling, replenishing, draining, and various speed and test phases, achieving fully automatic operation. During the test, the console displays key parameters such as motor frequency, speed, current, voltage, oil temperature, and oil pressure. External equipment can also be used to monitor parameters such as shaft power, noise, vibration, and the temperature of the unit components under test.

Claims

1. A composite natural gas compressor main engine no-load mechanical operation test device, comprising a base, a main engine system, a transmission system, a drive system, a lubrication system, and an electronic control system, characterized in that: The host system includes a host sub-base mounted on the base and a host to be tested mounted on the host sub-base. The host sub-base is divided into multiple specifications according to the machine model and is used to install different types of units. The drive system includes a drive device sub-base and a drive device mounted on the drive sub-base. The drive device sub-base is divided into multiple specifications and is used to install different types of drive devices. The transmission system is used to connect the drive device to the corresponding host shaft to be tested. The lubrication system is used to provide lubricating oil to the host to be tested. The electronic control system is used to control the host system, the drive system, and the lubrication system respectively; the transmission system includes a host shaft connector connected to the host shaft to be tested, a flywheel connected to the host shaft connector, a flexible long shaft connector connected to the flywheel, and a motor shaft connector connected to the other end of the flexible long shaft connector. The motor shaft connector is connected to the test motor shaft The spherical adjustment pad includes a spherical pad, a spherical bolt that cooperates with the lower end of the spherical pad through a spherical surface, and a round nut that is threadably connected to the lower end of the spherical bolt.

2. The no-load mechanical operation test device for a composite natural gas compressor main engine according to claim 1, characterized in that: The flexible long axis connector includes a connecting shaft, half of a cross-axis universal joint structure symmetrically arranged at both ends of the connecting shaft, and a connecting disk. One end of the connecting disk is a disk-shaped structure for connecting to other parts, and the other end is half of the cross-axis universal joint structure. It and the other half of the cross-axis universal joint structure of the connecting shaft form a complete cross-axis universal joint structure.

3. The no-load mechanical operation test device for a composite natural gas compressor main engine according to claim 1 or 2, characterized in that: The main engine shaft connecting piece includes a shaft sleeve and a connecting disk connected to the shaft sleeve. The shaft sleeve is used to fit the main engine shaft to be tested. The two are connected by a key. The connecting disk is vertically arranged to the shaft sleeve, and the shaft sleeve is connected to the flywheel.

4. The no-load mechanical operation test device for a composite natural gas compressor main engine according to claim 1 or 2, characterized in that: The motor shaft connector includes a motor shaft sleeve and a connecting disk connected to the motor shaft sleeve, the connecting disk is connected to the other end of the flexible long shaft connector, and the motor shaft sleeve is interference fit with the motor shaft.

5. The no-load mechanical operation test device for a composite natural gas compressor main engine according to claim 1 is characterized in that: The lubrication system is connected to the filter skid and the host to be tested through pre-buried pipelines. The lubrication system includes an oil tank, multiple oil pumps and control valve components. Oil collecting tanks are set around the cover to collect waste oil.

6. The no-load mechanical operation test device for a composite natural gas compressor main engine according to claim 1, characterized in that: The electronic control system includes a PLC controller, a frequency converter and a control console. The console can display the main engine operation stage test procedures of "flushing", "run-in" and "run-in with cylinder". The three stages of the test can be automatically or manually controlled at the console. The electronic control system can automatically add oil, add oil, drain oil and control the speed of each level and test stage.

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