Top driving force system assembly method, top driving force system and permanent magnet direct drive top drive

Abstract

The invention discloses a top driving force system assembling method, a top driving force system and a permanent magnet direct drive top drive. According to the assembling method, the stator assembly and the rotor assembly are assembled into a whole. And directly connecting the integrally assembled permanent magnet motor with the transmission shaft. The top driving force system is assembled by the assembling method. The permanent magnet direct drive top drive comprises a lifting box body and the top drive force system. In the design of the integrated main motor, after the permanent magnet rotor and the stator are assembled into a whole, the permanent magnet rotor and the stator are assembled with the top drive main shaft through spline connection, and the problems that the stator and the rotor of the main motor are assembled separately, the permanent magnet rotor generates strong magnetic attraction force to the stator, and the main motor is difficult to mount and dismount are solved.

Description

Technical Field

[0001] The invention relates to the technical field of oil drilling equipment, in particular to a top driving force system assembly method, a top driving force system and a permanent magnet direct drive top drive. Background Art

[0002] As a commonly used drilling equipment in the oil industry, top drive can complete operations such as rotating the drill string, circulating drilling fluid, loading and unloading the drill pipe, tripping, and rotating while tripping. Since the 1980s, domestic and foreign manufacturers have developed a variety of top drives, which are divided into gearbox top drives and direct drive top drives according to the structural form, and electric top drives and hydraulic top drives according to the driving mode. Among them, the electric top drive can use a variable frequency AC main motor or a permanent magnet motor as the main power source. In recent years, permanent magnet motors have become more popular due to their advantages such as light weight, low energy consumption, simple structure, and low noise.

[0003] In the related art, when the permanent magnet motor is installed on the main shaft of the top drive, the stator and the rotor are assembled separately. During this process, because the rotor is a permanent magnet with strong magnetic attraction, it will seriously affect the installation of the permanent magnet motor stator and the replacement of the permanent magnet motor. Summary of the invention

[0004] The purpose of the present invention is to provide a top driving force system assembly method, a top driving force system and a permanent magnet direct drive top drive in response to the above-mentioned problems. The main motor can be assembled as a whole, which can solve the problem of difficult on-site installation and disassembly of the permanent magnet top drive main motor. At the same time, a permanent magnet top drive with a smaller appearance is provided, which makes the installation and disassembly of the permanent magnet top drive in the factory and on-site more convenient, saves assembly and maintenance time, and improves drilling efficiency.

[0005] The technical solution adopted by the present invention is as follows: A method for assembling a power system of a top drive, the power system comprising a permanent magnet motor and a transmission shaft, the permanent magnet motor comprising a stator assembly and a rotor assembly, the transmission shaft being capable of transmitting power to a drill pipe through the permanent magnet motor; The power system assembly method comprises: Assembling the stator assembly and the rotor assembly into one piece; The permanent magnet motor assembled into one piece is directly connected to the transmission shaft.

[0006] A top driving power system is assembled by the assembly method as described above.

[0007] The permanent magnet motor comprises a stator assembly, a rotor assembly, an upper bearing, a lower bearing, an upper end cover and a lower end cover. The stator assembly and the rotor assembly are assembled into one piece through the upper bearing, the lower bearing, the upper end cover and the lower end cover.

[0008] The rotor assembly is configured as a hollow shaft, the hollow shaft is provided with an internal spline, the transmission shaft is provided with an external spline, the internal spline and the external spline cooperate to connect the permanent magnet motor and the transmission shaft; Alternatively, the rotor assembly and the transmission shaft are connected via an expansion sleeve.

[0009] A permanent magnet direct drive top drive comprises a lifting box and the top drive force system as described above.

[0010] The permanent magnet motor is arranged in the lifting box; or, the permanent magnet motor is arranged above the lifting box, the upper part of the lifting box is connected to a balancing system, the bottom sides of the lifting box are provided with lifting ring tilting assemblies, and the middle part of the lifting box passes through the transmission shaft.

[0011] The permanent magnet motor is connected to the lifting box through the lower end cover.

[0012] A main bearing for supporting the transmission shaft is arranged in the middle of the lifting box.

[0013] An IBOP assembly is installed below the power system, and a backup clamp assembly is installed outside the power system.

[0014] A flushing pipe assembly is arranged above the main motor, and the flushing pipe assembly is connected with a gooseneck pipe assembly.

[0015] Pulley assemblies are arranged on both sides of the lifting box.

[0016] An encoder device is provided on the lifting box.

[0017] The lifting box is also provided with a machine hydraulic station.

[0018] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. A top drive power system assembly method and a top drive power system provided by the present invention, in an integrated main motor design, after the permanent magnet rotor and the stator are assembled as one, they are assembled with the top drive main shaft through a spline connection, thereby avoiding the problem of separate assembly of the stator and the rotor of the main motor, the strong magnetic attraction generated by the permanent magnet rotor on the stator, and the difficulty in installing and disassembling the main motor.

[0019] 2. The permanent magnet direct-drive top drive provided by the present invention has a lifting box outside the body to reduce the height of the top drive body. The lifting box is outside and placed downward, and the tilting mechanism is directly connected to the lifting box, which reduces the height space occupied by the rotating head and effectively reduces the height of the top drive body. It is suitable for more small-sized derricks. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1It is a direct drive top drive intention; Figure 2 It is a cross-sectional schematic diagram of a permanent magnet direct drive top driving force system; Figure 3 It is a schematic diagram of the cross section of the transmission shaft and the permanent magnet motor assembly shaft; Figure 4 is a cross-sectional schematic diagram of a permanent magnet motor; Among them, 1-back clamp assembly, 2-IBOP assembly, 3-lifting ring tilt assembly, 4-balancing system, 5-punch pipe assembly, 6-gooseneck assembly, 7-pulley assembly, 8-encoder device, 9-power system, 10-machine hydraulic station, 901-drive shaft, 902-lifting box, 903-main bearing, 904-permanent magnet motor, 9041-stator assembly, 9042-rotor assembly, 9043-lower bearing, 9044-upper bearing, 9045-lower end cover, 9046-upper end cover. DETAILED DESCRIPTION

[0021] The present invention will be described in detail below in conjunction with the accompanying drawings.

[0022] All features disclosed in this specification, or steps in all methods or processes disclosed, except mutually exclusive features and / or steps, can be combined in any manner.

[0023] Any feature disclosed in this specification, unless otherwise stated, can be replaced by other equivalent or alternative features with similar purposes. That is, unless otherwise stated, each feature is only an example of a series of equivalent or similar features.

[0024] Embodiment 1 A method for assembling a top driving power system 9, wherein the power system 9 includes a permanent magnet motor 904 and a transmission shaft 901, wherein the permanent magnet motor 904 includes a stator assembly 9041 and a rotor assembly 9042, and the transmission shaft 901 can be used to transmit power to a drill pipe through the permanent magnet motor 904; The power system 9 assembly method comprises: Assemble the stator assembly 9041 and the rotor assembly 9042 into one piece; The permanent magnet motor 904 assembled into one piece is directly connected to the transmission shaft 901 .

[0025] The permanent magnet motor 904 is the core power source of the top drive system. It uses permanent magnets as rotors, has high efficiency, and reduces energy loss. The motor can be designed to be more compact and save space. The permanent magnet motor 904 is directly connected to the transmission shaft 901 without the need for transmission devices such as gear boxes, which reduces transmission losses and maintenance costs. This solution allows the installation of the rotor and stator of the main motor to be carried out under controllable conditions. After being installed as a whole, it is connected to the lifting box 902, avoiding the assembly difficulties caused by the strong magnetic attraction of the rotor when the stator and rotor of the main motor are connected and assembled with the lifting box 902 respectively. In addition, there is no need to assemble the rotor and stator separately, which can save some professional installation tools for the main motor, greatly improve the efficiency of the factory installation and on-site replacement of the top drive, optimize the installation performance of the permanent magnet top drive, and save assembly costs. If the motor needs to be repaired or replaced, it can be disassembled as a unit due to the overall assembly, instead of handling the rotor and stator separately, which reduces the complexity of maintenance.

[0026] Embodiment 2 A top drive power system 9, the power system 9 is assembled by the above-mentioned assembly method. The integrated design of the permanent magnet motor 904 means that the rotor and stator of the permanent magnet motor 904 are first assembled as one, and can be installed as a whole in the top drive equipment, which simplifies the installation process, can greatly shorten the installation time, and improve the overall production efficiency; and when the permanent magnet motor 904 needs to be replaced, the entire motor module can be directly replaced without complicated on-site assembly work. The problem that when the permanent magnet motor 904 is assembled, its permanent magnet stator is easily attracted to the rotor by magnetism, making it difficult to assemble and replace on site is solved.

[0027] As another specific embodiment, the permanent magnet motor 904 includes a stator assembly 9041, a rotor assembly 9042, an upper bearing 9044, a lower bearing 9043, an upper end cover 9046 and a lower end cover 9045. The stator assembly 9041 and the rotor assembly 9042 are assembled as a whole through the upper bearing 9044, the lower bearing 9043, the upper end cover 9046 and the lower end cover 9045. The stator assembly 9041 constitutes the internal space structure of the permanent magnet motor 904, and provides a place for the rotor assembly 9042 to be installed and operated. The rotor assembly 9042 is located inside the stator assembly 9041, and the magnetic field is generated by the permanent magnet. It can rotate freely and is the core part of the motor to achieve energy conversion. The upper and lower end covers 9045 and the bearings are located at the upper and lower ends of the rotor assembly 9042, which are used to support the rotor assembly 9042 so that it can rotate stably. The lower bearing 9043 and the upper bearing 9044 of the motor ensure that after the main motor and the main shaft are assembled, the stator assembly 9041 and the rotor assembly 9042 can rotate relative to each other and can withstand the deadweight of the main motor and the impact load during drilling.

[0028] As another specific embodiment, the rotor assembly 9042 is configured as a hollow shaft, an internal spline is provided on the hollow shaft, and an external spline is provided on the transmission shaft 901. The internal spline and the external spline cooperate with each other to connect the permanent magnet motor 904 and the transmission shaft 901; the spline structure is easy to install, and has the advantages of high load-bearing capacity, good centering and guiding properties, and low stress concentration. It can not only transmit torque, but also provide axial and radial positioning to prevent relative movement of components during operation.

[0029] Alternatively, the rotor assembly 9042 and the transmission shaft 901 are connected via an expansion sleeve, which is easy to install and does not require keyway processing.

[0030] A permanent magnet direct drive top drive comprises a lifting box 902 and the top drive power system 9 as described above. The lifting box 902 is connected to the permanent magnet motor 904 as a supporting structure, and the operator can use the lifting ring on the lifting box 902 to lift the top drive to the top of the drilling rig or remove it from the top of the drilling rig through equipment such as a crane or a winch.

[0031] As another specific embodiment, the permanent magnet motor 904 is arranged in the lifting box 902; or, the permanent magnet motor 904 is arranged above the lifting box 902, the upper part of the lifting box 902 is connected to the balancing system 4, and the bottom sides of the lifting box 902 are provided with a lifting ring tilting assembly 3, and the middle part of the lifting box 902 passes through the transmission shaft 901.

[0032] In the existing method, the lifting box 902 is arranged above the motor, and the lifting ring tilting assembly 3 is connected to the bottom of the motor through a rotating head driven by a gear meshing mechanism. In this method, the motor lifting is installed in or above the lifting box 902, and the lifting box 902 can be directly connected to the lifting ring tilting assembly 3, eliminating the height of the rotating head, and the lifting ring tilting mechanism can share a part of the height with the lifting box 902, and some necessary parts previously assembled on the top of the main motor are arranged inside, reducing the height of the top drive body, and being suitable for more small-sized derricks. At the same time, the lifting box 902 can isolate impurities and reduce the probability of impurities entering the main motor. Among them, the balance system 4 has a lifting load shock-absorbing and buffering function to prevent damage to the thread when making and breaking the buckle, thereby increasing the service life of the transmission shaft 901 protection joint and the drilling tool, reducing losses and drilling costs. The lifting ring tilting assembly 3. The lifting ring tilting cylinder can push the lifting ring to complete the forward and backward tilting. The maximum forward tilting (the cylinder piston rod extends) can drive the elevator to the mouse hole or ramp to grab a single pipe or other pipes. The maximum backward tilting (the cylinder piston rod retracts) can lift the elevator off the drilling floor without affecting the downward movement of the top drive device.

[0033] As another specific implementation, the permanent magnet motor 904 is connected to the lifting box 902 via the lower end cover 9045. The permanent magnet motor 904 and the lifting box 902 can be connected as one by only assembling the motor lower end cover 9045 and the lifting box 902 once, without the need to assemble the rotor and the stator to the lifting box 902 separately.

[0034] As another specific embodiment, a main bearing 903 for supporting the transmission shaft 901 is provided in the middle of the lifting box 902. The transmission shaft 901 is allowed to rotate freely in the lifting box 902, and the stability of the transmission shaft 901 during rotation is ensured. An observation hole is provided on the lifting box 902, which is convenient for observing the lubrication and use of the main bearing 903. An IBOP assembly 2 is installed below the power system 9, and a back-up clamp assembly 1 is installed outside the power system 9. The IBOP assembly 2 integrates the function of a blowout preventer, which can close the wellhead in an emergency to prevent well slugging or blowout. The back-up clamp assembly 1 mainly completes the clamping operation of the pipe so that the top drive can perform operations such as putting on and unhooking, spinning, and removing the protective joint on the pipe.

[0035] As another specific embodiment, a flushing pipe assembly 5 is provided above the main motor, and the flushing pipe assembly 5 is connected to a gooseneck assembly 6. The flushing pipe assembly 5 is used to transport drilling fluid to the inside of the drill pipe during the drilling process to clean the inside of the drill pipe, prevent the sediment on the inner wall of the drill pipe from clogging the drill bit water hole, and help cool the drill bit and the drill pipe. The gooseneck is a curved pipe in the top drive system, which connects the top drive body and the drill pipe and is used to guide the drilling fluid from the top drive to the inside of the drill pipe. The design of the gooseneck allows the circulation of the drilling fluid to be maintained when the drill pipe is raised and lowered.

[0036] As another specific implementation, pulley assemblies 7 are provided on both sides of the lifting box 902. The pulley assemblies 7 are in contact and friction with the guide rails, connecting the derrick guide rails and the top drive, and are used to limit the top drive from moving along the guide rails, guide the up and down movement of the top drive, ensure that the top drive center is concentric with the wellhead center, and transmit the counter torque of the top drive driving the drill string to the guide rails.

[0037] As another specific embodiment, the lifting box 902 is provided with an encoder device 8, which can accurately monitor the rotation position of the drill string, measure the rotation speed of the top drive motor, and feed these data back to the control system to adjust the working parameters of the motor and maintain a constant drilling speed.

[0038] As another specific implementation, a machine hydraulic station 10 is also provided on the lifting box 902. The hydraulic station generates high-pressure hydraulic oil through an oil pump to provide power for various hydraulic actuators of the top drive system.

[0039] The present invention is not limited to the above-mentioned specific embodiments, but extends to any new features or any new combination disclosed in this specification, as well as any new method or process steps or any new combination disclosed.

Claims

1. A method for assembling a top driving force system, characterized in that: The power system (9) comprises a permanent magnet motor (904) and a transmission shaft (901); the permanent magnet motor (904) comprises a stator assembly (9041) and a rotor assembly (9042); the transmission shaft (901) can be used to transmit power to a drill pipe through the permanent magnet motor (904); The power system (9) assembly method comprises: Assembling the stator assembly (9041) and the rotor assembly (9042) into one piece; The permanent magnet motor (904) assembled into one piece is directly connected to the transmission shaft (901).

2. A top driving force system, characterized in that: The power system (9) is assembled by the assembly method described in claim 1.

3. The top driving force system according to claim 2, characterized in that: The permanent magnet motor (904) comprises a stator assembly (9041), a rotor assembly (9042), an upper bearing (9044), a lower bearing (9043), an upper end cover (9046) and a lower end cover (9045); the stator assembly (9041) and the rotor assembly (9042) are assembled into one piece via the upper bearing (9044), the lower bearing (9043), the upper end cover (9046) and the lower end cover (9045).

4. The top driving force system according to claim 3, characterized in that: The rotor assembly (9042) is configured as a hollow shaft, the hollow shaft is provided with an internal spline, the transmission shaft (901) is provided with an external spline, the internal spline and the external spline cooperate to connect the permanent magnet motor (904) and the transmission shaft (901); Alternatively, the rotor assembly (9042) and the transmission shaft (901) are connected via an expansion sleeve.

5. A permanent magnet direct drive top drive, comprising a lifting box (902) and a top drive force system (9) according to any one of claims 2 to 4.

6. The permanent magnet direct drive top drive according to claim 5, characterized in that: The permanent magnet motor (904) is arranged in the lifting box (902); or, the permanent magnet motor (904) is arranged above the lifting box (902), the upper part of the lifting box (902) is connected to a balancing system (4), the bottom sides of the lifting box (902) are provided with a lifting ring tilting assembly (3), and the middle part of the lifting box (902) passes through the transmission shaft (901).

7. The permanent magnet direct drive top drive according to claim 6, characterized in that: The permanent magnet motor (904) is connected to the lifting box (902) via a lower end cover (9045).

8. The permanent magnet direct drive top drive according to claim 5, characterized in that: A main bearing (903) for supporting the transmission shaft (901) is provided in the middle of the lifting box (902).

9. The permanent magnet direct drive top drive according to claim 6, characterized in that: An IBOP assembly (2) is mounted below the power system (9), and a back-up clamp assembly (1) is mounted outside the power system (9).

10. The permanent magnet direct drive top drive according to claim 6, characterized in that: A flushing pipe assembly (5) is provided above the main motor, and the flushing pipe assembly (5) is connected to a gooseneck pipe assembly (6); pulley assemblies (7) are provided on both sides of the lifting box (902); an encoder device (8) is provided on the lifting box (902); and a tool hydraulic station (10) is also provided on the lifting box (902).

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