A horizontal heat dissipation system for a fracturing truck

Abstract

The present invention relates to the technical field of fracturing equipment, and particularly to a horizontal heat dissipation system for a fracturing truck, which includes a radiator unit, a cooling fan, a detection unit, an analysis unit and a control unit; the radiator unit is divided into two layers of cooling modules, the detection unit is used to detect the circulating temperature, the number of operations and the output displacement, the analysis unit is used to judge the distribution of the cooling modules that need heat dissipation according to the number of operations, calculate the maximum temperature difference according to the weight and the scoring coefficient to adjust the actual speed of the cooling fan, adjust the heat dissipation area according to the temperature difference judgment result, and determine the cooling degree and heat dissipation margin of each cooling module. The control unit adjusts the actual speed and the initial minimum speed of the cooling fan, and controls the working state of the thermostat and the opening and closing of the fixed switch; the present invention increases the flexibility and adaptability of heat dissipation for the fracturing truck by adaptively adjusting the heat dissipation area of the heat dissipation system.

Description

Technical Field

[0001] The present invention relates to the technical field of fracturing equipment, and particularly to a horizontal heat dissipation system for a fracturing truck. Background Art

[0002] Hydraulic fracturing trucks can, according to working conditions, adopt the means of power confluence of multiple engines to replace the traditional gearbox and transmission shaft, and flexibly adapt to the fracturing operation requirements of high pressure and large displacement. Due to the harsh working environment of hydraulic fracturing trucks and the changeable fracturing conditions, there often occurs the phenomenon that the fracturing truck needs to stop due to excessive oil temperature, which seriously affects the reliability and service life of the fracturing truck, thereby reducing the production efficiency of shale gas and gradually losing market vitality.

[0003] Chinese Patent Publication No.: CN108644001A discloses an intelligent heat dissipation system driven by a hydraulic motor and its heat dissipation method. The system includes a composite radiator, a radiator tail frame and a hydraulic system; the method includes the following steps: (1) respectively setting the response relationships between the fan speed and the gearbox oil temperature signal and the engine coolant temperature signal; (2) collecting the gearbox oil temperature signal and the engine coolant temperature signal in real time; (3) when both the gearbox oil temperature and the engine coolant temperature are less than the set opening value, the fan rotates at the initial speed n; when one of the gearbox oil temperature and the engine coolant temperature exceeds the set opening value, the fan rotates at the fan speed corresponding to the temperature parameter exceeding the set opening value; when both the gearbox oil temperature and the engine coolant temperature exceed the set opening value, comparing the magnitudes of the fan speeds corresponding to the two temperature parameters, and the fan rotates at the larger fan speed. Thus, the intelligent heat dissipation system driven by the hydraulic motor and its heat dissipation method have the following problems:

[0004] The method for adjusting the fan speed has poor accuracy, and there is a large difference in the cooling degree of the devices when dissipating heat from the internal devices of the fracturing truck. Summary of the Invention

[0005] Therefore, the present invention provides a horizontal heat dissipation system for a fracturing truck to overcome the problems in the prior art that the method for adjusting the fan speed has poor accuracy and there is a large difference in the cooling degree of the devices when dissipating heat from the internal devices of the fracturing truck.

[0006] To achieve the above object, the present invention provides a horizontal heat dissipation system for a fracturing truck, including:

[0007] A radiator unit, which is divided into two layers. The first layer of the radiator unit includes an engine fuel cooling module, a hydraulic oil cooling module, a pressure pump power end cooling module and a gearbox cooling module; the second layer of the radiator unit includes an engine cylinder water cooling module and an engine intercooler cooling module;

[0008] A cooling fan that blows cooling air into the radiator unit by rotation, and the cooling fan is connected to a hydraulic motor;

[0009] A detection unit, which is connected to the analysis unit, includes a temperature sensor, a displacement sensor, and a counter, and is used to detect the circulating temperature of the cooling medium, the number of thermostats working, and the output displacement of the fracturing truck, and transmit the data to the analysis unit;

[0010] An analysis unit, which is connected to the control unit. In the analysis unit, there are weights of each cooling module, temperature difference evaluation values, working temperature ranges of the thermostats, and scoring coefficients. The scoring coefficients include a first scoring standard coefficient for the first layer of the radiator unit and a second scoring standard coefficient for the second layer of the radiator unit;

[0011] The analysis unit is used to adjust the working state of the thermostat according to the working temperature range of the thermostat and the circulating temperature of the cooling medium, judge the distribution of the cooling modules that need to dissipate heat according to the number of thermostats working, calculate the maximum temperature difference according to the temperature difference between the circulating temperature and the corresponding minimum temperature value, the weight, and the scoring coefficient, adjust the actual rotation speed of the cooling fan according to the maximum temperature difference, adjust the heat dissipation area according to the temperature difference judgment result, and determine the cooling degree and heat dissipation margin of each cooling module;

[0012] A control unit, which is used to adjust the actual rotation speed and the initial minimum rotation speed of the cooling fan according to the instructions of the analysis module, and control the working state of the thermostat and the opening and closing of the fixed switch.

[0013] Furthermore, the engine fuel cooling module, the hydraulic oil cooling module, the pressure pump power end cooling module, and the transmission case cooling module in the first layer of the radiator unit are arranged in parallel at the bottom layer of the radiator unit;

[0014] The engine cylinder water cooling module and the engine intercooler cooling module in the second layer of the radiator unit are arranged in parallel at the upper layer of the radiator unit;

[0015] The cooling fan and the hydraulic motor are arranged at the bottom of the radiator unit;

[0016] There is a heat dissipation pipeline loop inside the cooling module. The pipeline loop inside the engine fuel cooling module is connected to the pipeline loop inside the hydraulic oil cooling module; the pipeline loop inside the pressure pump power end cooling module is connected to the pipeline loop inside the transmission case cooling module;

[0017] At the connection of the pipeline loop, there is a telescopic section that can move telescopically and a telescopic spring fixed on the pipeline wall. The telescopic section is connected to the telescopic spring, and a fixed switch is arranged inside the telescopic section. The fixed switch can fix the telescopic end at the initial position.

[0018] Further, the detection unit detects the circulating temperature of the cooling medium circulating in the pipeline loop of the cooling module.

[0019] If the circulating temperature exceeds the operating temperature range of the thermostat, the analysis unit determines that the circulating temperature of the cooling medium in the corresponding module loop exceeds the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the first operating state.

[0020] If the circulating temperature does not exceed the operating temperature range of the thermostat, the analysis unit determines that the circulating temperature of the cooling medium in the corresponding module loop does not exceed the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the second operating state.

[0021] Wherein, the cooling medium includes fuel oil, lubricating oil, hydraulic oil and cooling water.

[0022] Further, when any thermostat is in the second operating state, the thermostat is closed, and the cooling medium of the cooling module corresponding to the first layer of the radiator unit does not flow into the radiator unit, and the cooling medium circulates in the corresponding device and the pipeline loop; the cooling medium in the corresponding cooling module of the second layer of the radiator unit circulates in the radiator unit through the bypass pipeline, and the analysis unit determines the cooling degree of each cooling module.

[0023] When any thermostat is in the first operating state, the thermostat is opened, the cooling medium of the cooling module corresponding to the thermostat of the first layer of the radiator unit flows into the cooling module for cooling inside the circulation pipeline, and the cooling medium in the corresponding cooling module of the second layer of the radiator unit cools the corresponding device through the circulation pipeline, and the analysis unit adjusts the fan speed and operating state according to the number of operating thermostats.

[0024] Further, the detection unit detects the number of operating thermostats in the cooling module in the first operating state.

[0025] If the number of operating units is not one, the analysis unit determines that there are several cooling modules that need to dissipate heat, and judges the distribution of the cooling modules that need to dissipate heat according to the operating state of the thermostat.

[0026] If the number of operating units is equal to one, the analysis unit determines that there is only one cooling module that needs to dissipate heat, and calculates the temperature difference between the circulating temperature of the cooling medium detected by the detection unit and the minimum value of the operating temperature range of the thermostat, and increases the actual speed of the cooling fan according to the ratio of the temperature difference to the temperature difference evaluation value.

[0027] Specifically, the temperature difference evaluation value is a preset value set according to the historical data of the circulating temperature and the corresponding actual speed.

[0028] Further, when the number of jobs is not one, if the thermostat in the first working state is several of the third thermostat, the fourth thermostat, the fifth thermostat, and the sixth thermostat, or the thermostat in the first working state is the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need to dissipate heat are on the same layer;

[0029] If the thermostat in the first working state is several of the third thermostat, the fourth thermostat, the fifth thermostat, and the sixth thermostat and several of the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need to dissipate heat are not on the same layer.

[0030] Further, when the cooling modules that need to dissipate heat are on the same layer, the analysis unit calculates the temperature difference between the circulating temperatures of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan according to the ratio of the maximum temperature difference to the corresponding temperature difference evaluation value;

[0031] Among them, the maximum temperature difference is equal to the maximum value of the product of the temperature difference and the weight of the corresponding cooling module;

[0032] When the cooling modules that need to dissipate heat are not on the same layer, the cooling air of the cooling fan first flows through the first layer of the radiator unit and then through the second layer of the radiator unit. The analysis unit calculates the temperature difference between the circulating temperatures of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan according to the ratio of the maximum temperature difference to the corresponding temperature difference evaluation value;

[0033] Among them, the maximum temperature difference is equal to the maximum value of the product of the temperature difference, the weight of the corresponding cooling module, and the evaluation standard of the layer where it is located;

[0034] The evaluation standard is equal to the product of the first scoring standard coefficient or the second scoring standard coefficient and the sum of the weights of several cooling modules in the corresponding layer;

[0035] The weight of the engine fuel cooling module is greater than that of the transmission case cooling module, which is greater than that of the power end cooling module of the pressure pump, which is greater than that of the hydraulic oil cooling module; the first scoring standard coefficient is less than the second scoring standard coefficient.

[0036] Further, the analysis unit compares the temperature difference with the corresponding difference evaluation value,

[0037] If the temperature difference is less than or equal to the corresponding difference evaluation value, the analysis unit determines that the temperature difference is within the normal temperature difference range;

[0038] If the temperature difference is greater than the corresponding difference evaluation value, the analysis unit determines that the temperature difference exceeds the normal temperature difference range, and the control unit turns on the fixed switch inside the telescopic section.

[0039] Further, after the cooling medium is introduced into the cooling module, the detection unit detects the actual maximum value and the actual minimum value of the circulating temperature.

[0040] The analysis unit calculates the calorific value according to the actual difference between the actual maximum value and the minimum temperature of the thermostat working temperature range, calculates the heat dissipation according to the actual difference between the actual maximum value and the actual minimum value, and calculates the heat dissipation margin of the cooling module according to the calorific value and the heat dissipation. The heat dissipation margin is equal to the heat dissipation minus the calorific value.

[0041] If the heat dissipation margin is greater than or equal to the standard value, the analysis unit determines that the heat dissipation margin of the cooling module meets the standard.

[0042] If the heat dissipation margin is less than the standard value, the analysis unit determines that the heat dissipation margin of the cooling module does not meet the standard and there is a risk of overheating, and increases the initial minimum speed of the cooling fan according to the ratio of the standard value to the heat dissipation margin.

[0043] Further, when the thermostat is in the second working state, the detection unit detects the output displacement of the fracturing truck, and the analysis unit compares the output displacement with the critical displacement.

[0044] If the output displacement of the fracturing truck is less than the critical displacement, the analysis unit determines that the fuel combustion is sufficient.

[0045] If the output displacement of the fracturing truck is greater than or equal to the critical displacement, the analysis unit determines that the fuel combustion is insufficient, and the analysis unit increases the minimum temperature in the working temperature range of the third thermostat in the engine fuel cooling module.

[0046] Wherein, the critical displacement is a preset value set according to the temporary displacement data of the fracturing truck.

[0047] Compared with the prior art, the beneficial effects of the present invention are that the present invention sets different weights and scoring coefficients according to the influence of different cooling module cooling devices on the operation of the fracturing truck, adopts different cooling fan speed adjustment methods according to the specific heat dissipation conditions of the cooling modules that need to dissipate heat, calculates the maximum value of the temperature difference according to the weights of the cooling modules when the cooling modules that need to dissipate heat are on the same layer, and calculates the maximum value of the temperature difference according to the evaluation criteria and weights of the layers where the cooling modules are located when the cooling modules that need to dissipate heat are on two layers, further increasing the accuracy and adaptability of heat dissipation for the fracturing truck, avoiding the situation that some devices in the fracturing truck have qualified cooling degrees while some have unqualified cooling degrees, reducing the non-uniformity of the heat dissipation degree, and reducing the influence of different heat dissipation degrees on the operation of the fracturing truck.

[0048] Furthermore, when the number of operating thermostats is not one, two situations will occur. The cooling modules that need to dissipate heat are on the same layer of the first or second layer, or the cooling modules that need to dissipate heat are located on two layers of the heat dissipation unit. According to the operating status of the corresponding thermostat, the distribution of the cooling modules that need to dissipate heat is judged, and the actual speed of the cooling fan is adjusted, which increases the accuracy and adaptability of heat dissipation for the fracturing truck.

[0049] Furthermore, the analysis unit judges the circulating temperature of the cooling medium according to the temperature difference. When the circulating temperature exceeds the normal temperature range, the fixed switch inside the telescopic section is turned on. The telescopic section moves towards the adjacent cooling module under the pressure exerted by the cooling medium. After the cooling medium flows out of the pipeline circuit of the cooling module, the telescopic section moves back to the initial position under the action of the telescopic spring; by moving the telescopic section, the heat dissipation area of the cooling module is increased, the heat dissipation capacity and heat dissipation efficiency for the cooling medium are increased, and the adaptability and flexibility for controlling and adjusting the cooling degree are increased.

[0050] Furthermore, if the engine is overcooled, the cylinder temperature will be too low, the atomization degree of the combustible mixture will become poor, and the combustion will be incomplete, resulting in a decrease in engine power. The fuel that is not completely vaporized due to the low temperature increases the displacement of the fracturing truck, and the tail gas emission pollution is serious. In the present invention, the refrigeration capacity of the cooling modules in the radiator unit is quantified according to the output displacement of the fracturing truck, and the operating temperature range of the thermostat is increased according to the cooling degree, which reduces the pollution caused by tail gas emissions to the environment, increases the applicability of controlling and adjusting the cooling degree, and avoids incomplete fuel combustion caused by excessive cooling degree and the increase in the displacement of the fracturing truck due to the fuel that is not completely vaporized.

[0051] Furthermore, the heat dissipation margin refers to the additional heat dissipation capacity that the heat dissipation system can provide under normal working conditions. Due to reasons such as materials, heat dissipation area, and properties, the heat dissipation capacities of each module are different. The analysis module calculates the heat dissipation margin of each cooling module according to the heat generation and heat dissipation, and evaluates the reliability, safety, and adaptability under different working conditions of the heat dissipation system according to the comparison result of the heat dissipation margin with the standard value. By increasing the initial minimum speed of the cooling fan, the heat dissipation of each cooling module is increased, thereby increasing the heat dissipation margin of each cooling module, improving the reliability, safety, and adaptability of the heat dissipation system, and reducing the risk of overheating of the fracturing truck device under different working conditions. Description of the Drawings

[0052] Figure 1 It is a schematic diagram of the unit connection of a horizontal heat dissipation system for a fracturing truck in an embodiment of the present invention;

[0053] Figure 2 It is a schematic diagram of the connection between a fracturing truck and a horizontal heat dissipation system in an embodiment of the present invention;

[0054] Figure 3Schematic structural diagram of the radiator unit in the embodiment of the present invention;

[0055] Figure 4 Schematic cross-sectional view of the pipe loop connection of the cooling module in the embodiment of the present invention;

[0056] In the figure: 1 - the first layer of the radiator unit, 2 - the second layer of the radiator unit, 11 - the engine fuel cooling module, 12 - the hydraulic oil cooling module, 13 - the power end cooling module of the pressure pump, 14 - the transmission box cooling module, 21 - the engine cylinder liner water cooling module, 22 - the engine intercooler cooling module, 3 - the cooling fan, 4 - the hydraulic motor, 5 - the engine, 6 - the water pump, 7 - the intercooler, 8 - the water tank, 9 - the pipe loop, 91 - the telescopic section, 92 - the telescopic spring. Detailed implementation manners

[0057] In order to make the objectives and advantages of the present invention clearer and more understandable, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0058] The preferred implementation manners of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these implementation manners are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0059] It should be noted that in the description of the present invention, the terms indicating directions or positional relationships such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0060] In addition, it should also be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0061] Please refer to Figures 1-4 as shown Figure 1 Schematic diagram of the unit connection of a horizontal cooling system for a fracturing truck in the embodiment of the present invention; Figure 2 Schematic diagram of the connection between a fracturing truck and a horizontal cooling system in the embodiment of the present invention; Figure 3 Schematic structural diagram of the radiator unit in the embodiment of the present invention;Figure 4 Schematic cross-sectional view of the pipe loop connection at the cooling module in the embodiment of the present invention.

[0062] The present invention provides a horizontal heat dissipation system for a fracturing truck, comprising:

[0063] A radiator unit, which is divided into two layers. The first layer 1 of the radiator unit includes an engine fuel cooling module 11, a hydraulic oil cooling module 12, a pressure pump power end cooling module 13, and a transmission box cooling module 14; the second layer 2 of the radiator unit includes an engine cylinder jacket water cooling module 21 and an engine intercooler cooling module 22;

[0064] An engine cylinder jacket cooling module, which is used to cool the main part of the engine cylinder jacket through cooling water. The cooling medium circulating in the pipe loop 9 in the engine cylinder jacket water cooling module 21 is cooling water, and a first thermostat is provided in the engine cylinder jacket cooling module;

[0065] An engine intercooler cooling module 22, which is used to cool the engine intercooler through cooling water. The cooling medium circulating in the pipe loop 9 in the engine intercooler cooling module 22 is cooling water, and a second thermostat is provided in the engine intercooler cooling module 22;

[0066] An engine fuel cooling module 11, which is connected to the engine fuel pipeline and is used to dissipate heat from the fuel flowing through the radiator to ensure that the fuel works at a suitable temperature. The cooling medium circulating in the pipe loop 9 in the engine fuel cooling module 11 is fuel, and a third thermostat is provided in the engine fuel cooling module 11;

[0067] A hydraulic oil cooling module 12, which is connected to the hydraulic oil pipeline of the hydraulic system and is used to dissipate heat from the hydraulic oil flowing through the radiator to cool the hydraulic system. The cooling medium circulating in the pipe loop 9 in the hydraulic oil cooling module 12 is hydraulic oil, and a fourth thermostat is provided in the hydraulic oil cooling module 12;

[0068] A pressure pump power end cooling module 13, which is connected to the lubricating oil pipeline of the pressure pump power end and is used to dissipate heat from the lubricating oil of the pressure pump flowing through the radiator to cool the power end of the fracturing pump. The cooling medium circulating in the pipe loop 9 in the pressure pump power end cooling module 13 is lubricating oil, and a fifth thermostat is provided in the pressure pump power end cooling module 13;

[0069] A transmission box cooling module 14, which is connected to the lubricating oil pipeline of the transmission shaft in the transmission box and is used to dissipate heat from the lubricating oil of the transmission shaft flowing through the radiator. The cooling medium circulating in the pipe loop 9 in the transmission box cooling module 14 is lubricating oil, and a sixth thermostat is provided in the transmission box cooling module 14;

[0070] A cooling fan 3 blows cooling air into the radiator unit by rotation, and the cooling fan 3 is connected to a hydraulic motor 4;

[0071] A detection unit is connected to the analysis unit and includes a temperature sensor, a displacement sensor, and a counter, which are used to detect the circulating temperature of the cooling medium, the number of thermostats in operation, and the output displacement of the fracturing truck, and transmit the data to the analysis unit;

[0072] An analysis unit is connected to the control unit. In the analysis unit, there are weights of each cooling module, temperature difference evaluation values, operating temperature ranges of the thermostats, and scoring coefficients. The scoring coefficients include a first scoring standard coefficient for the first layer 1 of the radiator unit and a second scoring standard coefficient for the second layer 2 of the radiator unit;

[0073] The analysis unit is used to adjust the operating state of the thermostat according to the operating temperature range of the thermostat and the circulating temperature of the cooling medium, judge the distribution of the cooling modules that need to be cooled according to the number of thermostats in operation, calculate the maximum temperature difference according to the temperature difference between the circulating temperature and the corresponding minimum temperature value, the weight, and the scoring coefficient, adjust the actual rotation speed of the cooling fan 3 according to the maximum temperature difference, adjust the heat dissipation area according to the temperature difference judgment result, and determine the cooling degree and heat dissipation margin of each cooling module;

[0074] A control unit is used to adjust the actual rotation speed and the initial minimum rotation speed of the cooling fan 3 according to the instructions of the analysis module, and control the operating state of the thermostat and the opening and closing of the fixed switch.

[0075] Start the engine and the radiator through the hydraulic system. The power generated by the engine is transmitted to the pressure pump through the transmission shaft of the gearbox;

[0076] The engine fuel cooling module 11, the hydraulic oil cooling module 12, the pressure pump power end cooling module 13, and the gearbox cooling module 14 in the first layer 1 of the radiator unit are arranged in parallel at the bottom layer of the radiator unit;

[0077] A pipeline circuit 9 is arranged inside the cooling module for allowing the cooling medium to flow in when the thermostat is opened. The pipeline circuit 9 inside the engine fuel cooling module 11 is connected to the pipeline circuit 9 inside the hydraulic oil cooling module 12; the pipeline circuit 9 inside the pressure pump power end cooling module 13 is connected to the pipeline circuit 9 inside the gearbox cooling module 14;

[0078] At the connection of the pipeline circuit 9, there is a telescopic section 91 that can move telescopically and a telescopic spring 92 fixed on the pipeline wall. The telescopic section 91 is connected to the telescopic spring 92, and a fixed switch is arranged inside the telescopic section 91. The fixed switch can fix the telescopic end at the initial position;

[0079] Specifically, when the telescopic section 91 is subjected to an external force, it moves and drives the telescopic spring 92 to expand and contract, generating elastic deformation. When the external force is eliminated, the telescopic section 91 moves back to its initial position under the action of the telescopic spring 92 that has undergone elastic deformation.

[0080] The elastic coefficient of the telescopic spring 92 can be adjusted. It can be understood that the elastic coefficient of the spring and the magnitude of the external force determine the maximum moving distance of the telescopic section 91.

[0081] The engine steel sleeve water cooling module 21 and the engine intercooler cooling module 22 in the second layer 2 of the radiator unit are arranged side by side in the upper layer of the radiator unit;

[0082] The cooling fan 3 and the hydraulic motor 4 are arranged at the bottom of the radiator unit;

[0083] Thermostats with preset different working temperature ranges are provided in each cooling module. The working temperature range of the thermostat consists of a temperature maximum value and a temperature minimum value.

[0084] In this embodiment, the preset temperature minimum value of the first thermostat is 77 °C, the preset temperature minimum value of the second thermostat is 32 °C, the preset temperature minimum value of the third thermostat is 40 °C, the preset temperature minimum value of the fourth thermostat is 43 °C, the preset temperature minimum value of the fifth thermostat is 71 °C, and the preset temperature minimum value of the sixth thermostat is 93 °C.

[0085] The thermostat can control the working states, cooling state and circulation state of the cooling module according to the preset working temperature range, and is used to control the cooling medium to flow through the heat dissipation system for cooling.

[0086] After the hydraulic system of the fracturing truck starts the heat dissipation system, the cooling fan 3 rotates at the initial minimum speed;

[0087] The detection unit detects the circulating temperature of the cooling medium circulating in the pipeline circuit 9 of the cooling module;

[0088] In this embodiment, the cooling medium includes fuel oil, lubricating oil, hydraulic oil and cooling water;

[0089] If the circulating temperature exceeds the working temperature range of the thermostat, the analysis unit determines that the circulating temperature of the cooling medium in the corresponding module circuit exceeds the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the first working state;

[0090] If the circulating temperature does not exceed the working temperature range of the thermostat, the analysis unit determines that the circulating temperature of the cooling medium in the corresponding module circuit does not exceed the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the second working state.

[0091] When any thermostat is in the second working state, the thermostat is closed, and the cooling medium corresponding to the cooling module of the first layer 1 of the radiator unit does not flow into the radiator unit. The cooling medium circulates in the corresponding device and the pipeline circuit 9; the cooling medium in the corresponding cooling module of the second layer 2 of the radiator unit circulates in the radiator unit through the bypass pipeline, and the analysis unit determines the cooling degree of each cooling module.

[0092] When any thermostat is in the first working state, the thermostat is opened, and the cooling medium of the cooling module corresponding to the thermostat of the first layer 1 of the radiator unit flows into the cooling module for cooling inside the circulation pipeline. The cooling medium in the corresponding cooling module of the second layer 2 of the radiator unit cools the corresponding device through the circulation pipeline. The analysis unit adjusts the fan speed and working state according to the working quantity of the thermostat.

[0093] The detection unit detects the working quantity of the thermostat in the first working state in the cooling module.

[0094] If the working quantity is not one, the analysis unit determines that there are several cooling modules that need to dissipate heat, and judges the distribution of the cooling modules that need to dissipate heat according to the working states of the first thermostat and the sixth thermostat.

[0095] If the working quantity is equal to one, the analysis unit determines that there is only one cooling module that needs to dissipate heat, calculates the temperature difference between the circulating temperature of the cooling medium detected by the detection unit and the minimum value of the working temperature range of the thermostat, and increases the actual speed of the cooling fan 3 according to the ratio of the temperature difference to the temperature difference evaluation value.

[0096] Specifically, the temperature difference evaluation value is a preset value set according to the historical data of the circulating temperature and the corresponding actual speed.

[0097] Specifically, when the working quantity of the thermostat is not one, two situations will occur. The cooling modules that need to dissipate heat are on the same layer of the first layer or the second layer, and the cooling modules that need to dissipate heat are respectively located on the two layers of the radiator unit. The distribution of the cooling modules that need to dissipate heat is judged according to the working states of the corresponding thermostats, and the actual speed of the cooling fan 3 is adjusted, which improves the accuracy and adaptability of heat dissipation for the fracturing truck.

[0098] When the working quantity is not one, if the thermostats in the first working state are several of the third thermostat, the fourth thermostat, the fifth thermostat and the sixth thermostat, or the thermostats in the first working state are the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need to dissipate heat are on the same layer.

[0099] If the thermostat in the first working state is several of the third thermostat, the fourth thermostat, the fifth thermostat, and the sixth thermostat, and several of the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need to dissipate heat are not on the same layer;

[0100] When the cooling modules that need to dissipate heat are on the same layer, the analysis unit calculates the temperature difference between the circulating temperatures of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan 3 according to the ratio of the maximum temperature difference value to the corresponding temperature difference evaluation value;

[0101] Among them, the maximum temperature difference value is equal to the maximum value of the product of the temperature difference and the weight of the corresponding cooling module.

[0102] When the cooling modules that need to dissipate heat are not on the same layer, the cooling air of the cooling fan 3 first flows through the first layer 1 of the radiator unit and then through the second layer 2 of the radiator unit. The analysis unit calculates the temperature difference between the circulating temperatures of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan 3 according to the ratio of the maximum temperature difference value to the corresponding temperature difference evaluation value;

[0103] Among them, the maximum temperature difference value is equal to the maximum value of the product of the temperature difference, the weight of the corresponding cooling module, and the evaluation standard of the layer where it is located.

[0104] Specifically, the weight of the engine fuel cooling module 11 is greater than that of the transmission case cooling module 14, greater than that of the pressure pump power end cooling module 13, greater than that of the hydraulic oil cooling module 12, greater than that of the engine intercooler cooling module 22, and greater than that of the engine cylinder liner cooling module; the first scoring standard coefficient is greater than the second scoring standard coefficient.

[0105] Specifically, the evaluation standard is equal to the product of the scoring coefficient of each layer and the sum of the weights of several cooling modules in the same layer.

[0106] Specifically, the present invention sets different weights and scoring coefficients according to the influence of the devices cooled by different cooling modules on the operation of the fracturing truck. According to the specific heat dissipation situation of the cooling modules that need to dissipate heat, different cooling fan 3 speed adjustment methods are adopted. When the cooling modules that need to dissipate heat are on the same layer, the maximum temperature difference is calculated according to the weight of the cooling module. When the cooling modules that need to dissipate heat are on two layers, the maximum temperature difference is calculated according to the evaluation standard and weight of the layer where the cooling module is located, further increasing the accuracy and adaptability of heat dissipation for the fracturing truck, avoiding the situation that some devices in the fracturing truck have reached the cooling standard while some have not, reducing the non-uniformity of the heat dissipation degree, and reducing the impact of different heat dissipation degrees on the operation of the fracturing truck.

[0107] The analysis unit compares the temperature difference with the corresponding difference evaluation value.

[0108] If the temperature difference is less than or equal to the corresponding difference evaluation value, the analysis unit determines that the temperature difference is within the normal temperature difference range and the circulating temperature of the cooling medium is appropriate.

[0109] If the temperature difference is greater than the corresponding difference evaluation value, the analysis unit determines that the temperature difference exceeds the normal temperature difference range, and the difference between the circulating temperature of the cooling medium and the operating temperature range of the corresponding thermostat is large. The control unit turns on the fixed switch inside the telescopic section 91.

[0110] Specifically, the analysis unit determines the circulating temperature of the cooling medium based on the temperature difference. When the circulating temperature exceeds the normal temperature range, the fixed switch inside the telescopic section 91 is turned on. The telescopic section 91 moves towards the adjacent cooling module under the pressure exerted by the cooling medium. After the cooling medium flows out of the pipeline loop 9 of the cooling module, the telescopic section 91 moves back to its initial position under the action of the telescopic spring 92. By moving the telescopic section 91, the heat dissipation area of the cooling module is increased, the heat dissipation capacity and efficiency of the cooling medium are increased, and the adaptability and flexibility of controlling and adjusting the cooling degree are increased.

[0111] When the thermostat is in the second working state, the detection unit detects the output displacement of the fracturing truck, and the analysis unit compares the output displacement with the critical displacement.

[0112] If the output displacement of the fracturing truck is less than the critical displacement, the analysis unit determines that the fuel combustion is sufficient.

[0113] If the output displacement of the fracturing truck is greater than or equal to the critical displacement, the analysis unit determines that the fuel combustion is insufficient, and the analysis unit increases the minimum temperature in the working temperature range of the third thermostat in the engine fuel cooling module 11.

[0114] Wherein, the critical displacement is a preset value set according to the temporary displacement data of the fracturing truck.

[0115] Specifically, if the engine is over-cooled, the cylinder temperature will be too low, the atomization degree of the combustible mixture will become poor, the combustion will be insufficient, resulting in a decrease in the engine power. The fuel that is not completely vaporized due to the low temperature increases the displacement of the fracturing truck, and the tail gas emission pollution is serious. In the present invention, the refrigeration capacity of the cooling module in the radiator unit is quantified by the output displacement of the fracturing truck, and the working temperature range of the thermostat is increased according to the cooling degree, reducing the pollution of the tail gas emission to the environment, increasing the applicability of controlling and adjusting the cooling degree, and avoiding insufficient fuel combustion caused by excessive cooling degree and the increase in the displacement of the fracturing truck due to the fuel that is not completely vaporized.

[0116] When the thermostat is in the second working state, the cooling fan 3 rotates at the initial minimum speed.

[0117] After the cooling medium enters the cooling module, the detection unit detects the actual maximum value and the actual minimum value of the circulating temperature.

[0118] The analysis unit calculates the heat generation amount according to the actual difference between the actual maximum value and the minimum temperature value in the working temperature range of the thermostat, calculates the heat dissipation amount according to the actual difference between the actual maximum value and the actual minimum value, and calculates the heat dissipation margin of the cooling module according to the heat generation amount and the heat dissipation amount. The heat dissipation margin is equal to the heat dissipation amount minus the heat generation amount.

[0119] If the heat dissipation margin is greater than or equal to the standard value, the analysis unit determines that the heat dissipation margin of the cooling module meets the standard.

[0120] If the heat dissipation margin is less than the standard value, the analysis unit determines that the heat dissipation margin of the cooling module does not meet the standard and there is a risk of overheating, and sends a signal to the control unit according to the ratio of the standard value to the heat dissipation margin to increase the initial minimum speed of the cooling fan 3.

[0121] In this embodiment, the standard value of the heat dissipation margin of the hydraulic oil cooling module 12, the power end cooling module 13 of the pressure pump, and the transmission case cooling module 14 is 10%, and the standard value of the heat dissipation margin of the engine fuel cooling module 11, the engine cylinder sleeve water cooling module 21, and the engine intercooler cooling module 22 is 5%.

[0122] Specifically, the heat dissipation margin refers to the additional heat dissipation capacity that the heat dissipation system can provide under normal working conditions. Due to reasons such as materials, heat dissipation area, and properties, the heat dissipation capabilities of each module are different. The analysis module calculates the heat dissipation margin of each cooling module according to the heat generation amount and the heat dissipation amount, and evaluates the reliability, safety, and adaptability of the heat dissipation system under different working conditions based on the comparison result between the heat dissipation margin and the standard value. By increasing the initial minimum speed of the cooling fan 3, the heat dissipation amount of each cooling module is increased, thereby increasing the heat dissipation margin of each cooling module, improving the reliability, safety, and adaptability of the heat dissipation system, and reducing the risk of overheating of the devices of the fracturing truck under different working conditions.

[0123] In this embodiment, the cooling water of the cylinder sleeve and the intercooler 7 in the engine 5 flows through the second layer 2 of the radiator unit via the water pump 6. After the cooling water exchanges heat with the cooling air blown by the cooling fan 3 driven by the hydraulic motor 4 in the second layer of the radiator unit, it flows into the water tank 8. The water tank 8 stores the cooling water when the thermostat is not opened; the fuel in the engine 5 flows into the first layer 1 of the radiator unit after the thermostat is opened. After the fuel exchanges heat with the cooling air blown by the cooling fan 3 driven by the hydraulic motor 4 in the first layer of the radiator unit, it is transported back to the engine 5.

[0124] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, those skilled in the art can easily understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0125] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A horizontal heat dissipation system for a fracturing truck, characterized in that: include: The radiator unit is divided into two layers. The first layer of the radiator unit includes an engine fuel cooling module, a hydraulic oil cooling module, a pressure pump power end cooling module and a transmission case cooling module; the second layer of the radiator unit includes an engine steel jacket water cooling module and an engine intercooler cooling module; A cooling fan, which blows cooling air into the radiator unit by rotating, wherein the cooling fan is connected to a hydraulic motor; A detection unit, which is connected to the analysis unit and includes a temperature sensor, a displacement sensor and a counter, and is used to detect the circulation temperature of the cooling medium, the working number of the thermostat and the output displacement of the fracturing vehicle, and transmit the data to the analysis unit; An analysis unit connected to the control unit, wherein the analysis unit is provided with weights of each cooling module, temperature difference evaluation values, thermostat operating temperature ranges and scoring coefficients, wherein the scoring coefficients include a first scoring standard coefficient of the first layer of the radiator unit and a second scoring standard coefficient of the second layer of the radiator unit; The analysis unit is used to adjust the working state of the thermostat according to the working temperature range of the thermostat and the circulation temperature of the cooling medium, judge the distribution of cooling modules that need heat dissipation according to the working number of the thermostat, calculate the maximum value of the temperature difference according to the temperature difference and weight of the circulation temperature and the corresponding minimum temperature and the scoring coefficient, adjust the actual speed of the cooling fan according to the maximum value of the temperature difference, adjust the heat dissipation area according to the temperature difference judgment result, and judge the cooling degree and heat dissipation margin of each cooling module; The detection unit detects the number of thermostats in the cooling module that are in a first working state. If the number of operations is not one, the analysis unit determines that there are a number of cooling modules that need heat dissipation, and determines the distribution of the cooling modules that need heat dissipation according to the working state of the thermostat; If the number of jobs is equal to one, the analysis unit determines that there is only one cooling module that needs to dissipate heat, and calculates the temperature difference between the circulation temperature of the cooling medium detected by the detection unit and the minimum value of the working temperature range of the thermostat, and increases the actual speed of the cooling fan according to the ratio of the temperature difference to the temperature difference evaluation value; Specifically, the temperature difference evaluation value is a preset value set according to historical data of the cycle temperature and the corresponding actual rotation speed; When the working number is not one, if the thermostat in the first working state is some of the third thermostat, the fourth thermostat, the fifth thermostat and the sixth thermostat, or the thermostat in the first working state is the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need heat dissipation are in the same layer; If the thermostat in the first working state is some of the third thermostat, the fourth thermostat, the fifth thermostat and the sixth thermostat and some of the first thermostat and the second thermostat, the analysis unit determines that the cooling modules that need to dissipate heat are not in the same layer; When the cooling modules that need to dissipate heat are in the same layer, the analysis unit calculates the temperature difference between the circulation temperature of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan according to the ratio of the maximum value of the temperature difference to the corresponding temperature difference evaluation value; The maximum temperature difference is equal to the maximum value of the product of the temperature difference and the corresponding cooling module weight; When the cooling modules that need to dissipate heat are not in the same layer, the cooling air of the cooling fan first flows through the first layer of the radiator unit and then flows through the second layer of the radiator unit. The analysis unit calculates the temperature difference between the circulation temperature of several cooling media and the minimum value of the working temperature range of the corresponding thermostat, and increases the actual speed of the cooling fan according to the ratio of the maximum value of the temperature difference to the corresponding temperature difference evaluation value. The maximum temperature difference is equal to the maximum value of the product of the temperature difference, the corresponding cooling module weight and the evaluation standard of the layer number; The evaluation standard is equal to the product of the sum of the weights of several cooling modules on the same layer and the corresponding scoring coefficient; The weight of the engine fuel cooling module is greater than that of the transmission box cooling module, greater than that of the pressure pump power end cooling module, and greater than that of the hydraulic oil cooling module; the first scoring standard coefficient is less than the second scoring standard coefficient; A heat dissipation pipeline loop is arranged inside the cooling module, the pipeline loop inside the engine fuel cooling module is connected to the pipeline loop inside the hydraulic oil cooling module; the pipeline loop inside the pressure pump power end cooling module is connected to the pipeline loop inside the transmission box cooling module; A telescopic section that can be telescopically moved and a telescopic spring fixed to the pipeline wall are provided at the connection of the pipeline loop, the telescopic section is connected to the telescopic spring, and a fixed switch is provided inside the telescopic section, and the fixed switch can fix the telescopic end at the initial position; The control unit is used to adjust the actual speed and the initial minimum speed of the cooling fan according to the instructions of the analysis module, and control the working state of the thermostat and the opening and closing of the fixed switch.

2. The horizontal heat dissipation system of a fracturing truck according to claim 1, characterized in that: The engine fuel cooling module, hydraulic oil cooling module, pressure pump power end cooling module and transmission box cooling module in the first layer of the radiator unit are arranged in parallel on the bottom layer of the radiator unit; The engine steel jacket water cooling module and the engine intercooler cooling module in the second layer of the radiator unit are arranged in parallel on the upper layer of the radiator unit; The cooling fan and the hydraulic motor are disposed at the bottom of the radiator unit.

3. The horizontal heat dissipation system of a fracturing truck according to claim 1, characterized in that: The detection unit detects the circulation temperature of the cooling medium circulating in the pipeline loop in the cooling module. If the circulation temperature exceeds the operating temperature range of the thermostat, the analysis unit determines that the circulation temperature of the cooling medium in the corresponding module loop exceeds the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the first working state; If the circulation temperature does not exceed the operating temperature range of the thermostat, the analysis unit determines that the circulation temperature of the cooling medium in the corresponding module loop does not exceed the normal range, and the analysis unit sends a signal to the control unit to adjust the thermostat to the second working state; Wherein, the cooling medium includes fuel oil, lubricating oil, hydraulic oil and cooling water.

4. The horizontal heat dissipation system of a fracturing truck according to claim 3, characterized in that: When any thermostat is in the second working state, the thermostat is closed, the cooling medium corresponding to the cooling module of the first layer of the radiator unit does not flow into the radiator unit, and the cooling medium circulates in the corresponding device and pipeline loop; the cooling medium in the corresponding cooling module of the second layer of the radiator unit circulates in the radiator unit through the bypass pipeline, and the analysis unit determines the cooling degree of each cooling module; When any thermostat is in the first working state, the thermostat is opened, and the cooling medium of the cooling module corresponding to the thermostat of the first layer of the radiator unit is passed into the cooling module and cooled inside the circulation pipeline. The cooling medium in the corresponding cooling module of the second layer of the radiator unit cools the corresponding device through the circulation pipeline. The analysis unit adjusts the fan speed and working state according to the working number of the thermostat.

5. The horizontal heat dissipation system of a fracturing truck according to claim 1, characterized in that: The analysis unit compares the temperature difference with the corresponding difference evaluation value. If the temperature difference is less than or equal to the corresponding difference evaluation value, the analysis unit determines that the temperature difference is within the normal temperature difference range; If the temperature difference is greater than the corresponding difference evaluation value, the analysis unit determines that the temperature difference exceeds the normal temperature difference range, and the control unit opens the fixed switch inside the telescopic section.

6. The horizontal heat dissipation system of a fracturing truck according to claim 1, characterized in that: After the cooling medium is passed into the cooling module, the detection unit detects the actual maximum value and the actual minimum value of the circulation temperature; The analysis unit calculates the heat generation according to the actual difference between the actual maximum value and the temperature minimum value of the thermostat working temperature range, calculates the heat dissipation according to the actual difference between the actual maximum value and the actual minimum value, and calculates the heat dissipation margin of the cooling module according to the heat generation and the heat dissipation, wherein the heat dissipation margin is equal to the heat dissipation minus the heat generation, If the heat dissipation margin is greater than or equal to the standard value, the analysis unit determines that the heat dissipation margin of the cooling module meets the standard; If the heat dissipation margin is less than the standard value, the analysis unit determines that the heat dissipation margin of the cooling module does not meet the standard and there is a risk of overheating, and increases the initial minimum speed of the cooling fan according to the ratio of the standard value to the heat dissipation margin.

7. The horizontal heat dissipation system of a fracturing truck according to claim 3, characterized in that: When the thermostat is in the second working state, the detection unit detects the output displacement of the fracturing truck, and the analysis unit compares the output displacement with the critical displacement. If the output displacement of the fracturing truck is less than the critical displacement, the analysis unit determines that the fuel is fully burned; If the output displacement of the fracturing truck is greater than or equal to the critical displacement, the analysis unit determines that the fuel combustion is insufficient, and the analysis unit increases the minimum temperature value in the working temperature range of the third thermostat in the engine fuel cooling module; The critical displacement is a preset value set according to temporary displacement data of the fracturing truck.

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