Intelligent hydraulic pressurization control method

Abstract

An intelligent hydraulic pressurization control method comprises the following steps that intelligent hydraulic pressurization equipment is started to enter a working state, and meanwhile real-time position parameters, valve box liquid outlet pressure parameters, hydraulic oil liquid level parameters and hydraulic oil temperature parameters in the operation process of a hydraulic cylinder piston are collected; performing pressurization control adjustment by taking the multiple types of parameters as a set; the controller is in communication connection with the display to carry out visual monitoring and adjust the injection amount in real time, and the controller is matched with the electromagnetic flowmeter installed at the outlet to automatically detect the flow and feed back the flow to the controller; the controller controls the injection operation frequency of the motor oil pump, real-time control and adjustment of the injection amount are achieved, and stable injection of equipment according to the preset displacement is guaranteed through automatic closed-loop adjustment. The controller is matched with the driver so as to transmit driving instructions to the variable hydraulic pump assembly, the hydraulic driving assembly and the heat dissipation assembly, and automatic intelligent pressurization from 0 to the maximum pressurization value is completed within the pressurization range of the device.

Description

Technical Field:

[0001] The present invention relates to an intelligent hydraulic boosting control method. Background Art:

[0002] Due to changes in formation structure, reservoir physical properties, and crude oil physical properties, as well as reservoir pollution and blockage caused during the production process, many injection wells cannot achieve the injection allocation volume under the injection system pressure. Using conventional acid fracturing for formation plugging removal has a short effective period and high construction costs.

[0003] In view of the above defects, conventional acid fracturing is often used for formation plugging removal, and the overall effective period is relatively short. If the injection main line pressure is increased as a whole, it will lead to too high construction difficulty and construction cost. Therefore, in order to increase the injection pressure, it is necessary to install oilfield boosting injection equipment at the end of the oilfield injection system for single-well boosting.

[0004] Most of the existing hydraulic boosting control methods are realized by using mechanical characteristics and relying on high-pressure multistage centrifugal pumps and high-pressure triplex plunger pumps. The overall operating speed is too high, the working efficiency is low, and there is serious leakage and pollution during use, making the maintenance process too cumbersome. It cannot perform automatic control on the boosting process according to the corresponding detection parameters of the equipment, thus unable to meet the actual production requirements of boosting injection. Summary of the Invention:

[0005] An embodiment of the present invention provides an intelligent hydraulic boosting control method. The method is reasonably designed. According to the established control logic, it integrates multiple functions such as boosting injection, safety protection, data acquisition, automatic regulation, and remote monitoring into one by relying on an automatic control structure. It uses a variable hydraulic pump assembly to drive and fully utilizes the energy of the incoming water to push the pistons in two parallel cylinders to reciprocate for boosting, greatly improving the transmission efficiency, reducing energy consumption, leakage, and pollution, effectively reducing the vibration, impact, and noise of the equipment during operation. By using intelligent control and visual monitoring, it realizes real-time remote monitoring of the operation process, can automatically detect and feedback the flow rate and the water pressure of the incoming and outgoing water, reduces the outlet pressure pulsation rate, makes the output pressure stable. Under the condition of meeting a certain displacement, by using a large plunger with a long stroke and a low stroke frequency, it reduces the movement speed of the pistons in the left boosting cylinder and the right boosting cylinder, improves the service life of the boosting pistons, inlet and outlet liquid check valves, and seals, extends the equipment maintenance period, reduces the labor intensity of maintenance personnel, increases the continuous working time and the overall service life of the equipment, thus meeting the actual application requirements of boosting injection and solving the problems existing in the prior art.

[0006] The technical solution adopted by the present invention to solve the above technical problems is:

[0007] An intelligent hydraulic boosting control method, the boosting control method includes the following steps:

[0008] S1. The intelligent hydraulic boosting device starts and enters the working state. Meanwhile, it collects the real-time position parameters of the hydraulic cylinder piston during operation, the liquid outlet pressure parameters of the valve box, the liquid level parameters of the hydraulic oil, and the hydraulic oil temperature parameters, and conducts boosting control and adjustment with the above-mentioned multi-type parameters as a set.

[0009] S2. The controller is communicatively connected to the display for visual monitoring, and the injection volume is adjusted in real time. Cooperating with the electromagnetic flowmeter installed at the outlet, it automatically detects the flow rate and feeds it back to the controller.

[0010] S3. The controller controls the injection operation frequency of the motor oil pump to achieve real-time control and adjustment of the injection volume. The automatic closed-loop adjustment ensures that the equipment injects smoothly according to the preset displacement. An accumulator is installed to set the charging pressure according to the working pressure, reduce the outlet pressure pulsation rate, and make the output pressure stable.

[0011] S4. The controller cooperates with the driver to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive assembly, and the heat dissipation assembly respectively, and completes automatic intelligent boosting from 0 to the maximum boosting value within the boosting range of the equipment.

[0012] The boosting device includes a base, on which a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly, and a heat dissipation assembly are arranged to cooperate with each other. The variable hydraulic pump assembly is used to fully utilize the energy of water to push two reciprocatingly moving hydraulic cylinders arranged in parallel and communicating with each other to increase pressure and eliminate hydraulic shock during the commutation process. The hydraulic drive assembly is used to provide hydraulic power for the variable hydraulic pump assembly. The electrical control assembly is used to collect various types of electrical parameters to achieve intelligent control, and conduct real-time monitoring and adjustment of the hydraulic boosting process. The heat dissipation assembly is used to reduce the working temperature rise of the equipment.

[0013] The variable hydraulic pump assembly includes a reciprocating pump that reciprocates to increase pressure. The reciprocating pump includes two sets of valve boxes, bodies, and communicating hydraulic cylinders arranged in parallel. It performs long-stroke reciprocating motion through a simplified structure with fewer positioning points to reduce the requirement for the processing accuracy of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0014] A hydraulic cylinder barrel, a hydraulic piston rod, and a cylinder sleeve are configured in the hydraulic cylinder to control the reciprocating motion of the hydraulic cylinder. An oil suction filter, a second motor gear pump, and a second pipe-type one-way valve are also provided in the fuel tank to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by the backpressure effect of the one-way valve.

[0015] The hydraulic drive assembly includes an oil tank and a constant power variable oil pump. The constant power variable oil pump is used to convert the mechanical energy of the motor into the pressure energy of hydraulic oil, and then convert the pressure energy of the hydraulic oil into working hydraulic pressure energy through a hydraulic oscillator. The constant power variable oil pump is connected to the motor through a coupling. The inlet of the constant power variable oil pump is flexibly connected to the inlet oil filter at the outlet of the oil tank, so that the hydraulic oil in the oil tank enters the constant power variable oil pump after being filtered by the inlet oil filter. The outlet of the constant power variable oil pump is connected to a tubular check valve through a rubber hose.

[0016] The oil tank is connected to a motor oil pump through an inlet oil filter. A tubular check valve and a high-pressure oil filter are successively connected to the motor oil pump. A bladder accumulator, a pilot-operated relief valve and a first direct-acting relief valve are arranged at the rear end of the tubular check valve. The bladder accumulator is used to absorb the pulsation and shock during the hydraulic commutation process. The high-pressure oil filter, the tubular check valve and the bladder accumulator are integrated into a hydraulic valve block, so that the hydraulic oil enters the commutation valve block through the tubular check valve and the high-pressure oil filter.

[0017] The commutation valve block includes an electro-hydraulic commutation valve, a pilot-operated relief valve and a direct-acting relief valve. The A and B ports of the electro-hydraulic commutation valve are respectively connected to the rod chambers of two hydraulic cylinders.

[0018] Each valve box is respectively provided with a slurry inlet valve body seat and a slurry outlet valve body seat. An oil suction filter, a first motor gear pump, a second direct-acting relief valve, a first tubular check valve and a second manual ball valve are successively arranged between two connected hydraulic cylinders.

[0019] An inlet liquid valve body, an inlet liquid valve seat, an outlet liquid valve body and an outlet liquid valve seat are arranged in the valve box. A valve body guide is arranged on the upper part of the inlet liquid valve body. A small gland, a small split ring and a small cylinder head are arranged above the valve box. A large gland, a large split ring and a large cylinder head are arranged on the side of the valve box. A valve body fixing plate is also arranged in the valve box. A valve box support is arranged at the bottom of the valve box.

[0020] A piston is arranged in the hydraulic cylinder. The piston is connected to the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to cooperate with the piston rubber to form a sealing structure in the cylinder sleeve. Hydraulic cylinder end covers are respectively arranged at both ends of the hydraulic cylinder barrel. The rodless cavity end of the hydraulic cylinder is connected through a U-shaped oil pipe. Under the action of the piston, the inlet liquid pressure medium transmits energy to the hydraulic piston rod, and the hydraulic piston rod transmits energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity of the hydraulic cylinder and the U-shaped oil pipe, and then transmits it to the piston at the other end. An engine body support is arranged at the bottom of the engine body to support and protect the engine body.

[0021] An oil replenishment port and an exhaust hole are provided on the hydraulic cylinder end cover of the hydraulic cylinder. The oil replenishment port is used to replenish oil to the rodless cavity of the hydraulic cylinder via a motor oil pump; an electromagnetic valve is provided on the exhaust hole. The electromagnetic valve is used to connect to the fuel tank, and the working time is set via a controller to regularly open the electromagnetic valve to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder. The discharge amount is the volume of the hydraulic cylinder barrel corresponding to the difference between the maximum stroke and the minimum stroke of the displacement sensor provided on the hydraulic cylinder.

[0022] When the hydraulic cylinder needs to change the oil, the solenoid valve is automatically opened to return the hydraulic oil in the rodless cavity to the fuel tank, shortening the operating stroke of the hydraulic cylinder piston. When the stroke is shortened to the minimum stroke value, the solenoid valve is automatically closed and the motor oil pump is opened to replenish oil to the rodless cavity of the hydraulic cylinder. The oil replenishment stops when the hydraulic piston stroke reaches the maximum stroke value.

[0023] The electrical control component includes a power distribution cabinet provided on the base. A controller is provided in the power distribution cabinet. A displacement sensor, a pressure transmitter, a liquid level sensor, and a temperature sensor are electrically connected to the controller:

[0024] The displacement sensor is provided on the hydraulic cylinder to detect the real-time position during the operation of the hydraulic piston. At the same time, by setting the maximum and minimum position points, the hydraulic piston is controlled to reverse, completing the reciprocating motion of the hydraulic reciprocating pump; the pressure transmitter is provided on the liquid outlet pipe of the valve box to detect the liquid outlet pressure of the valve box; the liquid level sensor and the temperature sensor are provided in the fuel tank to detect the liquid level parameter and temperature parameter of the hydraulic oil in the fuel tank.

[0025] A display is connected to the controller via a communication line for visual monitoring, realizing real-time remote monitoring of the operation process; a driver is also provided on the control to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive component, and the heat dissipation component respectively, and automatically and intelligently boost the pressure from 0 to the maximum boost value within the equipment boost range.

[0026] The heat dissipation component includes an air-cooled radiator and a radiator circulation oil pump that are set in cooperation to ensure that the working temperature of the equipment is between +10°C and +70°C.

[0027] With the above structure, the present invention utilizes the energy of water through a variable hydraulic pump assembly to fully drive two reciprocatingly moving and interconnected hydraulic cylinders arranged in parallel for pressurization and eliminate hydraulic shock during the commutation process; a hydraulic drive assembly provides hydraulic power for the variable hydraulic pump assembly; an electrical control assembly collects various types of electrical parameters to achieve intelligent control, monitors and adjusts the hydraulic pressurization process in real time, and relies on the hydraulically pistons arranged in a parallel structure to ensure that the liquid inlet pressure received by one piston is completely transmitted to the other piston, ensuring that the hydraulic pressurization range can be from 0 to the maximum, overcoming the strict limitation of the mechanical three-cylinder pump on the inlet and outlet pressure difference, and achieving stepless injection between the inlet and outlet pressure differences from 0 to the maximum pressure difference; a heat dissipation assembly reduces the working temperature rise of the equipment to ensure the continuous and stable operation of the equipment, and has the advantages of stability, practicality, precision and high efficiency. BRIEF DESCRIPTION OF THE DRAWINGS:

[0028] Figure 1 It is a schematic flow chart of the present invention.

[0029] Figure 2 It is a schematic structural diagram of the intelligent hydraulic pressurization equipment of the present invention.

[0030] Figure 3 It is a schematic structural diagram of the variable hydraulic pump assembly of the present invention.

[0031] Figure 4 is Figure 2 top view of.

[0032] Figure 5 It is a hydraulic schematic diagram of the present invention.

[0033] In the figure, 1, oil tank; 2, inlet oil filter; 3, motor oil pump; 4, high-pressure filter; 5, bladder accumulator; 6, tube-type one-way valve; 7, pilot-operated relief valve; 8, first direct-acting relief valve; 9, electro-hydraulic directional valve; 10, return oil filter; 11, displacement sensor; 12, first manual ball valve; 13, hydraulic cylinder barrel; 14, hydraulic piston rod; 15, cylinder liner; 16, slurry inlet valve body seat; 17, slurry outlet valve body seat; 18, first suction oil filter; 19, first motor gear pump; 20, second direct-acting relief valve; 21, first tube-type one-way valve; 22, second manual ball valve; 23, second suction oil filter; 24, second motor gear pump; 25, second tube-type one-way valve; 26, air-cooled radiator. DETAILED DESCRIPTION OF THE EMBODIMENTS:

[0034] To clearly illustrate the technical features of this solution, the present invention will be described in detail below through specific embodiments and in conjunction with its accompanying drawings.

[0035] As Figures 1-5 shown in, an intelligent hydraulic pressurization control method, the pressurization control method includes the following steps:

[0036] S1. The intelligent hydraulic boosting device starts and enters the working state. Meanwhile, it collects the real-time position parameters of the hydraulic cylinder piston during operation, the liquid outlet pressure parameters of the valve box, the liquid level parameters of the hydraulic oil, and the hydraulic oil temperature parameters, and performs boosting control and adjustment with the above-mentioned multi-type parameters as a set.

[0037] S2. The controller is communicatively connected to the display for visual monitoring, adjusts the injection volume in real time, and cooperates with the electromagnetic flowmeter installed at the outlet to automatically detect the flow rate and feedback it to the controller.

[0038] S3. The controller controls the injection operation frequency of the motor oil pump to achieve real-time control and adjustment of the injection volume. The automatic closed-loop adjustment ensures that the equipment injects smoothly according to the preset displacement. The accumulator is installed and the inflation pressure is set according to the working pressure to reduce the outlet pressure pulsation rate and make the output pressure stable.

[0039] S4. The controller cooperates with the driver to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive assembly, and the heat dissipation assembly respectively, and completes automatic intelligent boosting from 0 to the maximum boosting value within the boosting range of the equipment.

[0040] The boosting device includes a base, on which a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly, and a heat dissipation assembly are arranged to cooperate with each other. The variable hydraulic pump assembly is used to fully utilize the energy of water to push two reciprocatingly moving hydraulic cylinders arranged in parallel and connected to eliminate the hydraulic shock during the commutation process. The hydraulic drive assembly is used to provide hydraulic power for the variable hydraulic pump assembly. The electrical control assembly is used to collect various types of electrical parameters to achieve intelligent control, and to monitor and adjust the hydraulic boosting process in real time. The heat dissipation assembly is used to reduce the working temperature rise of the equipment.

[0041] The variable hydraulic pump assembly includes a reciprocating pump that performs reciprocating motion for boosting. The reciprocating pump includes two sets of valve boxes, bodies, and connected hydraulic cylinders arranged in parallel. It performs long-stroke reciprocating motion through a simplified structure with fewer positioning points to reduce the requirements for the processing accuracy of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0042] A hydraulic cylinder barrel, a hydraulic piston rod, and a cylinder liner are arranged in the hydraulic cylinder to control the reciprocating motion of the hydraulic cylinder. An oil suction filter, a second motor gear pump, and a second tubular one-way valve are also arranged in the fuel tank to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by the backpressure effect of the one-way valve.

[0043] The hydraulic drive assembly includes an oil tank and a constant power variable oil pump. The constant power variable oil pump is used to convert the mechanical energy of the motor into the pressure energy of hydraulic oil, and then convert the pressure energy of the hydraulic oil into working hydraulic pressure energy through a hydraulic oscillator. The constant power variable oil pump is connected to the motor through a coupling. The inlet of the constant power variable oil pump is flexibly connected to the inlet oil filter at the outlet of the oil tank, so that the hydraulic oil in the oil tank enters the constant power variable oil pump after being filtered by the inlet oil filter. The outlet of the constant power variable oil pump is connected to a tube-type one-way valve through a rubber hose.

[0044] The oil tank is connected to an electric oil pump through an inlet oil filter. A tube-type one-way valve and a high-pressure oil filter are successively connected to the electric oil pump. A bladder accumulator, a pilot-operated relief valve and a first direct-acting relief valve are arranged at the rear end of the tube-type one-way valve. The bladder accumulator is used to absorb the pulsation and shock during the hydraulic commutation process. The high-pressure oil filter, the tube-type one-way valve and the bladder accumulator are integrated into a hydraulic valve block, so that the hydraulic oil enters the commutation valve block through the tube-type one-way valve and the high-pressure oil filter.

[0045] The commutation valve block includes an electro-hydraulic commutation valve, a pilot-operated relief valve and a direct-acting relief valve. The A and B ports of the electro-hydraulic commutation valve are respectively connected to the rod chambers of two hydraulic cylinders.

[0046] Each valve box is respectively provided with a slurry inlet valve body seat and a slurry outlet valve body seat. An oil suction filter, a first motor gear pump, a second direct-acting relief valve, a first tube-type one-way valve and a second manual ball valve are successively arranged between two connected hydraulic cylinders.

[0047] An inlet liquid valve body, an inlet liquid valve seat, an outlet liquid valve body and an outlet liquid valve seat are arranged in the valve box. A valve body guide is arranged on the upper part of the inlet liquid valve body. A small gland, a small retaining ring and a small cylinder head are arranged above the valve box. A large gland, a large retaining ring and a large cylinder head are arranged on the side of the valve box. A valve body fixing plate is also arranged in the valve box. A valve box support is arranged at the bottom of the valve box.

[0048] A piston is arranged in the hydraulic cylinder. The piston is connected to the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to cooperate with the piston rubber to form a sealing structure in the cylinder sleeve. Hydraulic cylinder end covers are respectively arranged at both ends of the hydraulic cylinder barrel. The rodless cavity end of the hydraulic cylinder is connected through a U-shaped oil pipe. Under the action of the piston, the inlet liquid pressure medium transmits energy to the hydraulic piston rod, and the hydraulic piston rod transmits energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity of the hydraulic cylinder and the U-shaped oil pipe, and then transmits it to the piston at the other end. An organism support is arranged at the bottom of the organism for supporting and protecting the organism.

[0049] An oil replenishment port and an exhaust hole are provided on the hydraulic cylinder end cover of the hydraulic cylinder. The oil replenishment port is used to replenish oil to the rodless cavity of the hydraulic cylinder via a motor oil pump; an electromagnetic valve is provided on the exhaust hole, and the electromagnetic valve is used to connect to the fuel tank. The working time is set via a controller, and the electromagnetic valve is regularly opened to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder. The discharge amount is the volume of the hydraulic cylinder barrel corresponding to the difference between the maximum stroke and the minimum stroke of the displacement sensor provided on the hydraulic cylinder.

[0050] When the hydraulic cylinder needs to change the oil, the solenoid valve is automatically opened to return the hydraulic oil in the rodless cavity to the fuel tank, shortening the operating stroke of the hydraulic cylinder piston. When the stroke is shortened to the minimum stroke value, the solenoid valve is automatically closed and the motor oil pump is started to replenish oil to the rodless cavity of the hydraulic cylinder. The oil replenishment stops when the hydraulic piston stroke reaches the maximum stroke value.

[0051] The electrical control component includes a power distribution cabinet provided on the base. A controller is provided in the power distribution cabinet. A displacement sensor, a pressure transmitter, a liquid level sensor, and a temperature sensor are electrically connected to the controller:

[0052] The displacement sensor is provided on the hydraulic cylinder to detect the real-time position during the operation of the hydraulic piston. At the same time, the hydraulic piston is controlled to reverse by setting the maximum and minimum position points to complete the reciprocating motion of the hydraulic reciprocating pump; the pressure transmitter is provided on the liquid outlet pipe of the valve box to detect the liquid outlet pressure of the valve box; the liquid level sensor and the temperature sensor are provided in the fuel tank to detect the liquid level parameter and temperature parameter of the hydraulic oil in the fuel tank.

[0053] A display is connected to the controller via a communication line for visual monitoring, realizing real-time remote monitoring of the operation process; a driver is also provided on the control to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive assembly, and the heat dissipation assembly respectively, and automatically and intelligently boost the pressure from 0 to the maximum boost value within the equipment boost range.

[0054] The heat dissipation component includes an air-cooled radiator and a radiator circulation oil pump that are set in cooperation to ensure that the working temperature of the equipment is between +10°C and +70°C.

[0055] The working principle of an intelligent hydraulic boosting control method in an embodiment of the present invention is as follows: According to the established control logic, it integrates multiple functions such as boosting injection, safety protection, data acquisition, automatic regulation, and remote monitoring into one by relying on an automated control structure. It uses a variable hydraulic pump assembly to drive and fully utilizes the energy of the incoming water, and promotes the pistons in two parallel cylinders to reciprocate for boosting. This greatly improves the transmission efficiency, reduces energy consumption and leakage pollution, and effectively reduces the vibration, impact, and noise during the operation of the equipment. By adopting intelligent control and visual monitoring, it realizes real-time remote monitoring during the operation process, can automatically detect and feedback the flow rate and the water pressure of the incoming and outgoing water, reduces the outlet pressure pulsation rate, makes the output pressure stable. When meeting a certain displacement, by using large plungers with long strokes and low strokes per minute, it reduces the movement speed of the pistons in the left boosting cylinder and the right boosting cylinder, improves the service life of the boosting pistons, inlet and outlet check valves, and seals, extends the equipment maintenance period, reduces the labor intensity of maintenance personnel, increases the continuous working time of the equipment and the overall service life, so as to meet the actual application requirements of boosting water injection.

[0056] Generally speaking, the existing conventional boosting water injection equipment mainly includes high-pressure multistage centrifugal pumps and high-pressure three-plunger pumps, and there are many problems in production applications, which are specifically as follows:

[0057] For high-pressure multistage centrifugal pumps, the overall efficiency is very low. The efficiency at the best operating point generally does not exceed 60%, and most efficiencies are lower than 40%. Therefore, the power consumption is large and the energy waste is particularly serious. At the same time, due to structural limitations, a large amount of leakage is extremely likely to occur at the mechanical seal of the pump shaft, causing environmental pollution; multistage centrifugal pumps can only be adapted to water injection with clear water. For water injection of oilfield sewage, due to the existence of particulate impurities, it is prone to wear and corrosion, and the service life is greatly shortened, and it may even not work properly.

[0058] For high-pressure three-plunger pumps, due to the influence of the crankshaft strength, the plunger diameter is relatively small, generally not more than 70mm; to meet a certain displacement, the stroke per minute of the plunger needs to be very high, generally as high as 100 - 200 times per minute. The high stroke per minute brings a series of problems to the plunger pump, such as high noise, large vibration, frequent collisions of the pump valves during opening and closing, and increased wear of the bearing shells, plungers, and packings, resulting in many failures, frequent replacement of parts, and high maintenance costs. Especially when the working pressure is greater than 25MPa, due to the deformation of the body and crankshaft under force, the vibration and noise will be more intense, and it may even cause abnormal operation; due to the influence of the crankshaft structure, the three-plunger boosting pump has relatively high requirements for the boosting range. The same plunger structure is only applicable to a specific boosting range interval. When the boosting range exceeds this interval, whether the boosting range is too large or too small will increase the load on the drive motor and the crankshaft, causing the drive motor to be overloaded and the crankshaft to be damaged due to excessive force. The boosting range of the three-plunger pump can only be a specific interval designed at the factory and cannot achieve stepless adjustment from 0 to the maximum boosting value.

[0059] Due to the drawbacks of existing equipment and control methods, this application utilizes the principle of hydraulic transmission. It converts the mechanical energy of the high-speed rotation of the motor into the pressure energy of hydraulic oil through a constant-power variable oil pump, and then the hydraulic oscillator directly converts the pressure energy of the hydraulic oil into the pressure energy of the working fluid through the piston. Thus, the traditional mechanical transmission chain is changed, the mechanical transmission links are reduced, and high-efficiency energy transfer is achieved. At the same time, an oil replenishment and drainage link is set up. When there is leakage in the hydraulic piston seal, hydraulic oil can be replenished in a timely manner to ensure that the hydraulic piston stroke meets the actual use requirements. The hydraulic oil in the rodless cavity is replaced regularly to prevent the hydraulic oil in the rodless cavity from emulsifying and deteriorating due to long-term high-pressure and high-temperature operation, and to prevent the high temperature of the hydraulic oil from damaging the hydraulic piston seal and affecting the transmission efficiency. A booster plunger seal body is added. Once the seal groove is corroded and damaged, only the booster plunger seal body can be replaced, effectively reducing the maintenance volume and operating cost of the equipment.

[0060] The equipment corresponding to the control method of this application can adjust the injection volume in real time. An electromagnetic flowmeter is installed at the outlet to automatically detect the flow rate and feedback it to the controller. The controller controls the injection operation frequency of the motor oil pump to achieve real-time control and adjustment of the injection volume. The automatic closed-loop adjustment ensures that the equipment injects smoothly according to the preset displacement. An accumulator is installed to set the charging pressure according to the working pressure, reduce the outlet pressure pulsation rate, and make the output pressure stable. Intelligent control and visual monitoring are adopted to achieve real-time remote monitoring and supervision of the operation process, realize unattended operation at the equipment site, and reduce the management difficulty.

[0061] In the overall solution, the booster control method includes the following steps: The intelligent hydraulic booster equipment starts and enters the working state. At the same time, it collects the real-time position parameters, the outlet liquid pressure parameters of the valve box, the liquid level parameters of the hydraulic oil, and the temperature parameters of the hydraulic oil during the operation of the hydraulic cylinder piston, and performs booster control adjustment with the above multi-type parameters as a set. The controller is communicatively connected to the display for visual monitoring, adjusts the injection volume in real time, and cooperates with the electromagnetic flowmeter installed at the outlet to automatically detect the flow rate and feedback it to the controller. The controller controls the injection operation frequency of the motor oil pump to achieve real-time control and adjustment of the injection volume. The automatic closed-loop adjustment ensures that the equipment injects smoothly according to the preset displacement. An accumulator is installed to set the charging pressure according to the working pressure, reduce the outlet pressure pulsation rate, and make the output pressure stable. The controller cooperates with the driver to transmit drive commands to the variable hydraulic pump assembly, the hydraulic drive assembly, and the heat dissipation assembly respectively to complete automatic intelligent boosting from 0 to the maximum boost value within the equipment boost range.

[0062] For an intelligent hydraulic boosting device, including a base, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly which cooperate with each other are arranged on the base; the variable hydraulic pump assembly is used to fully utilize the energy of water to push two reciprocatingly moving hydraulic cylinders arranged in parallel and communicated with each other to perform reciprocating motion for boosting and eliminate hydraulic shock during the commutation process; the hydraulic drive assembly is used to provide hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used to collect various types of electrical parameters to achieve intelligent control, and to monitor and adjust the hydraulic boosting process in real time; the heat dissipation assembly is used to reduce the working temperature rise of the device; the variable hydraulic pump assembly includes a reciprocating pump that performs reciprocating motion for boosting, and the reciprocating pump includes two sets of valve boxes, bodies and hydraulic cylinders arranged in parallel and communicated with each other, and performs long-stroke reciprocating motion through a streamlined structure with fewer positioning points to reduce the requirement for the processing accuracy of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0063] Further, a liquid inlet valve body, a liquid inlet valve seat, a liquid outlet valve body and a liquid outlet valve seat are arranged in the valve box in a configured manner, and a valve body guide is arranged on the upper part of the liquid inlet valve body; a small gland, a small split bearing and a small cylinder head are arranged above the valve box, a large gland, a large split bearing and a large cylinder head are arranged on the side of the valve box, a valve body fixing plate is further arranged in the valve box, and a valve box support is arranged at the bottom of the valve box; a piston is arranged in the hydraulic cylinder, and the piston is connected to the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to form a sealing structure in cooperation with the piston rubber in the cylinder liner; hydraulic cylinder end covers are respectively arranged at both ends of the hydraulic cylinder barrel, and the rodless cavity end of the hydraulic cylinder is connected through a U-shaped oil pipe; under the action of the piston, the inlet pressure medium transmits energy to the hydraulic piston rod, and the hydraulic piston rod transmits energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity of the hydraulic cylinder and the U-shaped oil pipe, and then transmits it to the piston at the other end; a body support is arranged at the bottom of the body to support and protect the body.

[0064] The two hydraulic cylinders are communicated with each other through a U-shaped oil pipe, and the controller sets the maximum displacement distance and the minimum displacement distance of the displacement sensor. Before the device starts to run, the rodless cavities of the two hydraulic cylinders are filled with oil by a motor oil pump, so that the device is suitable for on-line boosting injection, that is, the inlet of the injection pump is a medium with a certain pressure; the pressure medium transmits energy to the hydraulic piston rod through the piston, and the hydraulic piston rod transmits energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity, and then transmits it to the piston at the other end.

[0065] Preferably, an oil replenishing port and an exhaust hole are provided on the hydraulic cylinder end cover of the hydraulic cylinder. The oil replenishing port is used to replenish oil to the rodless cavity of the hydraulic cylinder via a motor oil pump. An electromagnetic valve is provided on the exhaust hole. The electromagnetic valve is used to connect to the fuel tank. The working time is set via a controller to periodically open the electromagnetic valve to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder. The discharge amount is the volume of the hydraulic cylinder barrel corresponding to the difference between the maximum stroke and the minimum stroke of the displacement sensor provided on the hydraulic cylinder. When the hydraulic cylinder needs to change the oil, the electromagnetic valve is automatically opened to return the hydraulic oil in the rodless cavity to the fuel tank, shortening the operating stroke of the hydraulic cylinder piston. When the stroke is shortened to the minimum stroke value, the electromagnetic valve is automatically closed and the motor oil pump is opened to replenish oil to the rodless cavity of the hydraulic cylinder. The oil replenishment stops when the hydraulic piston stroke reaches the maximum stroke value.

[0066] For the hydraulic drive assembly, it includes a fuel tank and a constant power variable oil pump. The constant power variable oil pump is used to convert the mechanical energy of the motor into the pressure energy of the hydraulic oil, and then convert the pressure energy of the hydraulic oil into the working hydraulic pressure energy via a hydraulic oscillator. The constant power variable oil pump is connected to the motor via a coupling. The inlet of the constant power variable oil pump is flexibly connected to the inlet oil filter at the outlet of the fuel tank, so that the hydraulic oil in the fuel tank enters the constant power variable oil pump after being filtered by the inlet oil filter. The outlet of the constant power variable oil pump is connected to a tube type one-way valve via a rubber hose. The fuel tank is connected to a motor oil pump via an inlet oil filter. A tube type one-way valve and a high-pressure oil filter are sequentially connected to the motor oil pump. A bladder accumulator, a pilot-operated relief valve and a first direct-acting relief valve are configured at the rear end of the tube type one-way valve. The bladder accumulator is used to absorb the pulsation and shock during the hydraulic commutation process. The high-pressure oil filter, the tube type one-way valve and the bladder accumulator are integrated into a hydraulic valve block, so that the hydraulic oil enters the commutation valve block via the tube type one-way valve and the high-pressure oil filter. The commutation valve block includes an electro-hydraulic commutation valve, a pilot-operated relief valve and a direct-acting relief valve. The A and B ports of the electro-hydraulic commutation valve are respectively connected to the rod chambers of two hydraulic cylinders. An inlet slurry valve body seat and an outlet slurry valve body seat are respectively configured in each valve box. An oil suction filter, a first motor gear pump, a second direct-acting relief valve, a first tube type one-way valve and a second manual ball valve are sequentially connected between the two connected hydraulic cylinders.

[0067] Furthermore, a hydraulic cylinder barrel, a hydraulic piston rod and a cylinder liner are configured in the hydraulic cylinder to control the reciprocating motion of the hydraulic cylinder. An oil suction filter, a second motor gear pump and a second tube type one-way valve are also provided in the fuel tank to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by the back pressure action of the one-way valve.

[0068] During the working process of the hydraulic drive assembly, the following formula can be used for calculation:

[0069] The area of the piston at the liquid inlet end * the liquid inlet pressure + the effective cross-sectional area of the rod chamber of the hydraulic cylinder * the pressure in the rod chamber of the hydraulic cylinder = the area of the piston at the liquid outlet end * the liquid outlet pressure; that is, the pressure value in the rod chamber of the hydraulic cylinder = (the liquid outlet pressure - the liquid inlet pressure) * the piston area / the effective cross-sectional area of the rod chamber.

[0070] It can be seen from this that the injection equipment can utilize the liquid inlet pressure to achieve online pressure boosting.

[0071] For the electrical control component of the present application, it includes a power distribution cabinet arranged on the base. Inside the power distribution cabinet, there is a controller. Electrically connected to the controller are a displacement sensor, a pressure transmitter, a liquid level sensor, and a temperature sensor: The displacement sensor is arranged on the hydraulic cylinder to detect the real-time position during the operation of the hydraulic piston. At the same time, by setting the maximum and minimum position points, it controls the hydraulic piston to reverse, completing the reciprocating motion of the hydraulic reciprocating pump; The pressure transmitter is arranged on the liquid outlet pipe of the valve box to detect the liquid outlet pressure of the valve box; The liquid level sensor and the temperature sensor are arranged inside the fuel tank to detect the liquid level parameter and temperature parameter of the hydraulic oil in the fuel tank; Connected to the controller via a communication line is a display for visual monitoring, realizing real-time remote monitoring during the operation process; On the control, there is also a driver to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive component, and the heat dissipation component respectively, and automatically and intelligently boost the pressure from 0 to the maximum boost value within the pressure boosting range of the equipment.

[0072] Generally speaking, the controller can be a PLC controller, which is a digital operation electronic system designed specifically for application in an industrial environment. It uses a programmable memory to store instructions for performing operations such as logical operations, sequential control, timing, counting, and arithmetic operations inside it, and controls various types of mechanical equipment or production processes through digital or analog inputs and outputs.

[0073] For the heat dissipation component of the present application, it includes an air-cooled radiator and a radiator circulation oil pump that are set to cooperate to ensure that the working temperature of the equipment is between +10°C and +70°C. During winter construction, due to the low outdoor temperature and the viscosity of the hydraulic oil, the commutation may be abnormal. If such a situation occurs, the overflow valve should be opened first and the equipment should be run without load for a period of time. After the temperature of the hydraulic oil rises above +10°C, then normal operation can be carried out.

[0074] In order to further improve the safety of the equipment, a safety valve is arranged on the valve box. The safety valve has been adjusted at the factory. Generally, it is not allowed for the operator to turn its handle. If it is necessary to adjust its safety pressure, the following steps should be strictly followed: Start the oil pump; Adjust the stroke of the displacement sensor to prevent the pump from reversing. While turning the handle of the safety valve, observe the system pressure gauge. When the pressure shown on the pressure gauge reaches the required pressure, tighten the locknut of the safety valve handle.

[0075] Specifically, when the pump of the present application is running normally, the overflow valve should be closed to avoid the overflow of hydraulic oil through the overflow valve, which may cause the rapid increase of hydraulic oil temperature and the reduction of pump strokes, resulting in pump shutdown or affecting the pump displacement; the circulating water in the spray pump water tank should be kept clean. If it is contaminated or there are sundries, the clean water should be replaced in time and the water tank should be cleaned to prevent dirt from clogging the suction pipeline of the spray pump and causing damage to the pump.

[0076] In summary, an intelligent hydraulic pressure boosting control method in an embodiment of the present invention integrates multiple functions such as pressure boosting injection, safety protection, data acquisition, automatic regulation, and remote monitoring into one according to a predefined control logic, relying on an automated control structure. It uses a variable hydraulic pump assembly to drive and fully utilizes the energy of the incoming water to push the pistons in two parallel cylinders to reciprocate for pressure boosting, greatly improving the transmission efficiency, reducing energy consumption and leakage pollution, and effectively reducing vibrations, impacts, and noises during equipment operation; by adopting intelligent control and visual monitoring, it realizes real-time remote monitoring during the operation process, can automatically detect and feedback the flow rate and the water pressure at the inlet and outlet, reduces the outlet pressure pulsation rate, makes the output pressure stable, and reduces the movement speed of the pistons in the left and right pressure boosting cylinders by using large plungers with long strokes and low strokes under a certain displacement condition, improving the service life of the pressure boosting pistons, inlet and outlet check valves, and seals, extending the equipment maintenance period, reducing the labor intensity of maintenance personnel, increasing the continuous working time and overall service life of the equipment, thus meeting the actual application requirements of pressure boosting injection.

[0077] The above specific implementation manners shall not be used to limit the protection scope of the present invention. For those skilled in the art of the present technology, any alternative improvement or transformation made to the embodiments of the present invention falls within the protection scope of the present invention.

[0078] Those parts not detailed in the present invention are all well-known technologies to those skilled in the art of the present technology.

Claims

1. An intelligent hydraulic boost control method, characterized in that: The boost control method comprises the following steps: S1, the intelligent hydraulic booster device starts to work, collects the real-time position parameters of the hydraulic cylinder piston, the valve box outlet pressure parameters, the hydraulic oil level parameters and the hydraulic oil temperature parameters during the operation process, and performs boost control and adjustment based on the above multi-type parameters; S2, the controller is connected to the display for visual monitoring, and the injection volume is adjusted in real time. The electromagnetic flow meter installed at the outlet automatically detects the flow and feeds back to the controller; S3, the controller controls the injection operation frequency of the motor oil pump to achieve real-time control and adjustment of the injection volume. The automatic closed-loop adjustment ensures that the equipment injects smoothly according to the preset displacement. The accumulator is installed to set the charging pressure according to the working pressure, reduce the outlet pressure pulsation rate, and make the output pressure stable; S4, the controller cooperates with the driver to transmit drive instructions to the variable hydraulic pump assembly, the hydraulic drive component and the heat dissipation component respectively, to complete automatic intelligent boosting from 0 to the maximum boost value within the boost range of the equipment.

2. The intelligent hydraulic boost control method according to claim 1, characterized in that: The boosting device comprises a base, on which are arranged a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly that cooperate with each other; the variable hydraulic pump assembly is used to fully drive two parallel and connected hydraulic cylinders to perform reciprocating motion to boost pressure and eliminate hydraulic shock during the switching process by using the energy of water; the hydraulic drive assembly is used to provide hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used to collect multiple types of electrical parameters to realize intelligent control, and to monitor and adjust the hydraulic boosting process in real time; the heat dissipation assembly is used to reduce the working temperature rise of the equipment; The variable hydraulic pump assembly includes a reciprocating pump that performs reciprocating motion to increase pressure. The reciprocating pump includes two sets of parallel valve boxes, a body and a connected hydraulic cylinder. The streamlined structure with fewer positioning points performs long-stroke reciprocating motion to reduce the requirements for the hydraulic pump's processing accuracy and improve the overall working efficiency of the hydraulic pump.

3. The intelligent hydraulic boost control method according to claim 2, characterized in that: A hydraulic cylinder barrel, a hydraulic piston rod and a cylinder sleeve are arranged in the hydraulic cylinder to control the reciprocating motion of the hydraulic cylinder; a matching oil suction filter, a second motor gear pump and a second tubular one-way valve are also arranged in the oil tank to provide circulating hydraulic oil for the heat dissipation component and utilize the back pressure of the one-way valve to protect the heat dissipation component.

4. The intelligent hydraulic boost control method according to claim 3, characterized in that: The hydraulic drive assembly includes an oil tank and a constant power variable oil pump, wherein the constant power variable oil pump is used to convert the mechanical energy of the motor into the pressure energy of the hydraulic oil, and then convert the pressure energy of the hydraulic oil into the working hydraulic pressure energy via the hydraulic oscillator; the constant power variable oil pump is connected to the motor through a coupling, and the oil inlet of the constant power variable oil pump is flexibly connected to the oil inlet filter at the outlet of the oil tank, so that the hydraulic oil in the oil tank enters the constant power variable oil pump after being filtered by the oil inlet filter; the oil outlet of the constant power variable oil pump is connected to the tubular one-way valve through a hose; The oil tank is connected to the motor oil pump through the oil inlet filter; the motor oil pump is connected with a tubular check valve and a high-pressure oil filter in sequence, and a bladder accumulator, a pilot relief valve and a first direct-acting relief valve are arranged at the rear end of the tubular check valve; the bladder accumulator is used to absorb pulsation and impact during the hydraulic reversing process; the high-pressure oil filter, the tubular check valve and the bladder accumulator are integrated into a hydraulic valve block, so that the hydraulic oil enters the reversing valve block through the tubular check valve and the high-pressure oil filter; The reversing valve block includes an electro-hydraulic reversing valve, a pilot relief valve, and a direct-acting relief valve. The A and B ports of the electro-hydraulic reversing valve are respectively connected to the rod chambers of the two hydraulic cylinders. Each valve box is respectively provided with a slurry inlet valve seat and a slurry outlet valve seat; between the two connected hydraulic cylinders are provided an oil suction filter, a first motor gear pump, a second direct-acting overflow valve, a first tubular one-way valve and a second manual ball valve which are connected in sequence.

5. The intelligent hydraulic boost control method according to claim 4, characterized in that: A liquid inlet valve body, a liquid inlet valve seat, a liquid outlet valve body and a liquid outlet valve seat are arranged in the valve box, and a valve body guide is arranged on the upper part of the liquid inlet valve body; a small pressure cover, a small slip and a small cylinder cover are arranged above the valve box, a large pressure cover, a large slip and a large cylinder cover are arranged on the side of the valve box, a valve body fixing plate is also arranged in the valve box, and a valve box bracket is arranged at the bottom of the valve box; A piston is provided in the hydraulic cylinder, and the piston is connected to the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to cooperate with the piston rubber to form a sealing structure in the cylinder sleeve; hydraulic cylinder end covers are provided at both ends of the hydraulic cylinder barrel, and the rodless cavity ends of the hydraulic cylinder are connected through a U-shaped oil guide pipe; under the action of the piston, the liquid pressure medium transfers energy to the hydraulic piston rod, and the hydraulic piston rod transfers energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity of the hydraulic cylinder and the U-shaped oil guide pipe, and then transfers it to the other end piston; a body bracket is provided at the bottom of the body for supporting and protecting the body.

6. The intelligent hydraulic boost control method according to claim 5, characterized in that: An oil replenishing port and an exhaust hole are provided on the hydraulic cylinder end cover of the hydraulic cylinder. The oil replenishing port is used to replenish oil to the rodless cavity of the hydraulic cylinder via the motor oil pump; an electromagnetic valve is provided on the exhaust hole. The electromagnetic valve is used to connect the oil tank. The working time is set by the controller. The electromagnetic valve is opened regularly to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder. The discharge amount is the internal volume of the hydraulic cylinder barrel corresponding to the difference between the maximum stroke and the minimum stroke of the displacement sensor provided on the hydraulic cylinder; When the hydraulic cylinder needs to change the oil, the solenoid valve will automatically open to return the hydraulic oil in the rodless chamber to the oil tank, shortening the operating stroke of the hydraulic cylinder piston. When the stroke is shortened to the minimum stroke value, the solenoid valve will automatically close and the motor oil pump will be turned on to replenish oil in the rodless chamber of the hydraulic cylinder. When the oil is replenished to the maximum stroke value of the hydraulic piston, the oil replenishment will stop.

7. The intelligent hydraulic boost control method according to claim 5, characterized in that: The electrical control assembly includes a power distribution cabinet arranged on a base, a controller is arranged in the power distribution cabinet, and a displacement sensor, a pressure transmitter, a liquid level sensor and a temperature sensor are electrically connected to the controller: The displacement sensor is arranged on the hydraulic cylinder to detect the real-time position of the hydraulic piston during operation, and at the same time controls the hydraulic piston to switch by setting the maximum and minimum position points to complete the reciprocating motion of the hydraulic reciprocating pump; the pressure transmitter is arranged on the outlet pipe of the valve box to detect the outlet pressure of the valve box; the liquid level sensor and temperature sensor are arranged in the oil tank to detect the liquid level parameters and temperature parameters of the hydraulic oil in the oil tank; A display is connected to the controller via a communication line for visual monitoring, realizing real-time remote monitoring of the operation process; a driver is also provided on the control to transmit drive instructions to the variable hydraulic pump assembly, hydraulic drive component and heat dissipation component respectively, to complete automatic intelligent boosting from 0 to the maximum boost value within the boost range of the equipment.

8. The intelligent hydraulic boost control method according to claim 1, characterized in that: The heat dissipation assembly includes an air-cooled radiator and a radiator circulating oil pump that are matched to ensure that the operating temperature of the equipment is between +10°C and +70°C.

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