Intelligent hydraulic supercharging device based on integrated control

Abstract

The application discloses an intelligent hydraulic pressure boosting device based on integrated control, which comprises a base, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly which are arranged on the base and act in cooperation; the variable hydraulic pump assembly is used for fully pushing two parallel arranged and interconnected hydraulic cylinders to perform reciprocating motion boosting and eliminating hydraulic impact in the commutation process by using the energy of water; the hydraulic drive assembly is used for providing hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used for collecting multiple types of electrical parameters to realize intelligent control, and performing real-time monitoring and adjustment on the hydraulic pressure boosting process; and the heat dissipation assembly is used for reducing the working temperature rise of the device; long stroke reciprocating motion is performed through a simplified structure with less positioning points, so that the machining precision requirement of the hydraulic pump is reduced, and the overall working efficiency of the hydraulic pump is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to an intelligent hydraulic supercharging device based on integrated control. BACKGROUND

[0002] Due to the changes in formation structure, reservoir properties and crude oil properties, and the pollution and blockage of reservoirs caused by the production process, many injection wells cannot complete the injection allocation under the injection system pressure. The use of conventional acidification and fracturing for formation deblocking has a short effective period and high construction cost.

[0003] In view of the above defects, conventional acidification and fracturing are often used for formation deblocking, and the overall effective period is short. If the injection main line pressure is improved, the construction difficulty and cost will be too high. Therefore, in order to improve the injection pressure, an oilfield supercharging injection device needs to be installed at the end of the oilfield injection system to increase the pressure of a single well.

[0004] The existing oilfield supercharging injection device mainly includes a high-pressure multistage centrifugal pump and a high-pressure three-plunger pump. Since the existing two devices mostly use mechanical transmission structure, the overall running speed is too high, the work efficiency is low, the working noise is too large, the leakage pollution is serious, the maintenance is frequent, the overall degree of automatic control is low, and the actual production requirements of supercharging injection cannot be met. SUMMARY

[0005] The embodiment of the present application provides an intelligent hydraulic supercharging device based on integrated control. The structure design is reasonable, and multiple functions such as supercharging injection, safety protection, data acquisition, automatic regulation and control, and remote monitoring are integrated. A variable hydraulic pump assembly is used to drive and fully utilize the energy of the incoming water to drive the pistons in the two parallel hydraulic cylinders to reciprocate for supercharging, greatly improving the transmission efficiency, reducing energy consumption and leakage pollution, effectively reducing the vibration, impact and noise of the equipment during operation. Intelligent control and visual monitoring are adopted to realize real-time remote monitoring of the operation process, automatic detection and feedback of the flow and water pressure, reduction of the outlet pressure pulsation rate, smooth output pressure, reduction of the movement speed of the pistons in the left and right supercharging cylinders through large plunger long stroke low impact, improvement of the service life of the supercharging pistons, inlet and outlet liquid one-way valves and sealing elements, extension of the equipment maintenance period, reduction of the labor intensity of maintenance personnel, increase of the working time and overall service life of the equipment, and meeting of the actual application requirements of supercharging injection, thereby solving the problems in the prior art.

[0006] The technical scheme adopted by the present application to solve the above technical problems is:

[0007] The intelligent hydraulic supercharging device based on integrated control comprises a base, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly arranged on the base and cooperating with each other; the variable hydraulic pump assembly is used for fully pushing two parallel arranged and interconnected hydraulic cylinders to perform reciprocating motion supercharging and eliminating hydraulic impact in the reversing process by using the energy of water; the hydraulic drive assembly is used for providing hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used for collecting multiple types of electrical parameters to realize intelligent control, and performing real-time monitoring and adjustment on the hydraulic supercharging process; and the heat dissipation assembly is used for reducing the working temperature rise of the device.

[0008] The variable hydraulic pump assembly comprises a reciprocating pump for reciprocating motion supercharging, and the reciprocating pump comprises two sets of parallel arranged valve boxes, bodies and interconnected hydraulic cylinders, and performs long stroke reciprocating motion through a simplified structure with fewer positioning points to reduce the requirement on the machining precision of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0009] The hydraulic drive assembly comprises an oil tank and a constant power variable oil pump, the constant power variable oil pump is used for converting the mechanical energy of the motor into pressure energy of hydraulic oil, and then converting the pressure energy of the hydraulic oil into working hydraulic pressure energy through a hydraulic oscillator; the constant power variable oil pump is connected with the motor through a shaft coupling, the oil inlet of the constant power variable oil pump is flexibly connected with an oil inlet filter of the outlet of the oil tank, so that the hydraulic oil in the oil tank is filtered through the oil inlet filter and then enters the constant power variable oil pump; and the oil outlet of the constant power variable oil pump is connected with a tubular check valve through a rubber pipe.

[0010] The oil tank is connected with a motor oil pump through an oil inlet filter; a tubular check valve and a high pressure oil filter are sequentially connected on the motor oil pump, a capsule accumulator, a pilot overflow valve and a first direct overflow valve are arranged at the rear end of the tubular check valve; the capsule accumulator is used for absorbing the pulsation and impact in the hydraulic reversing process; the high pressure oil filter, the tubular check valve and the capsule 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.

[0011] The reversing valve block comprises an electro-hydraulic reversing valve, a pilot overflow valve and a direct overflow valve, the A and B ports of the electro-hydraulic reversing valve are respectively connected with the rod cavity of the two hydraulic cylinders.

[0012] An oil inlet valve body seat and an oil outlet valve body seat are respectively arranged in each valve box; an oil suction filter, a first motor gear pump, a second direct overflow valve, a first tubular check valve and a second manual ball valve are sequentially arranged between the two interconnected hydraulic cylinders.

[0013] The hydraulic cylinder is provided with a hydraulic cylinder barrel, a hydraulic piston rod and a cylinder sleeve to control the reciprocating motion of the hydraulic cylinder; the oil tank is also provided with a matched oil suction filter, a second motor gear pump and a second tubular check valve to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by using the back pressure of the check valve.

[0014] The valve box is provided with a matched inlet valve body, an inlet valve seat, an outlet valve body and an outlet valve seat, and the upper part of the inlet valve body is provided with a valve body guide; the upper part of the valve box is provided with a small gland, a small slip bowl and a small cylinder cover, the side of the valve box is provided with a large gland, a large slip bowl and a large cylinder cover, the valve box is also provided with a valve body fixing plate, and the bottom of the valve box is provided with a valve box support;

[0015] The hydraulic cylinder is provided with a piston connected with the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to form a sealing structure with the piston rubber in the cylinder sleeve; the two ends of the hydraulic cylinder barrel are respectively provided with hydraulic cylinder end covers, and the rodless cavity of the hydraulic cylinder is connected through a U-shaped oil guide pipe; under the action of the piston, the inlet hydraulic medium can transmit energy to the hydraulic piston rod, 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 guide pipe, and then to the other end of the piston; the bottom of the machine body is provided with a machine body support for supporting and protecting the machine body.

[0016] The hydraulic cylinder end cover of the hydraulic cylinder is provided with an oil supplement port and an exhaust hole, the oil supplement port is used for supplementing oil to the rodless cavity of the hydraulic cylinder through the motor oil pump; the electromagnetic valve is arranged on the exhaust hole, the electromagnetic valve is used for connecting the oil tank, the working time is set through the controller, the electromagnetic valve is opened regularly to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder, and the discharge amount is the difference between the maximum stroke and the minimum stroke of the displacement sensor arranged on the hydraulic cylinder corresponding to the internal volume of the hydraulic cylinder barrel;

[0017] When the hydraulic cylinder needs to be refilled, the electromagnetic valve is automatically opened to return the hydraulic oil in the rodless cavity to the oil tank, so that the running stroke of the hydraulic cylinder piston is shortened, and when the stroke is shortened to the minimum stroke value, the electromagnetic valve is automatically closed and the motor oil pump is opened to supplement oil to the rodless cavity of the hydraulic cylinder, and the oil supplement is stopped when the hydraulic piston stroke reaches the maximum stroke value.

[0018] The electrical control assembly includes a power distribution cabinet arranged on the base, a controller arranged in the power distribution cabinet, and a displacement sensor, a pressure transmitter, a liquid level sensor and a temperature sensor electrically connected to the controller:

[0019] The displacement sensor is arranged on the hydraulic cylinder and is used for detecting the real-time position of the hydraulic piston during operation, and controls the hydraulic piston to reverse through setting maximum and minimum position points, so that the reciprocating motion of the hydraulic reciprocating pump is completed; the pressure transmitter is arranged on the liquid outlet pipe of the valve box and is used for detecting the outlet pressure of the valve box; the liquid level sensor and the temperature sensor are arranged in the oil tank and are used for detecting the liquid level parameter and the temperature parameter of the hydraulic oil in the oil tank.

[0020] The display is connected to the controller through the communication line to realize visual monitoring and realize real-time remote monitoring of the operation process; the driver is further arranged on the controller to transmit driving instructions to the variable hydraulic pump assembly, the hydraulic driving assembly and the heat dissipation assembly respectively, so that the automatic intelligent pressurization from 0 to the maximum pressurization value is completed in the pressurization range of the equipment.

[0021] The heat dissipation assembly includes the air-cooled radiator and the radiator circulating oil pump arranged in cooperation to ensure that the working temperature of the equipment is +10℃-+70℃.

[0022] The safety valve is arranged on the valve box to improve the operation safety of the equipment.

[0023] The variable hydraulic pump assembly fully pushes the two parallel arranged and interconnected hydraulic cylinders to reciprocate and eliminate the hydraulic impact in the reversing process by using the energy of water; the hydraulic driving assembly provides hydraulic power for the variable hydraulic pump assembly; the electrical control assembly collects multiple types of electrical parameters to realize intelligent control, realizes real-time monitoring and adjustment of the hydraulic pressurization process, and relies on the parallel structure of the hydraulic piston to make the liquid inlet pressure of one end piston be completely transmitted to the other end piston, so that the hydraulic pressurization range can be from 0 to the maximum, the strict requirement of the mechanical three-cylinder pump on the inlet and outlet pressure difference is overcome, and stepless injection between the inlet and outlet pressure difference from 0 to the maximum pressure difference is realized; the heat dissipation assembly reduces the working temperature rise of the equipment, ensures the continuous and stable work of the equipment, and has the advantages of stable and practical, precise and efficient. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 It is a structural schematic view of the present application.

[0025] Figure 2 It is a structural schematic view of the variable hydraulic pump assembly of the present application.

[0026] Figure 3 It is a top view of Figure 1 .

[0027] Figure 4 It is a hydraulic principle diagram of the present application.

[0028] In the figure, 1, oil tank, 2, oil inlet filter, 3, motor oil pump, 4, high pressure oil filter, 5, bladder accumulator, 6, tubular check valve, 7, pilot overflow valve, 8, first direct-acting overflow valve, 9, electro-hydraulic directional control valve, 10, oil return filter, 11, displacement sensor, 12, first manual ball valve, 13, hydraulic cylinder barrel, 14, hydraulic piston rod, 15, cylinder sleeve, 16, pulp inlet valve body seat, 17, pulp outlet valve body seat, 18, first oil suction filter, 19, first motor gear pump, 20, second direct-acting overflow valve, 21, first tubular check valve, 22, second manual ball valve, 23, second oil suction filter, 24, second motor gear pump, 25, second tubular check valve, 26, air-cooled radiator. DETAILED DESCRIPTION

[0029] To clearly illustrate the technical features of the present scheme, the present application will be described in detail below through specific embodiments, and in conjunction with the accompanying drawings.

[0030] As shown in Figures 1-4 The intelligent hydraulic supercharging device based on integrated control comprises a base, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly are arranged on the base and act in cooperation; the variable hydraulic pump assembly is used for fully driving two parallel arranged and interconnected hydraulic cylinders to reciprocate for supercharging and eliminating hydraulic impact in the switching process by using the energy of water; the hydraulic drive assembly is used for providing hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used for collecting multiple types of electrical parameters to realize intelligent control, and for monitoring and adjusting the hydraulic supercharging process in real time; and the heat dissipation assembly is used for reducing the working temperature rise of the device.

[0031] The variable hydraulic pump assembly comprises a reciprocating pump for reciprocating to supercharge, and the reciprocating pump comprises two sets of parallel arranged valve boxes, bodies and interconnected hydraulic cylinders, and performs long stroke reciprocation through a simplified structure with fewer positioning points to reduce the requirement for machining precision of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0032] The hydraulic drive assembly comprises an oil tank and a constant-power variable oil pump, the constant-power variable oil pump is used for converting mechanical energy of the motor into pressure energy of the hydraulic oil, and then converting the pressure energy of the hydraulic oil into working hydraulic pressure energy through a hydraulic oscillator; the constant-power variable oil pump is connected with the motor through a shaft coupling, the constant-power variable oil pump inlet is flexibly connected with an 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; and the constant-power variable oil pump outlet is connected with the tubular check valve through a rubber tube.

[0033] The oil tank is connected with a motor oil pump through an oil inlet filter; a tubular check valve and a high-pressure oil filter are sequentially connected on the motor oil pump, and a bag-type accumulator, a pilot overflow valve and a first direct-acting overflow valve are arranged at the rear end of the tubular check valve; the bag-type accumulator is used to absorb pulsation and impact in hydraulic reversing process; the high-pressure oil filter, the tubular check valve and the bag-type accumulator are integrated into one hydraulic valve block, so that hydraulic oil enters the reversing valve block through the tubular check valve and the high-pressure oil filter;

[0034] The reversing valve block comprises an electro-hydraulic reversing valve and a pilot overflow valve and a direct-acting overflow valve, and A and B ports of the electro-hydraulic reversing valve are connected with rod cavities of two hydraulic cylinders respectively;

[0035] An inlet valve body seat and an outlet valve body seat are arranged in each valve tank respectively; an oil suction filter, a first motor gear pump, a second direct-acting overflow valve, a first tubular check valve and a second manual ball valve are sequentially arranged between the two hydraulic cylinders connected in communication.

[0036] 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; an oil suction filter, a second motor gear pump and a second tubular check valve are further arranged in the oil tank to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by using the back pressure of the check valve.

[0037] An inlet valve body, an inlet valve seat, an outlet valve body and an outlet valve seat are arranged in the valve tank, and a valve body guide is arranged on the upper part of the inlet valve body; a small gland, a small slip and a small cylinder cover are arranged above the valve tank, a large gland, a large slip and a large cylinder cover are arranged on the side surface of the valve tank, a valve body fixing plate is further arranged in the valve tank, and a valve tank support is arranged at the bottom of the valve tank;

[0038] A piston is arranged in the hydraulic cylinder, and the piston is connected with the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod to form a sealing structure with the rubber of the piston in the cylinder sleeve; hydraulic cylinder end covers are 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 guide pipe; under the action of the piston, the inlet hydraulic medium transmits energy to the hydraulic piston rod, the hydraulic piston rod transmits energy to the other hydraulic piston rod through the hydraulic oil in the rodless cavity of the hydraulic cylinder and the U-shaped oil guide pipe, and then to the other end piston; a machine body support is arranged at the bottom of the machine body to support and protect the machine body.

[0039] The hydraulic cylinder end cover of the hydraulic cylinder is provided with an oil supplement port and an exhaust hole, the oil supplement port is used for supplementing oil to the rodless cavity of the hydraulic cylinder via the motor oil pump, and the electromagnetic valve is arranged on the exhaust hole and used for connecting the oil tank, and the electromagnetic valve is opened regularly to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder via the controller setting the working time, and the discharge amount is the difference between the maximum stroke and the minimum stroke of the displacement sensor arranged on the hydraulic cylinder corresponding to the internal volume of the hydraulic cylinder barrel.

[0040] When the hydraulic cylinder needs to be refilled, the electromagnetic valve is automatically opened to return the hydraulic oil in the rodless cavity to the oil tank, so that the running stroke of the hydraulic cylinder piston is shortened, and when the stroke is shortened to the minimum stroke value, the electromagnetic valve is automatically closed and the motor oil pump is opened to supplement the oil in the rodless cavity of the hydraulic cylinder, and the oil supplement is stopped when the hydraulic piston stroke reaches the maximum stroke value.

[0041] The electrical control assembly comprises a power distribution cabinet arranged on the base, the controller is arranged in the power distribution cabinet, and the displacement sensor, the pressure transmitter, the liquid level sensor and the temperature sensor are electrically connected to the controller.

[0042] The displacement sensor is arranged on the hydraulic cylinder and used for detecting the real-time position of the hydraulic piston during operation, and the maximum and minimum position points are arranged to control the reversing of the hydraulic piston and complete the reciprocating motion of the hydraulic reciprocating pump; the pressure transmitter is arranged on the outlet pipe of the valve tank to detect the outlet pressure of the valve tank; and the liquid level sensor and the temperature sensor are arranged in the oil tank to detect the liquid level parameter and the temperature parameter of the hydraulic oil in the oil tank.

[0043] The display is connected to the controller via the communication line to realize visual monitoring and realize real-time remote monitoring during operation; the driver is arranged on the controller to transmit driving instructions to the variable hydraulic pump assembly, the hydraulic drive assembly and the heat dissipation assembly respectively, and the automatic intelligent pressurization from 0 to the maximum pressurization value is completed in the pressurization range of the equipment.

[0044] The heat dissipation assembly comprises the air-cooled radiator and the radiator circulating oil pump arranged in cooperation to ensure that the working temperature of the equipment is +10℃-+70℃.

[0045] The safety valve is arranged on the valve tank to improve the operation safety of the equipment.

[0046] The working principle of the intelligent hydraulic pressure boosting device based on integrated control in the embodiment of the application is that multiple functions such as pressure boosting injection, safety protection, data acquisition, automatic regulation and control, and remote monitoring are integrated into one, a variable hydraulic pump assembly is used to drive and fully utilize the energy of incoming water, and the pistons in the two parallel hydraulic cylinders are driven to reciprocate to boost pressure, thereby greatly improving transmission efficiency, reducing energy consumption and leakage pollution, effectively reducing vibration, impact and noise during operation of the device; intelligent control and visual monitoring are used to realize real-time remote monitoring of the operation process, automatic detection and feedback of flow and water pressure in and out, reduce outlet pressure pulsation rate, make output pressure stable, under the condition of meeting a certain displacement, reduce the movement speed of the pistons in the left and right pressure boosting cylinders through large plunger long stroke and low stroke frequency, improve the service life of the pressure boosting pistons, inlet and outlet one-way valves and sealing elements, prolong the equipment maintenance period, reduce the labor intensity of maintenance personnel, increase the working time and overall service life of the device in continuous use, thereby meeting the actual application requirements of pressure boosting injection.

[0047] The current pressure boosting injection equipment mainly includes high-pressure multi-stage centrifugal pumps and high-pressure three-plunger pumps, which have many problems in production and application, as follows.

[0048] For the high-pressure multi-stage centrifugal pump, the overall efficiency is very low, the efficiency of the best working condition point is generally not more than 60%, and the efficiency of most is less than 40%, so the power consumption is large and the energy waste is particularly serious. At the same time, due to the structural limitation, a large amount of leakage easily occurs at the pump shaft mechanical seal, causing environmental pollution; the multi-stage centrifugal pump can only be used for clean water injection, and cannot be used for oil field sewage injection due to the existence of particulate impurities, which easily causes wear and corrosion, greatly shortens the service life, and even cannot work normally.

[0049] For the high-pressure three-plunger pump, due to the influence of the crankshaft strength, the plunger diameter is relatively small, generally not more than 70mm; in order to meet a certain displacement, the stroke frequency of the plunger needs to be very high, generally up to 100-200 times per minute. The high stroke frequency brings a series of problems to the plunger pump, such as high noise, large vibration, frequent collision of pump valve opening and closing, and intensified wear of bearing bush, plunger and packing, which causes many faults, frequent replacement of parts, high maintenance cost, especially when the working pressure is greater than 25MPa, the stress deformation, vibration and noise of the body and crankshaft are more severe, and even the plunger pump cannot work normally; due to the influence of the crankshaft structure, the three-plunger pressure boosting pump has high requirements for the pressure boosting range, and the same plunger structure is only suitable for a certain specific pressure boosting range interval. When the pressure boosting range exceeds this interval, the pressure boosting range is too large or too small, which will increase the load of the driving motor and the crankshaft, cause the driving motor to be overloaded, and the crankshaft to be damaged due to excessive stress. The pressure boosting range of the three-plunger pump can only be the specific interval designed at the factory, and cannot realize stepless adjustment from 0 to the maximum pressure boosting value.

[0050] In view of the drawbacks in the prior art, the hydraulic transmission principle is used to convert the high-speed rotating mechanical energy of the motor into pressure energy of hydraulic oil through a constant power variable oil pump, and then the pressure energy of the hydraulic oil is directly converted into pressure energy of working fluid by a hydraulic oscillator through a piston, thereby changing the traditional mechanical transmission chain, reducing the mechanical transmission links, and realizing efficient energy transmission; Meanwhile, a supplement oil link is arranged, which can supplement hydraulic oil in time when there is leakage in the hydraulic piston seal, ensure that the hydraulic piston stroke meets the actual use requirement, periodically replace the hydraulic oil in the rodless cavity, prevent the emulsification deterioration and damage of the hydraulic piston seal caused by long-term high pressure and high temperature work of the hydraulic oil in the rodless cavity, affect the transmission efficiency, add a pressurizing plunger seal body, and only replace the pressurizing plunger seal body once the seal groove is corroded and damaged, thereby effectively reducing the maintenance amount and operation cost of the equipment.

[0051] Compared with the pressurized multi-stage centrifugal pump, the energy saving can reach 30-40%, compared with the pressurized plunger pump, the energy saving can reach 15-20%, compared with the pressurized multi-stage centrifugal pump, the maintenance cycle can be increased by 3-5 times, compared with the pressurized three-plunger pump, the maintenance cycle can be increased by 5-10 times, and compared with the pressurized plunger pump and the pressurized multi-stage centrifugal pump, the noise can be reduced by 1 / 3.

[0052] The device can adjust the injection amount in real time, an electromagnetic flowmeter is installed at the outlet, the flow is automatically detected and fed back to the controller, the controller controls the injection operation frequency of the motor oil pump, realizes real-time control and adjustment of the injection amount, and automatically closed-loop adjustment ensures that the device smoothly injects according to the preset displacement; an accumulator is installed and the inflation pressure is set according to the working pressure, the outlet pressure pulsation rate is reduced, and the output pressure is stable; intelligent control and visual monitoring are adopted, real-time remote monitoring and monitoring of the running process are realized, the device is unattended on site, and the management difficulty is reduced.

[0053] In the overall scheme, a base is mainly included, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly are arranged on the base and act in cooperation; the variable hydraulic pump assembly is used for fully driving two parallel arranged and interconnected hydraulic cylinders to reciprocate for pressure boosting and eliminating hydraulic impact in the commutation process by using the energy of water; the hydraulic drive assembly is used for providing hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used for collecting multiple types of electrical parameters to realize intelligent control, and realizes real-time monitoring and adjustment of the hydraulic pressure boosting process; the heat dissipation assembly is used for reducing the working temperature rise of the device; the variable hydraulic pump assembly includes a reciprocating pump for reciprocating pressure boosting, the reciprocating pump includes two sets of parallel arranged valve boxes, bodies and interconnected hydraulic cylinders, and a long stroke reciprocating motion is performed through a simplified structure with fewer positioning points to reduce the requirement for the machining precision of the hydraulic pump and improve the overall working efficiency of the hydraulic pump.

[0054] Further, the valve box is provided with a corresponding inlet valve body, inlet valve seat, outlet valve body and outlet valve seat, the upper part of the inlet valve body is provided with a valve body guide; the upper part of the valve box is provided with a small gland, small slip and small cylinder cover, the side of the valve box is provided with a large gland, large slip and large cylinder cover, the valve box is further provided with a valve body fixing plate, the bottom of the valve box is provided with a valve box support; the hydraulic cylinder is provided with a piston, the piston is connected with the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod, so as to form a sealing structure with the rubber of the piston in the cylinder sleeve; the two ends of the hydraulic cylinder are respectively provided with a hydraulic cylinder end cover, the rodless cavity end of the hydraulic cylinder is connected through a U-shaped oil guide pipe; under the action of the piston, the inlet pressure medium can transmit energy to the hydraulic piston rod, 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 guide pipe, and then transmits energy to another piston; the bottom of the machine body is provided with a machine body support for supporting and protecting the machine body.

[0055] The two hydraulic cylinders are connected through a U-shaped oil guide pipe, the controller sets the maximum displacement distance and the minimum displacement distance of the displacement sensor, and the two rodless cavities of the hydraulic cylinders are supplemented by the motor oil pump before the equipment starts to run, so that the equipment is suitable for online pressurized injection, that is, the inlet of the injection pump is provided with a medium with a certain pressure; the pressure medium transmits energy to the hydraulic piston rod through the piston, the hydraulic piston rod transmits energy to another hydraulic piston rod through the hydraulic oil in the rodless cavity, and then transmits energy to another piston.

[0056] Preferably, the hydraulic cylinder end cover of the hydraulic cylinder is provided with a supplementing oil port and an exhaust hole, the supplementing oil port is used for supplementing oil to the rodless cavity of the hydraulic cylinder through the motor oil pump; the exhaust hole is provided with a solenoid valve, the solenoid valve is used for connecting an oil tank, the working time is set through the controller, the solenoid valve is opened regularly to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder, and the discharge amount is the difference between the maximum stroke and the minimum stroke of the displacement sensor arranged on the hydraulic cylinder corresponding to the internal volume of the hydraulic cylinder barrel; when the hydraulic cylinder needs to be refilled, the solenoid valve is automatically opened to return the hydraulic oil in the rodless cavity to the oil tank, so that the running stroke of the hydraulic cylinder piston is shortened, and when the stroke is shortened to the minimum stroke value, the solenoid valve is automatically closed and the motor oil pump is opened to supplement oil to the rodless cavity of the hydraulic cylinder, and the supplementing oil is stopped when the hydraulic piston stroke reaches the maximum stroke value.

[0057] For the hydraulic drive assembly, including 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 the hydraulic oil, and then convert the pressure energy of the hydraulic oil into the working hydraulic pressure energy through a hydraulic oscillator; the constant power variable oil pump is connected with the motor through a shaft coupling, the oil inlet of the constant power variable oil pump is flexibly connected with an oil inlet filter of the oil tank outlet, 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 with a tubular check valve through a rubber pipe; the oil tank is connected with a motor oil pump through the oil inlet filter; a tubular check valve and a high-pressure oil filter are sequentially connected on the motor oil pump, and a bag-type accumulator, a pilot overflow valve and a first direct-acting overflow valve are arranged at the rear end of the tubular check valve; the bag-type accumulator is used to absorb the pulsation and impact in the hydraulic reversing process; the high-pressure oil filter, the tubular check valve and the bag-type 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 overflow valve and a direct-acting overflow valve, the A and B ports of the electro-hydraulic reversing valve are respectively connected with the rod cavities of two hydraulic cylinders; an inlet valve body seat and an outlet valve body seat are respectively arranged in each valve box; an oil suction filter, a first motor gear pump, a second direct-acting overflow valve, a first tubular check valve and a second manual ball valve are sequentially connected between the two hydraulic cylinders in communication.

[0058] Further, 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 cooperating oil suction filter, a second motor gear pump and a second tubular check valve are further arranged in the oil tank to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by using the back pressure of the check valve.

[0059] During the working process of the hydraulic drive assembly, the following formula can be used for calculation:

[0060] Piston area of the liquid inlet end * inlet pressure + effective cross-sectional area of the rod cavity of the hydraulic cylinder * pressure of the rod cavity of the hydraulic cylinder = piston area of the liquid outlet end * outlet pressure; that is, the pressure value of the rod cavity of the hydraulic cylinder = (outlet pressure - inlet pressure) * piston area / effective cross-sectional area of the rod cavity.

[0061] It can be seen that the injection equipment can realize online pressure boosting by using the inlet pressure.

[0062] For the electrical control assembly of the application, a power distribution cabinet is arranged on the 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 and is used to detect the real-time position of the hydraulic piston during operation, and the hydraulic piston is controlled to reverse by setting the maximum and minimum position points, so as to complete 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 outlet pressure of the valve box; the liquid level sensor and the temperature sensor are arranged in the oil tank to detect the liquid level parameter and the temperature parameter of the hydraulic oil in the oil tank; a display is connected to the controller through a communication line to realize visual monitoring and realize real-time remote monitoring during operation; a driver is further arranged on the controller to transmit driving instructions to the variable hydraulic pump assembly, the hydraulic drive assembly and the heat dissipation assembly respectively, and to complete automatic intelligent pressurization from 0 to the maximum pressurization value within the pressurization range of the equipment.

[0063] Generally, the controller can be a PLC controller, which is a digital operation electronic system specially designed for application in industrial environment. A programmable memory is adopted to store instructions for performing logic operation, sequence control, timing, counting and arithmetic operation in the internal memory, and various types of mechanical equipment or production process are controlled through digital or analog input and output.

[0064] For the heat dissipation assembly of the application, a forced air cooling radiator and a radiator circulating oil pump are arranged in cooperation to ensure that the working temperature of the equipment is within +10℃-+70℃. In winter construction, due to low outdoor temperature, the hydraulic oil is viscous, which may cause abnormal reversing. If this situation occurs, the overflow valve should be opened first and run empty for a period of time. When the temperature of the hydraulic oil rises above +10℃, normal operation can be performed.

[0065] In order to further improve the safety of the equipment, a safety valve is arranged on the valve box. The safety valve is adjusted when it leaves the factory, and generally the operator is not allowed to turn the handle. If it is necessary to adjust the safety pressure, the following steps should be strictly followed: start the oil pump; adjust the displacement sensor stroke to prevent the pump from reversing, turn the safety valve handle while observing the system pressure gauge, and tighten the safety valve handle when the pressure gauge shows the required pressure.

[0066] It is particularly pointed out that when the pump of the application is normally running, the overflow valve should be closed to avoid the overflow of the hydraulic oil through the overflow valve, which may cause the temperature of the hydraulic oil to rise too fast and the pump stroke to decrease, resulting in pump stop or affecting the displacement of the pump; the circulating water in the water tank of the spray pump should be kept clean. If pollution or debris occurs, the water should be replaced and the water tank should be cleaned in time to prevent the debris from blocking the suction pipeline of the spray pump and causing damage to the pump.

[0067] In summary, the intelligent hydraulic supercharging equipment based on integrated control in the embodiment of the application integrates multiple functions such as supercharging injection, safety protection, data acquisition, automatic regulation and control, remote monitoring and the like into one, adopts a variable hydraulic pump assembly for driving and fully utilizes the energy of incoming water to drive the pistons in two parallel arranged hydraulic cylinders to reciprocate for supercharging, greatly improves the transmission efficiency, reduces energy consumption and leakage pollution, effectively reduces the vibration, impact and noise of the equipment during operation, realizes real-time remote monitoring of the operation process through intelligent control and visual monitoring, can automatically detect and feedback the flow and water pressure in and out, reduces the outlet pressure pulsation rate, makes the output pressure stable, under the condition of meeting a certain displacement, reduces the movement speed of the pistons in the left and right supercharging cylinders through large plunger long stroke low impact, prolongs the service life of the supercharging pistons, inlet and outlet liquid one-way valves and sealing elements, prolongs the equipment maintenance period, reduces the labor intensity of maintenance personnel, increases the working time and overall service life of the equipment for continuous use, thereby meeting the actual application requirements of supercharging water injection.

[0068] The above detailed description cannot be regarded as a limitation on the protection scope of the application, and any alternative improvement or change made by those skilled in the art to the embodiments of the application falls within the protection scope of the application.

[0069] The parts not described in detail in the application are known to those skilled in the art.

Claims

1. An intelligent hydraulic supercharging device based on integrated control, characterized in that: The supercharging device comprises a base, a variable hydraulic pump assembly, a hydraulic drive assembly, an electrical control assembly and a heat dissipation assembly arranged on the base and cooperating with each other; the variable hydraulic pump assembly is used for fully pushing two parallel arranged and interconnected hydraulic cylinders to perform reciprocating motion for supercharging and eliminating hydraulic impact in the commutation process by using the energy of water; the hydraulic drive assembly is used for providing hydraulic power for the variable hydraulic pump assembly; the electrical control assembly is used for collecting multiple types of electrical parameters to realize intelligent control, and performing real-time monitoring and adjustment on the hydraulic supercharging process; and the heat dissipation assembly is used for reducing the working temperature rise of the device; The variable hydraulic pump assembly comprises a reciprocating pump for performing reciprocating motion for supercharging, and the reciprocating pump comprises two sets of parallel arranged valve boxes, bodies and interconnected hydraulic cylinders, and performs long stroke reciprocating motion through a simplified structure with fewer positioning points to reduce the machining precision requirement of the hydraulic pump and improve the overall working efficiency of the hydraulic pump. The hydraulic drive assembly comprises an oil tank and a constant power variable oil pump, the constant power variable oil pump is used for converting the mechanical energy of the motor into pressure energy of the hydraulic oil, and then converting the pressure energy of the hydraulic oil into working hydraulic pressure energy through a hydraulic oscillator; the constant power variable oil pump is connected with the motor through a shaft coupling, the oil inlet of the constant power variable oil pump is flexibly connected with the oil filter of the outlet of the oil tank, so that the hydraulic oil in the oil tank is filtered through the oil inlet filter and then enters the constant power variable oil pump; and the oil outlet of the constant power variable oil pump is connected with a tubular check valve through a rubber pipe. The oil tank is connected with a motor oil pump through an oil inlet filter; a tubular check valve and a high pressure oil filter are sequentially connected on the motor oil pump, a bladder accumulator, a pilot overflow valve and a first direct acting overflow valve are arranged at the rear end of the tubular check valve; the bladder accumulator is used for absorbing the pulsation and impact in 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; The commutation valve block comprises an electro-hydraulic commutation valve, a pilot overflow valve and a direct acting overflow valve, and the A and B ports of the electro-hydraulic commutation valve are connected with the rod cavity of the two hydraulic cylinders respectively; An inlet and outlet valve body seat is arranged in each valve box respectively; an oil suction filter, a first motor gear pump, a second direct acting overflow valve, a first tubular check valve and a second manual ball valve are sequentially connected between the two interconnected hydraulic cylinders; A safety valve is arranged on the valve box.

2. The intelligent hydraulic supercharging device based on integrated control according to claim 1, 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; an oil suction filter, a second motor gear pump and a second tubular check valve are arranged in the oil tank in cooperation to provide circulating hydraulic oil for the heat dissipation assembly and protect the heat dissipation assembly by using the back pressure of the check valve.

3. The integrated control based intelligent hydraulic supercharging apparatus according to claim 2, wherein: The valve box is provided with a liquid inlet valve body, a liquid inlet valve seat, a liquid outlet valve body and a liquid outlet valve seat arranged in the valve box, a valve body guide is arranged on the upper portion of the liquid inlet valve body, a small gland, a small slip bowl and a small cylinder cover are arranged on the upper portion of the valve box, a large gland, a large slip bowl and a large cylinder cover are arranged on the side of the valve box, a valve body fixing plate is arranged in the valve box, and a valve box support is arranged on the bottom of the valve box; The piston is arranged in the hydraulic cylinder, the piston is connected with the hydraulic cylinder through a hydraulic mud rod and a hydraulic piston rod, so as to form a sealing structure with the rubber of the piston in the cylinder sleeve; the hydraulic cylinder end covers are 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 guide pipe; under the action of the piston, the liquid pressure medium can transmit energy to the hydraulic piston rod, 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 guide pipe, and then the energy is transmitted to the other end of the piston; the machine body support is arranged at the bottom of the machine body and used for supporting and protecting the machine body.

4. The integrated control based intelligent hydraulic supercharging apparatus according to claim 3, wherein: The oil supplement port and the exhaust hole are arranged on the hydraulic cylinder end cover of the hydraulic cylinder, the oil supplement port is used for supplementing oil to the rodless cavity of the hydraulic cylinder through the motor oil pump, and the electromagnetic valve is arranged on the exhaust hole and used for connecting the oil tank, regularly opening the electromagnetic valve to discharge a part of the hydraulic oil in the rodless cavity of the hydraulic cylinder, and the discharge amount is the difference between the maximum stroke and the minimum stroke of the displacement sensor arranged on the hydraulic cylinder. When the hydraulic cylinder needs to be refilled, the electromagnetic valve is automatically opened to return the hydraulic oil in the rodless cavity to the oil tank, so that the running stroke of the hydraulic cylinder piston is shortened, and when the stroke is shortened to the minimum stroke value, the electromagnetic valve is automatically closed and the motor oil pump is opened to supplement oil to the rodless cavity of the hydraulic cylinder, and the oil supplement is stopped when the hydraulic piston stroke reaches the maximum stroke value.

5. The intelligent hydraulic supercharging device based on integrated control according to claim 3, characterized in that: The electrical control assembly comprises a power distribution cabinet arranged on the 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 and used for detecting the real-time position of the hydraulic piston in the running process, and the maximum and minimum position points are arranged to control the hydraulic piston to change direction and complete the reciprocating motion of the hydraulic reciprocating pump; the pressure transmitter is arranged on the liquid outlet pipe of the valve box and used for detecting the outlet pressure of the valve box; the liquid level sensor and the temperature sensor are arranged in the oil tank and used for detecting the liquid level parameter and the temperature parameter of the hydraulic oil in the oil tank. A display is connected to the controller through a communication line to realize visual monitoring and realize real-time remote monitoring of the running process; a driver is further arranged on the controller to transmit driving instructions to the variable hydraulic pump assembly, the hydraulic driving assembly and the heat dissipation assembly respectively, and the automatic intelligent pressurization from 0 to the maximum pressurization value in the pressurization range of the equipment is completed.

6. The integrated control based intelligent hydraulic supercharging apparatus according to claim 1, wherein: The heat dissipation assembly comprises a forced air cooling radiator and a radiator circulating oil pump arranged in cooperation to ensure that the working temperature of the equipment is +10℃-+70℃.

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