Chassis truck of fracturing pump truck and control method

Abstract

The invention relates to the technical field of oil field engineering vehicles, and particularly discloses a chassis truck of a fracturing pump truck and a control method, the chassis truck of the fracturing pump truck comprises a chassis, a power source, a four-axis transmission device, a wheel system, a construction device and a control system; wherein the four-shaft transmission device is respectively connected with the wheel system and a plunger pump in the construction device. The chassis truck of the fracturing pump truck has two working modes: in a running mode, a single power source drives a transmission wheel set to drive wheels; in the construction operation mode, the multiple power sources drive the multiple transmission wheel sets to output in a linkage mode, and the plunger pump is driven to work. The chassis truck of the fracturing pump truck is flexible in power switching, efficient in driving and capable of meeting the multi-working-condition operation requirements.

Description

Technical Field

[0001] The invention relates to the technical field of oilfield engineering vehicles, and in particular discloses a chassis vehicle of a fracturing pump truck and a control method thereof. Background Art

[0002] At present, the chassis of a fracturing pump truck is a key equipment for fracturing construction in oil and gas production. It is usually composed of a chassis, an engine, a hydraulic system, and a control system. Its main task is to complete high-pressure fluid injection operations at the well site. The chassis of traditional fracturing pump trucks are mostly driven by a single engine or a single motor (such as a diesel engine). The power is transmitted to the plunger pump through a simple transmission structure to complete the fracturing task. The process is complex and the power combination form is single. Especially in the scenario of alternating long-distance movement and high-intensity continuous fracturing operations, the power system lacks flexible deployment capabilities.

[0003] Therefore, there is an urgent need for a new energy power configuration that can effectively utilize the power of the chassis vehicle and can flexibly switch between vehicle driving and fracturing operations, and at the same time, a new transmission device that can realize parallel output of multiple power sources, improve transmission efficiency, and reduce manufacturing and use costs. Summary of the invention

[0004] In order to overcome the technical problems in the prior art that a single power output cannot effectively utilize the power of the chassis vehicle and that a multi-power system cannot be used to flexibly switch between the two working modes of driving and fracturing operation, the purpose of the present invention is to provide a new chassis vehicle of a fracturing pump truck that can flexibly switch the power configuration between vehicle driving and fracturing operation, and a control method for the chassis vehicle of a fracturing pump truck.

[0005] To achieve the above-mentioned purpose, a chassis vehicle of a fracturing pump truck of the present invention comprises a chassis, a power source, a four-axis transmission device, a wheel system, a construction device and a control system which are mutually connected; the four-axis transmission device comprises a transmission system, a linkage mechanism and a clutch mechanism, the transmission system comprises four transmission wheel sets which are transmission-connected with the linkage mechanism and the clutch mechanism, the four transmission wheel sets each have an input end, and two transmission wheel sets each have an output end, the input end of the transmission wheel set is used to cooperate with the power source, and the output ends of the two transmission wheel sets are respectively used to cooperate with the wheel system and the plunger pump of the construction device;

[0006] The linkage mechanism is used to combine the power of the four transmission wheel groups, the clutch mechanism is used to regulate the engagement or separation of the input end of the transmission wheel group with the power source, and the clutch mechanism is also used to regulate the engagement or separation of the output end of the transmission wheel group with the plunger pump;

[0007] The chassis of the fracturing pump truck has two working modes: in the driving mode, one power source cooperates with one drive wheel set to drive the wheel system to move; in the construction operation mode, multiple power sources cooperate with multiple drive wheel sets to be connected in parallel and input to drive the plunger pump to operate.

[0008] Further, the drive wheel set includes a main shaft body, a first gear disk connected to the main shaft body in a matching manner, and a flange connecting member connected to the first gear disk in a matching manner. The linkage mechanism is a gear mechanism. There are three groups of the gear mechanisms. The first drive wheel set is meshed and driven with the first gear disks of the remaining three drive wheel sets respectively through the three groups of the gear mechanisms.

[0009] Further, the flange connecting member includes a flange disk and a connecting cylinder formed integrally. The central axes of the flange disk and the connecting cylinder coincide with each other. The outer diameter of the flange disk is larger than that of the connecting cylinder. A plurality of circular holes are arranged in an array on the outer edge portion of the flange disk for passing bolts. An internal tooth is formed inside the connecting cylinder for meshing and connecting with a power input device and a power output device.

[0010] Further, the linkage mechanism includes a first driven gear, a second driven gear, and a third driven gear. Each driven gear is located between two adjacent drive wheel sets. The output end of the first drive wheel set is engaged or disengaged with the plunger pump.

[0011] Further, a plurality of circular through holes are arranged in the wheel body regions of the first driven gear, the second driven gear, the third driven gear, and the first gear disk of the drive wheel set. The plurality of circular through holes are arranged in a circumferential array around the central axis of the wheel body. The arrangement of the plurality of circular through holes significantly reduces the overall mass of the gear, especially the mass far from the rotation center, thereby greatly reducing the moment of inertia of the gear. This enables the entire transmission device to require less energy during startup, acceleration, and braking, respond more quickly, and improves the dynamic performance and efficiency of the system. The uniformly distributed circular holes help to achieve a more balanced distribution of the gear mass, effectively reducing the centrifugal force generated by the unbalanced mass, thereby reducing the vibration and noise during high-speed rotation and improving the running smoothness of the transmission system.

[0012] Further, central holes are opened at the centers of the first driven gear, the second driven gear, the third driven gear, and the first gear disk of the drive wheel set. An inner connection structure distributed in a circumferential direction is formed on the inner wall of the central holes of the second driven gear and the third driven gear. The inner connection structure is preferably an internal spline or an internal tooth. An outer connection structure is provided on the outer wall of the central hole of the first driven gear, and the outer connection structure is an external tooth.

[0013] The internal spline or internal teeth are composed of a plurality of radially protruding splines or teeth, which are concentrically arranged with the central hole and are designed to engage and connect with corresponding external splines or external teeth on a mating component (such as a shaft or a sleeve). The driven gear or gear disc provided by the present invention realizes high-strength and reliable torque transmission and relative rotation locking with the mating component through the internal spline or internal tooth structure on its inner ring.

[0014] Further, an engine and a power generation and electric integration machine are provided at the input end of a transmission wheel set, and the output end of the transmission wheel set is used to connect to the wheel system of the pump truck.

[0015] Further, the first gear discs of the four transmission wheel sets of the transmission system are arranged coplanarly.

[0016] Further, the four transmission wheel sets are arranged in a T shape, the rotation axes of the four transmission wheel sets are parallel, and the rotation axes of three of the transmission wheel sets are arranged coplanarly. Each linkage mechanism is respectively connected to two adjacent transmission wheel sets in a matching manner.

[0017] Further, a gearbox is provided between the transmission wheel set and the power source, and the gearbox is used to adjust the output speed and torque of the power source to improve the power adaptability and transmission efficiency of the four-axis transmission device.

[0018] Further, the diameter of the first driven gear is larger than the diameters of the second driven gear and the third driven gear, the diameters of the second driven gear and the third driven gear are equal, and the number of teeth of the first driven gear is larger than the number of teeth of the second driven gear; the output ends of the two transmission wheel sets connected to the first driven gear are respectively connected to the wheel system of the pump truck and the plunger pump of the vehicle platform in a matching manner.

[0019] Further, the input ends of two transmission wheel sets are used to be connected to a combined power source in a matching manner, and the power input ends of the other two transmission wheel sets are used to be connected to two auxiliary drive sources of the vehicle platform in a matching manner. The combined power source includes an engine and a power generation and electric integration machine, the auxiliary drive source is a power generation and electric integration machine, and the output end of the transmission wheel set driven by the combined power source is used to be connected to the wheel system of the chassis truck of the fracturing pump truck in a matching manner.

[0020] Further, the chassis truck of the fracturing pump truck further includes an energy management system arranged in cooperation with the four-axis transmission device, and the energy management system includes an electric energy conversion module, an electric energy management module, and an electric energy storage unit.

[0021] The electric energy conversion module includes an inverter-rectifier device connected to a power generation and electric drive integrated machine (the power generation and electric drive integrated machine connected to the engine) of the drive pulley set. The inverter-rectifier device is used to convert the alternating current output by the power generation and electric drive integrated machine into direct current when the four-axis drive device is in the construction operation mode, and output it to the electric energy storage unit or supply power to other power generation and electric drive integrated machines.

[0022] The electric energy management module is used to control the power generation and electric drive integrated machine to switch to the power generation mode in the construction operation mode, and control the power generation and electric drive integrated machine to switch to the hybrid power mode of drive or power generation when the pump truck needs to travel.

[0023] The electric energy storage unit is preferably a high-power density battery pack or a supercapacitor pack, which is used to store the electric energy generated by the power generation and electric drive integrated machine or the electric energy charged by a fixed charging pile, and supply power to other power generation and electric drive integrated machines or auxiliary equipment as needed.

[0024] Further, the inverter-rectifier device is electrically connected to the electric energy management module, the electric energy management module is electrically connected to the energy storage unit, and the electric energy management module is communicatively connected to the clutch mechanism of the four-axis drive device, and is used to control the working state switching of the power generation and electric drive integrated machine of the combined power source according to the working mode instruction.

[0025] Further, in the construction operation mode, the power generation and electric drive integrated machine works in cooperation with the engine and outputs electric energy as a generator. A part of the generated electric energy is directly supplied to at least one other power generation and electric drive integrated machine to drive construction devices such as a plunger pump, and the remaining electric energy is input to the electric energy storage unit for storage; in the pump truck driving mode, the electric energy management module controls the power generation and electric drive integrated machine to switch from the power generation mode to the hybrid power mode of drive or power generation, and disconnects the direct connection with the energy storage system to realize power driving of the pump truck wheel system.

[0026] In the construction operation mode, the four-axis drive device is controlled to switch to the construction state through the clutch mechanism. The first power generation and electric drive integrated machine switches from the drive state to the power generation state under the instruction of the electric energy management module, and generates electric energy by using the power provided by the engine. After being converted by the inverter-rectifier module, a part of the generated electric energy is supplied to the plunger pump power generation and electric drive integrated machine in real time, and the other part is stored in the electric energy storage unit. When the construction operation load changes, the energy management module dynamically distributes the power generation and power consumption ratio to ensure stable output of construction power. When the full power is output in this mode, the engines of the two combined power sources output greater power. While driving the pump truck for construction, they drive the power generation and electric drive integrated machine to generate electricity, and the generated electricity is supplied to the power generation and electric drive integrated machines of the two auxiliary power sources to drive the pump truck for construction.

[0027] Through the above improvements, the present invention realizes the secondary utilization of the engine power during the construction operation of the pump truck. The power generation and electric integration machine of the combined power source generates electricity, improving the energy recovery rate, effectively reducing the energy consumption, and enhancing the fuel economy. At the same time, through intelligent switching and energy management, the coordinated operation of the power system and the electric energy system is achieved, improving the overall energy efficiency and reliability of the transmission device, and extending the service life of the power system and auxiliary equipment. In addition, the setting of the power storage unit also provides power buffer support for the short-term high-load working conditions during construction, improving the construction efficiency and stability of the chassis truck of the fracturing pump truck as a whole.

[0028] A control method for the chassis truck of a fracturing pump truck according to the present invention includes the following steps:

[0029] Step S1: The clutch mechanism receives the operation mode instruction input by the control system or manually, and the operation mode instruction includes a driving mode and a construction operation mode;

[0030] Step S2: Control of the driving mode. If the control system inputs the driving mode, the clutch mechanism is used to engage the input end and the output end corresponding to the transmission wheel set, and separate the connection between the input end of the remaining transmission wheel sets and the power source; start the combined power source, and the power of the combined power source is adjusted by the gearbox and then drives the output end of the transmission wheel set to drive the wheel system to move;

[0031] Step S3: Control of the construction operation mode. If the control system inputs the construction operation mode, the clutch mechanism is used to engage the connection between the input ends of the four transmission wheel sets and the power source, and at the same time engage the output end of the transmission wheel set and the plunger pump; start the engine and the power generation and electric integration machine, and the power of multiple transmission wheel sets is combined through the linkage mechanism and then output to the plunger pump of the construction device; use the gearbox to adjust the output speed and torque of the power source in real time to make the plunger pump work in the preset power range.

[0032] A chassis truck of a fracturing pump truck and its control method provided by the present invention, through structural innovation and energy management optimization, has the following beneficial effects:

[0033] (1) The chassis truck of the fracturing pump truck provided by the present invention has two working states of "driving mode" and "construction operation mode", and can be switched with one key according to the operation requirements, improving the flexibility and practicality of the equipment in the moving and operation scenarios.

[0034] (2) Four transmission wheel sets are provided in the transmission system, and power combination is achieved through the linkage mechanism, supporting the coordinated drive of the engine and multiple power generation and electric integration machines, effectively improving the reliability of the power system.

[0035] (3) By precisely controlling the clutch mechanism, the independent switching of the input and output states of the drive wheel set is achieved, significantly reducing the energy transfer loss and improving the overall operation efficiency.

[0036] (4) The drive wheel set is arranged in a T-shape, with the axes designed to be parallel and partially coplanar. This not only optimizes the spatial layout but also facilitates gear meshing, maintenance, and replacement, enhancing the structural reliability and maintenance convenience of the equipment.

[0037] (5) The integrated inverter-rectifier device, power management module, and power energy storage unit can switch the power generation and electric drive integrated machine to the power generation state during construction operations, support real-time power supply and surplus energy storage, effectively improve the energy recovery rate, and extend the system endurance time.

[0038] (6) The control method provided by the present invention can issue a working mode command through the control system or directly manually control the clutch mechanism, and use the clutch mechanism to regulate the output and input modes of the drive shaft group to achieve free power switching, improving the operation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 is a three-dimensional structural schematic diagram of the four-axis drive device of the present invention;

[0040] Figure 2 is an exploded structural schematic diagram of the four-axis drive device of the present invention;

[0041] Figure 3 is a structural schematic diagram of the power transmission direction of the four-axis drive device of the present invention;

[0042] Figure 4 is an exploded structural schematic diagram of the drive wheel set of the present invention;

[0043] Figure 5 is Figure 4 an enlarged structural schematic diagram of part A in

[0044] Figure 6 is a structural schematic diagram of the chassis truck of the fracturing pump truck of the present invention;

[0045] Figure 7 is a flow schematic diagram of the control method of the chassis truck of the fracturing pump truck of the present invention.

[0046] Reference numerals include:

[0047] 1. Transmission system; 2. Linkage mechanism; 3. Clutch mechanism; 5. Gearbox; 6. Wheel system; 11. Transmission wheel set; 111. Shaft; 112. First gear plate; 113. Flange connector; 1131. Flange plate; 1132. Connecting tube; 1133. Circular hole; 12. Input end; 13. Output end; 21. First driven gear; 22. Second driven gear; 23. Third driven gear; 24. Circular through hole; 25. Center hole; 26. Internal connection structure; 27. External connection structure; 41. Generator and electric machine; 42. Engine. DETAILED DESCRIPTION

[0048] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation mode, structure, characteristics and effects of the present invention are described in detail below in combination with the accompanying drawings and preferred embodiments.

[0049] See also Figures 1 to 7 As shown, a chassis vehicle of a fracturing pump truck of the present invention comprises a chassis, a power source, a four-axis transmission device, a wheel system 6, a construction device and a control system connected to each other; the four-axis transmission device comprises a transmission system 1, a linkage mechanism 2 and a clutch mechanism 3, the transmission system 1 has four transmission wheel groups 11 connected to the linkage mechanism 2 and the clutch mechanism 3, the four transmission wheel groups 11 each have an input end 12, and the two transmission wheel groups 11 each have an output end 13, the input end 12 of the transmission wheel group 11 is used to cooperate with the power source, and the output ends 13 of the two transmission wheel groups 11 are respectively used to cooperate with the wheel system 6 and the plunger pump of the construction device;

[0050] The linkage mechanism 2 is used to combine the power of the four transmission wheel groups 11, the clutch mechanism 3 is used to regulate the engagement or separation of the input end 12 of the transmission wheel group 11 with the power source, and the clutch mechanism 3 is also used to regulate the engagement or separation of the output end 13 of the transmission wheel group 11 with the plunger pump;

[0051] The chassis of the fracturing pump truck has two working modes: in the driving mode, one power source cooperates with one transmission wheel set 11 to drive the wheel system 6 to move; in the construction operation mode, multiple power sources cooperate with multiple transmission wheel sets 11 to link and input the vehicle to drive the plunger pump to operate.

[0052] Through the design of a four-axis transmission device, this solution allows the chassis of the fracturing pump truck to be adjusted and switched in different working modes, so that the pump truck can reasonably distribute power during driving and construction operations, thereby improving power utilization efficiency and equipment applicability.

[0053] Specifically, the drive pulley set 11 includes a main shaft body 111, a first gear disc 112, and a flange connecting member 113. The linkage mechanism 2 is composed of three gear transmission mechanisms, and each group meshes and transmits with two adjacent first gear discs 112. This solution uses a gear transmission mechanism with high transmission efficiency and good stability, which can accurately transmit power and realize the power linkage between the drive pulley sets 11.

[0054] Specifically, the linkage mechanism 2 is composed of a first driven gear 21, a second driven gear 22, and a third driven gear 23. Each driven gear is located between two adjacent drive pulley sets 11. The setting of the driven gear further clarifies the transmission mode of the linkage mechanism 2, making the power transmission between the drive pulley sets 11 more flexible.

[0055] This solution uses 3 gear transmission mechanisms. The first gear discs 112 of two adjacent drive pulley sets 11 are meshed through the intermediate driven gears (for example, the gear disc of the first drive pulley set 11 is connected to the gear disc of the second drive pulley set 11 through the first driven gear 21 (large diameter and many teeth), the second drive pulley set 11 is connected to the third drive pulley set 11 through the second driven gear 22, and the third drive pulley set 11 is connected to the fourth drive pulley set 11 through the third driven gear 23). The second drive pulley set 11 is arranged at the center of gravity of the T-shaped structure and meshes and transmits with the adjacent second driven gear 22 and third driven gear 23 through the clutch mechanism 3 to form a chain drive structure. When the clutch mechanism 3 connects the transmission path corresponding to a certain driven gear, the driving gear (first gear disc 112) drives the driven gear to rotate, and then drives the driving gears of the adjacent drive pulley sets 11 to rotate synchronously, realizing the power transmission across the drive pulley sets 11.

[0056] This kind of gear meshing transmission has high precision (stable transmission ratio) and strong anti-impact ability, and is suitable for the power synchronization requirements in high-pressure operation scenarios. The unified design of the drive pulley set 11 using a gear disc + flange connecting member 113 reduces the manufacturing and maintenance costs. The gear transmission mechanism can adjust the transmission ratio by replacing the driven gear to adapt to different working conditions.

[0057] Specifically, in this embodiment, the clutch mechanism 3 uses a multi-link synchronous clutch. Each driven gear corresponds to an independent electromagnetic clutch, and the engagement and separation are realized through an axially sliding sleeve. A synchronous ring is sleeved inside the sleeve to ensure the same speed when the gears are engaged and reduce the impact. Each electromagnetic clutch drives the sleeve to move axially through a hydraulic cylinder. The central hole 25 of each driven gear is connected to the shaft body 111 through a spline, and a cross universal joint is used between the driven gear and the shaft body 111 to compensate for the axis angle deviation.

[0058] During actual use, the PLC control system is utilized to control the hydraulic cylinder to drive the sliding sleeve to reciprocate for clutch engagement. For example, when switching from the independent drive of the first driven gear 21 to the parallel drive of the second driven gear 22 and the third driven gear 23, the PLC first disconnects the electromagnetic clutch of the first driven gear 21, and then regulates the hydraulic cylinder to drive the sleeves of the second driven gear 22 and the third driven gear 23 to move synchronously. After the synchronous rings ensure that the rotational speeds match, they engage.

[0059] In another embodiment, the clutch mechanism 3 adopts a manual clutch operation. The clutch mechanism 3 includes a set of multiple clutch assemblies that are cooperatively connected to the input ends 12 and output ends 13 of each transmission wheel set 11, and is equipped with a linkage lever mechanism, a pedal control device, and a displacement feedback locking device. The operator can achieve centralized control of the states of each clutch by stepping on the main clutch pedal provided in the cab.

[0060] Specifically, each clutch assembly adopts a friction plate structure, including a driving friction plate, a driven friction plate, a compression spring, and a release mechanism, which are respectively installed between the input end 12 and the output end 13 of the corresponding transmission wheel set 11. When the compression spring is in a natural state, the driving plate and the driven plate are pressed and engaged to achieve power transmission; when the operator steps on the clutch pedal, the hydraulic assist cylinder is driven to act through the linkage mechanism, pushing the release shaft to move axially, overcoming the pre-pressure of the compression spring to separate the friction plates, thereby disconnecting the power path.

[0061] Different from the precise actions executed by the electric control system according to logical instructions, this mechanical clutch structure allows the operator to flexibly control the engagement or separation states of each transmission wheel set according to actual operation needs. For example, if entering the driving mode, the operator only needs to step on the clutch pedal to the first stroke. There is a first mechanical limit device at this position, which only connects the power input end 12 and the output end 13 of the main transmission wheel set 11, and the remaining three transmission wheel sets 11 remain in a separated state; when it is necessary to switch to the construction operation mode, the operator continues to step on the pedal to the second extreme position. At this time, the four clutches are simultaneously engaged, and the system ensures that all transmission wheel sets are synchronously connected to the power source through the mechanical linkage structure, and drives the plunger pump into the operation state.

[0062] The displacement feedback locking device physically holds the current clutch state through a ratchet and pawl structure, preventing misoperations such as the pedal rebounding or being released midway under different working conditions. In addition, to enhance the operating feel and stroke feedback, the clutch pedal is equipped with a multi-stage damping spring group, which respectively corresponds to the operating forces required for different modes, realizing precise linkage from the human-machine interface to the mechanical execution. The structure of the above embodiment does not require the participation of electric control logic, and completely realizes the manual switching of the chassis vehicle mode of the fracturing pump truck through mechanical and hydraulic principles, having the advantages of fast response, reliable structure, and adaptability to extreme working conditions, and is especially suitable for use in environments with extremely high requirements for reliability and maintainability in the oil and gas field.

[0063] Each driven gear independently corresponds to a set of adjacent transmission wheel sets 11. Through the clutch mechanism 3, the driven gear can be selectively activated (for example, when only the first driven gear 21 is activated, the first transmission wheel set 11 and the second transmission wheel set 11 are linked, and the remaining transmission wheel sets 11 are independent), so as to realize the linkage of some transmission wheel sets 11 or the parallel connection of all transmission wheel sets 11.

[0064] Specifically, the first gear discs 112 of the four transmission wheel sets 11 of the transmission system 1 are arranged in the same plane. The arrangement in the same plane facilitates the meshing transmission between gears, making the power transmission more stable and reliable, and reducing the transmission error and energy loss.

[0065] Specifically, the 4 transmission wheel sets 11 are arranged in a "T" shape, that is, one transmission wheel set 11 and an adjacent transmission wheel set 11 are arranged vertically (only referring to the drawings in the specification, defined as the vertical transmission wheel set 11, the input end 12 of the lower part is connected to the combined power source, and the output end 13 on the right side of the lower part is connected to the wheel system 6), and three transmission wheel sets 11 are arranged horizontally (defined as the horizontal transmission wheel set 11, the input end 12 is connected to the auxiliary power generation and electric integration machine 41, and the output end 13 on the right side of the upper part is connected to the plunger pump). The horizontal transmission wheel set 11 and the vertical transmission wheel set 11 are connected by the linkage mechanism 2 to form a "T" structure.

[0066] The electric power generation and integration machine 41 is actually a device that can realize the mutual conversion between mechanical energy and electrical energy. This machine can be used as a generator when needed to convert mechanical energy into electrical energy; while at other times, it can be used as a motor to convert electrical energy into mechanical energy. This conversion is achieved through the internal electromagnetic field and electronic circuit, and the specific implementation method is relatively common in new energy vehicles.

[0067] This kind of "T" layout is adapted to the pump truck chassis structure (the horizontal transmission wheel set 11 is arranged along the width direction of the vehicle body, and the vertical transmission wheel set 11 is arranged along the height direction of the vehicle body), making full use of the idle space under the chassis and avoiding interference with components such as the engine 42 and fuel tank. Moreover, the adjacent transmission wheel sets 11 are directly connected by the linkage mechanism 2, shortening the power transmission path and reducing the energy loss (for example, the power of the horizontal transmission wheel set 11 is directly transmitted to the vertical transmission wheel set 11 through the first driven gear 21 without a long-distance shaft body 111).

[0068] Specifically, the first gear discs 112 of the four transmission wheel sets 11 are installed in the same plane (such as the horizontal middle plane of the device housing). The central axes of the first gear discs 112 are parallel to each other and have equal spacing (or the spacing is adjusted according to the size of the driven gear), ensuring that all the first gear discs 112 mesh with the corresponding driven gears in the same plane, and avoiding the transmission error caused by spatial intersection. This coplanar meshing eliminates the axial load, reduces gear wear and noise, and at the same time facilitates installation and debugging (no need for three-dimensional centering), reducing the assembly difficulty. In addition, the gear sets in the same plane can be sealed by a unified protective cover to prevent dust and oil from invading and extend the service life.

[0069] Specifically, a gearbox 5 (such as a manual gearbox 5, an automatic gearbox 5 or a continuously variable transmission 5) is connected in series between the input end 12 of each transmission wheel set 11 and the power source. The input shaft of the gearbox 5 is connected to the power source (such as the output shaft of the engine 42), and the output shaft is connected to the main spindle body 111 of the transmission wheel set 11. Multiple sets of gear pairs (such as high-speed gears and low-speed gears) are arranged inside the gearbox 5, and the transmission ratio is adjusted through a shifting mechanism (hydraulic or electric drive). In the driving mode, the torque is increased through the low-speed gear of the gearbox 5 (suitable for starting and climbing slopes), and the speed is reduced through the high-speed gear (suitable for high-speed driving); in the construction operation mode, the speed of the power source is adjusted through the gearbox 5 so that the plunger pump operates in the corresponding range (such as ±5% of the rated speed).

[0070] Specifically, the gearbox 5 is internally provided with an overload protection device (such as a clutch slipping mechanism). When the plunger pump suddenly jams, the power transmission is automatically cut off to avoid damaging the transmission wheel set 11.

[0071] Specifically, the diameter D1 of the first driven gear 21 (connecting the driving transmission wheel set 11 and the adjacent transverse transmission wheel set 11) > the diameters D2 = D3 of the second and third driven gears 23, and the number of teeth Z1 > Z2 (Z2 = Z3). For example, D1 = 500 mm, D2 = 300 mm, Z1 = 80 teeth, and Z2 = 56 teeth. The output ends 13 of the two transmission wheel sets 11 meshing with the first driven gear 21 are respectively connected to the wheels (requiring low speed and high torque) and the plunger pump (requiring high speed and medium torque).

[0072] Specifically, the input ends 12 of the two transmission wheel sets 11 (please refer to the attached Figure 3 and the attached Figure 6 ) are connected to the combined power source (the engine 42 and the power generation and electric integration machine 41), and the input ends 12 of the other two transmission wheel sets 11 (horizontally arranged in the attached Figure 3 ) are connected to the auxiliary drive source (the power generation and electric integration machine 41) of the vehicle platform. The output end 13 of the transmission wheel set 11 driven by the combined power source is connected to the chassis vehicle wheel system 6 of the fracturing pump truck.

[0073] The combined power source of the chassis vehicle part focuses on driving the wheels (requiring high power and a wide speed range), and the combined power source and auxiliary power source of the upper vehicle part focus on driving the working device (requiring constant speed and high precision), avoiding the efficiency loss of a single power source to meet both working conditions simultaneously. The auxiliary power generation and electric integration machine 41 can use the electric energy of the electric energy storage unit (such as a battery pack) to achieve the complementarity of fuel power and electric power, reducing the fuel consumption during operation (especially when high-pressure pumping for a long time, mainly relying on electric drive).

[0074] The engine 42 and the power generation and electric integration machine 41 are connected through a clutch or a coupler (for example, the output shaft of the engine 42 is connected to the rotor shaft of the power generation and electric integration machine 41 through a clutch, and the stator of the power generation and electric integration machine 41 is fixed to the housing of the transmission wheel set 11). In the driving mode, pure electric (the power generation and electric integration machine 41 works alone), pure fuel (the engine 42 works alone), or hybrid drive (both work simultaneously) can be selected according to the working conditions, improving energy efficiency and endurance. When either the engine 42 or the power generation and electric integration machine 41 fails, the other power source can independently drive the wheels to ensure the basic driving function of the pump truck.

[0075] Via the addition of a transmission device and an energy management system, the chassis vehicle of the fracturing pump truck of the present invention can adjust two working modes. The driving mode of the chassis vehicle of the fracturing pump truck: engage the linkage mechanism 2 associated with the transmission wheel set 11 and disengage the linkage mechanism 2 associated with another transmission wheel set 11. The combined power source composed of the engine 42 and the power generation and electric integration machine 41 drives the transmission wheel set 11 connected thereto. After adjusting the speed and torque through the gearbox 5, the power is transmitted to the wheel assembly through the main shaft body 111, the first gear disc 112, etc., to drive the pump truck to travel.

[0076] The construction operation mode: Multiple power sources (2 engines 42 and 4 power generation and electric integration machines 41) cooperate with multiple transmission wheel sets 11 to link and input in parallel. The engine 42 and the power generation and electric integration machine 41 connected thereto work together. The two power generation and electric integration machines 41 are switched to the power generation mode under the control of the electric energy management module and the engine 42 (the clutch mechanism 3 connects the linkage paths of all transmission wheel sets 11, and the electric energy management module controls the core power generation and electric integration machine 41 to switch to the power generation mode. The shaft of the engine 42 and the power generation and electric integration machine 41 rotates to generate alternating current, which is converted into direct current through an inverter rectification device. Part of the electric energy is directly supplied to other power generation and electric integration machines 41 to drive construction devices such as plunger pumps, and the remaining electric energy is stored in the electric energy storage unit. The power of the four transmission wheel sets 11 is combined in parallel through the driven gears of the linkage mechanism 2 and output to the output end 13 of one transmission wheel set 11 to drive the construction device to work.

[0077] Through different working modes and transmission mechanism designs, power can be flexibly distributed according to the different requirements of the pump truck during driving and construction operations, improving power utilization efficiency. In the operation mode, the excess power of the engine 42 is converted into electrical energy by the core power generation and electric integration unit 41 for the auxiliary power generation and electric integration unit 41 to use, reducing fuel waste. The independent auxiliary power generation and electric integration unit 41 is powered by the energy storage unit or the power grid (if external connection is required), avoiding excessive dependence on the engine 42 during operation. Especially when the engine 42 fails, it can be temporarily powered by the energy storage unit to complete emergency operations.

[0078] The working process of the chassis vehicle of the fracturing pump truck of the present invention is described below in conjunction with specific embodiments.

[0079] Chassis vehicle driving mode of the fracturing pump truck:

[0080] Step 1, Power source activation: The driver selects the "driving mode" through the operation panel, and the power management module sends an instruction to make the clutch mechanism 3 only connect the input and output paths of the driving wheel set 11 (the linkage mechanisms 2 of other wheel sets 11 are separated). The core power generation and electric integration unit 41 switches to the driving mode (driven directly by the battery pack or the engine 42, depending on the energy selection).

[0081] Step 2, Power transmission: The combined power source (engine 42 + power generation and electric integration unit 41) outputs power, the gearbox 5 adjusts the speed and torque, and drives the main shaft body 111 of the driving wheel set 11, the first gear disk 112 (not engaged with the driven gear, rotating independently), the flange connecting piece 113, the drive axle, and the wheels.

[0082] Step 3, Energy management: The power management module adjusts the generator load by controlling the working state (power generation or driving) of the power generation and electric integration unit 41, making the generator work in the efficient range and improving the working efficiency.

[0083] Chassis vehicle construction mode of the fracturing pump truck:

[0084] Step 1, Power source activation: The operation panel selects the "operation mode", and the power management module sends an instruction to the clutch mechanism 3. The clutch mechanism 3 connects the linkage mechanisms 2 of all wheel sets 11 (all 3 groups of driven gears are engaged). Core power generation and electric integration unit 41: Switches to the power generation mode (driven by the engine 42 to rotate and operates as a generator).

[0085] Step 2, Power transmission: While the engine 42 outputs power to drive the piston pump, it also drives the core power generation and electric integration unit 41 to generate electricity. The inverter rectifier device converts AC to DC, the DC bus, and the DC bus directly supplies power to 2 auxiliary power generation and electric integration units 41 (driving 2 working wheel sets 11 respectively), the main shaft body 111, the first gear disk 112, the driven gear linkage, and the power is aggregated to a certain wheel set 11 (see the appendixFigure 3 Output terminal 13 at the upper right) output terminal 13, plunger pump and other construction devices.

[0086] Energy storage charging: Excess electrical energy is stored in a high-power battery pack / supercapacitor (the charging current is dynamically adjusted by the power management module).

[0087] Step 3: Energy management: The power management module monitors the DC bus voltage in real time. When the power of the energy storage unit is greater than 80%, the charging current is automatically reduced to give priority to power supply to the construction equipment.

[0088] The four-axis transmission device of the present invention significantly improves the stability, accuracy and impact resistance of power transmission through the coordinated design of the multi-transmission wheel set 11, the linkage mechanism 2 and the coupling mechanism, combined with the coplanar layout of the gears and the differentiated gear parameter settings. The multi-link synchronous clutch is used to achieve rapid switching of the transmission path, and the layout of the T-type transmission wheel set 11 is used to optimize the space utilization, effectively reduce energy loss and enhance the compactness of the system.

[0089] A control method for a chassis vehicle of a fracturing pump truck of the present invention specifically comprises the following steps:

[0090] Step S1: receiving a driving mode or a construction operation mode input by a control system;

[0091] Step S2: Driving mode control

[0092] If it is in driving mode, the clutch mechanism 3 engages the input end 12 and the output end 13 corresponding to the transmission wheel set 11 (the transmission 11 connected to the combined power source), and disconnects the input end 12 of the remaining transmission wheel sets 11 from the power source;

[0093] The engine 42 and the integrated generator and motor 41 are started, and the power is adjusted by the gearbox 5 to drive the output end 13 of the transmission wheel set 11 to drive the wheel system 6 to move;

[0094] Since the generator-motor integrated machine 41 participates in power output, the power management module controls the generator-motor integrated machine 41 to switch to a driving mode or a power generation mode, and is powered by the energy storage unit;

[0095] Step S3: Construction operation mode control

[0096] If it is the construction operation mode, the clutch mechanism 3 is used to connect the input ends 12 of all the transmission wheel groups 11 with the power source, and at the same time, the output end 13 of one transmission wheel group 11 (the transmission wheel group 11 located in the center of the T-shape) is connected with the transmission path of the plunger pump;

[0097] Start the engine 42 and all the power generation and electric drive integrated machines 41. The engine 42 drives the power generation and electric drive integrated machines 41 of the drive wheel sets 11 connected thereto to switch to the power generation mode. The generated electric energy is converted into direct current through the inverter-rectifier device. A part of the electric energy is directly supplied to the plunger pump power generation and electric drive integrated machine, and the remaining electric energy is stored in the energy storage unit;

[0098] The power of multiple drive wheel sets 11 is output to the plunger pump after being combined by the gear meshing of the linkage mechanism 2;

[0099] The transmission 5 adjusts the output speed and torque of the power source in real time to make the plunger pump operate in the rated power range;

[0100] Step S4: Dynamic energy management

[0101] In the construction operation mode, monitor the remaining power of the energy storage unit and the load demand of the plunger pump:

[0102] If the power of the energy storage unit is lower than the threshold value, such as 30%, the engine 42 is preferentially driven to generate power;

[0103] If the load suddenly increases, the energy storage unit releases electric energy to assist in driving the plunger pump;

[0104] In the driving mode, if the power of the power generation and electric drive integrated machine 41 is insufficient, the engine 42 drives the wheel system 6 and charges the energy storage unit at the same time.

[0105] The energy management system integrates an inverter-rectifier module and a power storage unit. In the construction operation mode, it converts the redundant power of the engine 42 into electric energy for storage or directly drives auxiliary equipment, realizing the efficient recovery and dynamic distribution of energy, and significantly improving the fuel economy. The overload protection function of the transmission 5 and the redundant design of the hybrid power source further ensure the reliability and adaptability of the equipment, meeting both the high torque requirements during the pump truck driving and ensuring the stable output during the construction operation.

[0106] Through structural optimization and intelligent control, this device solves the problems of uneven power distribution, mode switching hysteresis and energy waste in the traditional transmission system 1, has the characteristics of high efficiency, energy saving and multi-condition adaptability, and significantly improves the comprehensive performance and operation efficiency of the chassis vehicle of the fracturing pump truck.

[0107] The above is only a preferred embodiment of the present invention, and does not impose any form of limitation on the present invention. Although the present invention has been disclosed above with the preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to make equivalent embodiments with equivalent changes. However, as long as it does not depart from the technical content of the present invention, any brief modifications, equivalent changes and modifications made to the above embodiments according to the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A chassis vehicle of a fracturing pump truck, characterized in that: The invention comprises a chassis, a power source, a four-axis transmission device, a wheel system (6), a construction device and a control system which are mutually connected; the four-axis transmission device comprises a transmission system (1), a linkage mechanism (2) and a clutch mechanism (3); the transmission system (1) comprises four transmission wheel sets (11) which are transmission-connected to the linkage mechanism (2) and the clutch mechanism (3); the four transmission wheel sets (11) each have an input end (12); two transmission wheel sets (11) each have an output end (13); the input end (12) of the transmission wheel set (11) is used for being connected to the power source; the output ends (13) of the two transmission wheel sets (11) are used for being connected to the wheel system (6) of the pump truck and the plunger pump of the construction device respectively; The linkage mechanism (2) is used to combine the power of the four transmission wheel groups (11); the clutch mechanism (3) is used to regulate the engagement or separation of the input end (12) of the transmission wheel group (11) and the power source; the clutch mechanism (3) is also used to regulate the engagement or separation of the output end (13) of the transmission wheel group (11) and the plunger pump; The chassis of the fracturing pump truck has two working modes: in the driving mode, one power source cooperates with one transmission wheel group (11) to drive the wheel system (6) to move; in the construction operation mode, multiple power sources cooperate with multiple transmission wheel groups (11) to link and input the vehicle to drive the plunger pump to operate.

2. The chassis truck of the fracturing pump truck according to claim 1, characterized in that: The transmission wheel set (11) comprises a shaft (111), a first gear plate (112) matched with the shaft (111), and a flange connection piece (113) matched with the first gear plate (112); the linkage mechanism (2) is a gear mechanism, and the gear mechanism is provided with three groups. The first transmission wheel set (11) is respectively meshed with the first gear plates (112) of the remaining three transmission wheel sets (11) via the three groups of the gear mechanisms for transmission.

3. The chassis truck of the fracturing pump truck according to claim 2, characterized in that: The linkage mechanism (2) comprises a first driven gear (21), a second driven gear (22) and a third driven gear (23); the first driven gear (21) is located between the first transmission wheel group (11) and the second transmission wheel group (11); the second driven gear (22) is located between the second transmission wheel group (11) and the third transmission wheel group (11); and the third driven gear (23) is located between the second transmission wheel group (11) and the fourth transmission wheel group (11).

4. The chassis truck of the hydraulic fracturing pump truck according to claim 1, characterized in that: The power source comprises a generator-motor integrated machine (41) and / or an engine (42), and the input end (12) of the transmission wheel set (11) is used to connect the generator-motor integrated machine (41) and / or the engine (42).

5. The chassis truck of the fracturing pump truck according to claim 4, characterized in that: The chassis vehicle of the fracturing pump truck also includes an energy management system arranged in cooperation with the four-axis transmission device, and the energy management system includes an electric energy conversion module, an electric energy management module and an electric power storage unit. The electric energy conversion module includes an inverter rectifier device connected to a generator-electric integrated machine. The inverter rectifier device is used to convert the AC power output by the generator-electric integrated machine into DC power when the chassis vehicle of the fracturing pump truck is in the construction operation mode, and output it to the power storage unit or supply power to other generator-electric integrated machines. The electric energy management module is used to control the integrated power generation and electric drive unit to switch to the power generation mode in the construction operation mode, and to control the integrated power generation and electric drive unit to switch to the drive mode when the chassis truck of the fracturing pump truck needs to travel.

6. The chassis truck of the fracturing pump truck according to claim 1, characterized in that: The four transmission wheel sets (11) are arranged in a T shape, and the rotation axes of the four transmission wheel sets (11) are parallel to each other, and the rotation axes of three of the transmission wheel sets (11) are coplanar.

7. The chassis truck of the fracturing pump truck according to claim 1, wherein: A gearbox (5) is provided between the transmission wheel set (11) of the four-axis transmission device and the power source, and the gearbox (5) is used to adjust the output speed and torque of the power source to improve the power adaptability and transmission efficiency of the four-axis transmission device.

8. The chassis truck of the fracturing pump truck according to claim 3, characterized in that: The diameter of the first driven gear (21) is larger than the diameters of the second driven gear (22) and the third driven gear (23), the diameters of the second driven gear (22) and the third driven gear (23) are equal, and the number of teeth of the first driven gear (21) is greater than the number of teeth of the second driven gear (22); the output ends (13) of the two transmission wheel sets (11) connected to the first driven gear (21) are respectively connected to the wheel system (6) and the plunger pump of the vehicle platform.

9. The chassis vehicle of the fracturing pump truck according to claim 1, characterized in that: The input ends (12) of two transmission wheel sets (11) are used to be connected to the combined power source in a matching manner, and the input ends (12) of the other two transmission wheel sets (11) are used to be connected to the two auxiliary drive sources of the chassis in a matching manner. The combined power source includes an engine (42) and an integrated power generation and electric drive unit (41), the auxiliary drive source is the integrated power generation and electric drive unit (41), and the output end (13) of the transmission wheel set (11) driven by the combined power source is used to be connected to the plunger pump of the vehicle platform and the wheel system (6) of the chassis truck of the pressure pump truck in a matching manner.

10. A control method for a chassis vehicle of a fracturing pump truck, characterized in that: The control method is applicable to the chassis truck of the fracturing pump truck according to any one of claims 1-9, and the control method includes the following steps: Step S1: The clutch mechanism (3) receives the operation mode instruction input by the control system or manually, and the operation mode instruction includes a driving mode and a construction operation mode; Step S2: Driving mode control. If the control system inputs the driving mode, the clutch mechanism (3) engages the input end (12) and the output end (13) corresponding to the two transmission wheel sets (11), and separates the connection between the input end (12) of the remaining two transmission wheel sets (11) and the power source; start the combined power source, and the power of the combined power source drives the wheel system (6) to move through the output ends of the two transmission wheel sets; Step S3: Construction operation mode control. If the control system inputs the construction operation mode, the clutch mechanism (3) engages the connection between the input ends (12) of the four transmission wheel sets (11) and the power source, and at the same time engages the output ends (13) of the two transmission wheel sets (11) and the plunger pump; start the engine (42) and the integrated power generation and electric drive unit (41), and the power of the multiple transmission wheel sets (11) is combined through the linkage mechanism (2) and then output to the plunger pump of the construction device.

Images