A chassis and control method for a fracturing pump truck

Abstract

This invention relates to the field of oilfield engineering vehicle technology, and in particular discloses a chassis and control method for a fracturing pump truck. The chassis of the fracturing pump truck includes a chassis, a power source, a four-axle transmission device, a wheel system, a construction device, and a control system; wherein the four-axle transmission device is connected to the wheel system and the plunger pump in the construction device. The chassis of this fracturing pump truck has two working modes: in driving mode, a single power source drives one transmission wheel set to drive the wheels; in construction operation mode, multiple power sources drive multiple transmission wheel sets in a coordinated output to drive the plunger pump. The fracturing pump truck chassis of this invention has flexible power switching and high driving efficiency, and can adapt to the needs of multiple working conditions.

Description

Technical Field

[0001] This invention relates to the field of oilfield engineering vehicle technology, and in particular discloses a chassis and control method for a fracturing pump truck. Background Technology

[0002] Currently, fracturing pump truck chassis, as key equipment in fracturing operations during oil and gas extraction, typically consist of a chassis, engine, hydraulic system, and control system. Their primary task is to perform high-pressure fluid injection operations at the well site. Traditional fracturing pump truck chassis often use a single engine or a single electric motor (such as a diesel engine) for drive. Power is transmitted to the plunger pump via a simple transmission structure to complete the fracturing task. This process is complex, and the power combination is limited. Especially in scenarios involving long-distance movement and alternating 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 chassis vehicle's power and flexibly switch between vehicle driving and fracturing operations, while also enabling multiple power sources to be output in parallel, improving transmission efficiency, and reducing manufacturing and operating costs. Summary of the Invention

[0004] In order to overcome the technical problems in the existing technology that a single power output cannot effectively utilize the chassis vehicle's power and that multiple power systems cannot be used to flexibly switch between driving and fracturing operation modes, the purpose of this invention is to provide a new type of fracturing pump truck chassis vehicle and a control method for the fracturing pump truck chassis vehicle that can flexibly switch power configurations between vehicle driving and fracturing operation.

[0005] To achieve the above objectives, the present invention provides a chassis for a fracturing pump truck, comprising a chassis, a power source, a four-axle transmission device, a wheel system, a construction device, and a control system that are connected to each other; the four-axle transmission device includes a transmission system, a linkage mechanism, and a clutch mechanism, the transmission system having four transmission wheel sets that are connected to the linkage mechanism and the clutch mechanism, each of the four transmission wheel sets having an input end, and two of the transmission wheel sets having an output end, the input end of the transmission wheel set being used to connect with the power source, and the output ends of the two transmission wheel sets being used to connect with the plunger pump of the wheel system and the construction device, respectively;

[0006] The linkage mechanism is used to combine the power of the four transmission wheel sets, the clutch mechanism is used to control the engagement or disengagement of the input end of the transmission wheel set with the power source, and the clutch mechanism is also used to control the engagement or disengagement of the output end of the transmission wheel set with the plunger pump.

[0007] The chassis of the fracturing pump truck has two working modes: in driving mode, one power source works with one transmission wheel set to drive the wheel system; in construction operation mode, multiple power sources work with multiple transmission wheel sets in a coordinated manner to drive the plunger pump.

[0008] Furthermore, the transmission wheel set includes a main shaft, a first gear disk that is connected to the main shaft, and a flange connector that is connected to the first gear disk. The linkage mechanism is a gear mechanism, which has three sets. The first transmission wheel set is driven by the first gear disk of the remaining three transmission wheel sets through the three sets of gear mechanisms.

[0009] Furthermore, the flange connector includes an integrally formed flange and a connecting cylinder, the central axes of the flange and the connecting cylinder coincide, and the outer diameter of the flange is larger than the outer diameter of the connecting cylinder; the outer edge of the flange is provided with a plurality of circular holes arranged in an array for bolts to pass through, and the connecting cylinder is formed with internal teeth for meshing and connecting with the power input device and the power output device.

[0010] Furthermore, the linkage mechanism includes a first driven gear, a second driven gear, and a third driven gear, with each driven gear located between two adjacent transmission wheel sets; the output end of the first transmission wheel set is engaged or disengaged from the plunger pump.

[0011] Furthermore, the first driven gear, second driven gear, third driven gear, and the first gear disc have multiple circular through holes arranged in a circumferential array around the central axis of the gear body. The presence of these circular through holes significantly reduces the overall mass of the gears, especially the mass far from the center of rotation, thereby substantially reducing the gear's moment of inertia. This results in the transmission device requiring less energy during startup, acceleration, and braking, responding more quickly, and improving the system's dynamic performance and efficiency. The evenly distributed circular holes help achieve a more balanced distribution of gear mass, effectively reducing the centrifugal force generated by unbalanced mass, thus reducing vibration and noise during high-speed rotation and improving the smoothness of the transmission system's operation.

[0012] Furthermore, the first driven gear, the second driven gear, the third driven gear, and the first gear disc of the transmission gear set all have a central hole. The inner walls of the central holes of the second and third driven gears have a ring of circumferentially distributed internal connecting structures, preferably internal splines or internal teeth. The outer wall of the central hole of the first driven gear has an external connecting structure, which is an external tooth.

[0013] The internal spline or internal teeth consist of multiple radially projecting splines or teeth, which are concentrically arranged with the central hole and designed to mesh with corresponding external splines or external teeth on mating components (e.g., shafts or sleeves). The driven gear or gear disk provided by this invention achieves high-strength, reliable torque transmission and relative rotational locking with mating components through the internal spline or internal tooth structure of its inner ring.

[0014] Furthermore, the input end of a drive wheel assembly is equipped with an integrated engine and generator, and the output end of the drive wheel assembly is used to connect to the wheel system of the pump truck.

[0015] Furthermore, the first gear discs of the four transmission wheel sets of the transmission system are arranged in a coplanar manner.

[0016] Furthermore, the four transmission wheel sets are arranged in a T-shape, with the rotation axes of the four transmission wheel sets being parallel. The rotation axes of three of the transmission wheel sets are coplanar, and each linkage mechanism is connected to two adjacent transmission wheel sets.

[0017] Furthermore, a gearbox is provided between the transmission wheel assembly and the power source. 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] Furthermore, the diameter of the first driven gear is larger than the diameters of the second and third driven gears, the diameters of the second and third driven gears are equal, and the number of teeth of the first driven gear is greater than the number of teeth of the second driven gear; the output ends of the two transmission wheel sets that are connected to the first driven gear are respectively connected to the wheel system of the pump truck and the plunger pump of the platform.

[0019] Furthermore, the input ends of the two transmission wheel sets are used to connect with the combined power source of the vehicle, and the power input ends of the other two transmission wheel sets are used to connect with the two auxiliary drive sources of the vehicle platform. The combined power source includes an engine and a generator-electric integrated machine, and the auxiliary drive source is a generator-electric integrated machine. The output ends of the transmission wheel sets driven by the combined power source are used to connect with the wheel system of the chassis of the fracturing pump truck.

[0020] Furthermore, the chassis of the fracturing pump truck also includes an energy management system that works in conjunction with the four-axle drive system. The energy management system includes an energy conversion module, an energy management module, and an energy storage unit.

[0021] The power conversion module includes an inverter rectifier connected to a generator-motor unit (a generator-motor unit connected to the engine) of the transmission wheel assembly. The inverter rectifier is used to convert the AC power output by the generator-motor unit into DC power when the four-axis transmission device is in the construction operation mode, and output it to the power storage unit or to power other generator-motor units.

[0022] The power management module is used to control the integrated generator to switch to power generation mode in the construction operation mode, and to control the integrated generator to switch to hybrid mode (drive or generate electricity) when the pump truck needs to travel.

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

[0024] Furthermore, the inverter rectifier is electrically connected to the power management module, the power management module is electrically connected to the energy storage unit, and the power management module is communicatively connected to the clutch mechanism of the four-axis transmission device, which is used to control the switching of the working state of the generator-motor integrated unit of the combined power source according to the working mode command.

[0025] Furthermore, in the construction operation mode, the generator-electric integrated unit works in conjunction with the engine, acting as a generator to output electrical energy. A portion of the generated energy is directly supplied to at least one other generator-electric integrated unit to drive construction devices such as plunger pumps, while the remaining electrical energy is input to the power storage unit for storage. In the pump truck driving mode, the power management module controls the generator-electric integrated unit to switch from the power generation mode to a hybrid mode of driving or generating, and disconnects the direct connection with the energy storage system to realize the power drive of the pump truck wheel system.

[0026] In construction mode, the clutch mechanism controls the four-axis transmission to switch to construction mode. Under the command of the energy management module, the first generator-electric unit switches from drive mode to generator mode, using the power provided by the engine to generate electricity. The generated electricity is converted by the inverter and rectifier module; part of it is supplied to the plunger pump generator-electric unit in real time, and the other part is stored in the power storage unit. When the construction load changes, the energy management module dynamically allocates the power generation and consumption ratio to ensure stable power output. In this mode, at full power output, the engines of the two combined power sources output significant power, driving the pump truck while simultaneously driving the generator-electric unit to generate electricity, which supplies the generator-electric units of the two auxiliary power sources to drive the pump truck.

[0027] Through the aforementioned improvements, this invention enables the secondary utilization of engine power during pump truck operations. By combining the power source with a generator-electric integrated unit, energy recovery rate is improved, effectively reducing energy consumption and enhancing fuel economy. Simultaneously, intelligent switching and energy management achieve coordinated operation of the power system and electrical system, improving the overall energy efficiency and reliability of the transmission device and extending the service life of the power system and auxiliary equipment. Furthermore, the inclusion of a power storage unit provides electrical buffer support for short-term high-load conditions during construction, enhancing the overall construction efficiency and stability of the fracturing pump truck chassis.

[0028] The present invention provides a control method for the chassis of a fracturing pump truck, comprising the following steps:

[0029] Step S1: The clutch mechanism receives the operating mode command from the control system or manually input, the operating mode command including driving mode and construction operation mode;

[0030] Step S2: Driving mode control. If the control system inputs a driving mode, the clutch mechanism engages the input and output ends corresponding to the transmission wheel set, and disconnects the input ends of the other transmission wheel sets from the power source. The combined power source is started, and the power from the combined power source is adjusted by the gearbox to drive the output ends of the transmission wheel set to move the wheel system.

[0031] Step S3: Construction operation mode control. If the control system inputs the construction operation mode, the clutch mechanism is used to connect the input ends of the four transmission wheel sets to the power source, and at the same time, the output ends of the transmission wheel sets are connected to the plunger pump. The engine and generator-motor are started, and the power of the multiple transmission wheel sets is output to the plunger pump of the construction device after being combined by the linkage mechanism. The gearbox is used to adjust the output speed and torque of the power source in real time, so that the plunger pump works in the preset power range.

[0032] The present invention provides a chassis for a fracturing pump truck and its control method, which, through structural innovation and energy management optimization, has the following beneficial effects:

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

[0034] (2) The transmission system is equipped with four transmission wheel sets and a power combination is realized through the linkage mechanism, which supports the coordinated drive of the engine and multiple generator-electric integrated machines, effectively improving the reliability of the power system.

[0035] (3) By precisely controlling the clutch mechanism, the input and output states of the transmission wheel set can be switched independently, which significantly reduces energy transmission loss and improves overall operating efficiency.

[0036] (4) The transmission wheel set adopts a T-shaped arrangement, and the axis is designed to be parallel and partially coplanar, which not only optimizes the spatial layout, but also facilitates gear meshing and maintenance and replacement, thereby improving the structural reliability and maintenance convenience of the equipment.

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

[0038] (6) The control method provided by the present invention can issue working mode commands through the control system or directly manually control the clutch mechanism, and use the clutch mechanism to adjust the output and input modes of the transmission shaft group to achieve free switching of power and improve work efficiency. Attached Figure Description

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

[0040] Figure 2 This is an exploded view of the four-axis transmission device of the present invention;

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

[0042] Figure 4 This is an exploded view of the transmission wheel assembly of the present invention;

[0043] Figure 5 for Figure 4 A magnified structural diagram of part A in the middle;

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

[0045] Figure 7 This is a schematic flowchart of the control method for the chassis of the fracturing pump truck of the present invention.

[0046] The reference numerals in the figures 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 disc; 113. Flange connector; 1131. Flange; 1132. Connecting cylinder; 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-motor integrated unit; 42. Engine. Detailed Implementation

[0048] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0049] Please see Figures 1 to 7 As shown, the chassis of a fracturing pump truck of the present invention includes a chassis, a power source, a four-axle transmission device, a wheel system 6, a construction device, and a control system that are connected to each other. The four-axle transmission device includes a transmission system 1, a linkage mechanism 2, and a clutch mechanism 3. The transmission system 1 has four transmission wheel sets 11 that are connected to the linkage mechanism 2 and the clutch mechanism 3. Each of the four transmission wheel sets 11 has an input end 12, and two of the transmission wheel sets 11 have an output end 13. The input end 12 of the transmission wheel set 11 is used to connect with the power source, and the output ends 13 of the two transmission wheel sets 11 are respectively used to connect 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 sets 11. The clutch mechanism 3 is used to control the engagement or disengagement of the input end 12 of the transmission wheel set 11 with the power source. The clutch mechanism 3 is also used to control the engagement or disengagement of the output end 13 of the transmission wheel set 11 with the plunger pump.

[0051] The chassis of the fracturing pump truck has two working modes: in driving mode, one power source works with one transmission wheel set 11 to drive the wheel system 6; in construction operation mode, multiple power sources work with multiple transmission wheel sets 11 in a coordinated manner to drive the plunger pump.

[0052] This solution utilizes a four-axis drive system to allow the chassis of the fracturing pump truck to be adjusted and switched between different working modes, enabling the pump truck to rationally allocate power during travel and construction operations, thereby improving power utilization efficiency and equipment applicability.

[0053] Specifically, the transmission wheel set 11 includes a main shaft 111, a first gear disk 112, and a flange connector 113. The linkage mechanism 2 consists of three sets of gear transmission mechanisms, each of which meshes with two adjacent first gear disks 112 for transmission. This scheme uses a gear transmission mechanism with high transmission efficiency and good stability, which can accurately transmit power and realize the power linkage between the transmission wheel sets 11.

[0054] Specifically, the linkage mechanism 2 consists of a first driven gear 21, a second driven gear 22, and a third driven gear 23, with each driven gear located between two adjacent transmission wheel sets 11. The arrangement of the driven gears further clarifies the transmission method of the linkage mechanism 2, making the transmission of power between the transmission wheel sets 11 more flexible.

[0055] This scheme employs three sets of gear transmission mechanisms. The first gear discs 112 of two adjacent transmission wheel sets 11 mesh with the intermediate driven gears (e.g., the gear discs of the first and second transmission wheel sets 11 are connected by the first driven gear 21 (large diameter, high tooth count); the second and third transmission wheel sets 11 are connected by the second driven gear 22; and the third and fourth transmission wheel sets 11 are connected by the third driven gear 23). The second transmission wheel set 11 is located at the center of gravity of the T-shaped structure and meshes with the adjacent second and third driven gears 22 and 23 through the clutch mechanism 3, forming a chain transmission 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, thereby causing the driving gears of the adjacent transmission wheel sets 11 to rotate synchronously, realizing the transmission of power across the transmission wheel sets 11.

[0056] This type of gear meshing transmission offers high precision (stable transmission ratio) and strong impact resistance, making it suitable for power synchronization requirements in high-pressure operating scenarios. The unified design of the transmission wheel set 11, using a gear disc and flange connector 113, reduces manufacturing and maintenance costs. The gear transmission mechanism allows for adjustment of the transmission ratio by replacing the driven gear, adapting to different working conditions.

[0057] Specifically, in this embodiment, the clutch mechanism 3 adopts a multi-stage synchronous clutch, with each driven gear corresponding to an independent electromagnetic clutch. Engagement and disengagement are achieved through an axial sliding sleeve. A synchronizing ring is fitted inside the sleeve to ensure synchronized speeds during gear engagement and reduce impact. Each electromagnetic clutch drives the sleeve to move axially via a hydraulic cylinder. The center hole 25 of each driven gear is connected to the shaft 111 via a spline. A universal joint is used between the driven gear and the shaft 111 to compensate for axial angle deviations.

[0058] In actual use, the PLC control system controls the hydraulic cylinder to drive the sliding sleeve to reciprocate to achieve clutch engagement. For example, when switching from driving the first driven gear 21 alone to driving the second driven gear 22 and the third driven gear 23 in parallel, the PLC first disconnects the electromagnetic clutch of the first driven gear 21, and then controls the hydraulic cylinder to drive the sleeves of the second driven gear 22 and the third driven gear 23 to move synchronously. The synchronization ring ensures that the speeds are matched before meshing.

[0059] In another embodiment, the clutch mechanism 3 adopts manual clutch operation. The clutch mechanism 3 includes a set of multiple clutch assemblies that are connected to the input end 12 and output end 13 of each transmission wheel set 11. It 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 status of each clutch by stepping on the main clutch pedal located in the cockpit.

[0060] Specifically, each clutch assembly adopts a friction plate structure, including an active friction plate, a driven friction plate, a pressure 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 pressure spring is in its natural state, the active plate and the driven plate are pressed together to realize the transmission of power. When the operator depresses the clutch pedal, the hydraulic booster cylinder is driven to move through the linkage mechanism, pushing the release axial movement to overcome the preload of the pressure spring and separate the friction plates, thereby disconnecting the power path.

[0061] Unlike electronic control systems that execute precise actions based on logical instructions, this mechanical clutch structure allows the operator to flexibly control the engagement or disengagement of each transmission wheel set according to actual operational needs. For example, to enter driving mode, the operator only needs to depress the clutch pedal to the first stage of its travel. At this position, a first mechanical limit device is installed, connecting only the power input end 12 and output end 13 of the main transmission wheel set 11, while the other three transmission wheel sets 11 remain disengaged. When switching to the construction operation mode, the operator continues to depress the pedal to the second limit position. At this time, all four clutches engage simultaneously. The system ensures that all transmission wheel sets are synchronously connected to the power source through a mechanical linkage structure, driving the plunger pump into operation.

[0062] The displacement feedback locking device physically maintains the current clutch state through a ratchet and pawl structure, preventing accidental pedal rebound or mid-operation release under different operating conditions. Furthermore, to enhance the handling feel and stroke feedback, the clutch pedal is equipped with a multi-stage damping spring assembly, each corresponding to the operating force required for different modes, achieving precise linkage from the human-machine interface to mechanical execution. The structure of the above embodiment requires no electronic control logic, achieving manual switching of the fracturing pump truck's chassis mode entirely through mechanical and hydraulic principles. It boasts advantages such as rapid response, reliable structure, and adaptability to extreme operating conditions, making it particularly suitable for use in oil and gas field environments with extremely high reliability and maintainability requirements.

[0063] Each driven gear independently corresponds to a set of adjacent transmission wheel sets 11. The driven gear is selectively activated by the clutch mechanism 3 (for example, when only the first driven gear 21 is activated, the first transmission wheel set 11 is linked with the second transmission wheel set 11, and the remaining transmission wheel sets 11 are independent), so that some transmission wheel sets 11 are linked or all transmission wheel sets 11 are connected in parallel.

[0064] Specifically, the first gear discs 112 of the four transmission wheel sets 11 of the transmission system 1 are arranged coplanarly. Coplanar arrangement facilitates meshing transmission between gears, making power transmission smoother and more reliable, and reducing transmission errors and energy loss.

[0065] Specifically, the four transmission wheel sets 11 are arranged in a "T" shape, that is, one transmission wheel set 11 and the adjacent transmission wheel set 11 are located vertically (refer to the attached drawings in the specification, defined as vertical transmission wheel set 11, the lower input end 12 is connected to the combined power source, and the lower right output end 13 is connected to the wheel system 6), and the three transmission wheel sets 11 are arranged horizontally (defined as horizontal transmission wheel set 11, the input end 12 is connected to the auxiliary generator electric motor 41, and the upper right output end 13 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 integrated electric generator 41 is actually a device capable of converting mechanical energy into electrical energy. This machine can be used as a generator when needed, converting mechanical energy into electrical energy; and at other times, it can be used as a motor, converting electrical energy into mechanical energy. This conversion is achieved through internal electromagnetic fields and electronic circuits, a method commonly found in new energy vehicles.

[0067] This T-shaped layout is compatible with the concrete pump truck chassis structure (the transverse drive wheel set 11 is arranged along the width of the vehicle body, and the longitudinal drive wheel set 11 is arranged along the height of the vehicle body), making full use of the unused space under the chassis and avoiding interference with components such as the engine 42 and fuel tank. Furthermore, adjacent drive wheel sets 11 are directly connected via the linkage mechanism 2, shortening the power transmission path and reducing energy loss (e.g., the power of the transverse drive wheel set 11 is directly transmitted to the longitudinal drive wheel set 11 via the first driven gear 21, eliminating the need for a long axle 111).

[0068] Specifically, the first gear discs 112 of the four transmission gear sets 11 are mounted on the same plane (such as the horizontal mid-plane of the device housing). The central axes of the first gear discs 112 are parallel to each other and equally spaced (or the spacing is adjusted according to the size of the driven gear), ensuring that all the first gear discs 112 mesh with their corresponding driven gears in the same plane, avoiding transmission errors caused by spatial misalignment. This coplanar meshing eliminates axial loads, reduces gear wear and noise, and facilitates installation and debugging (no three-dimensional spatial alignment is required), reducing assembly difficulty. In addition, gear sets in the same plane can be sealed with a uniform protective cover to prevent dust and oil from entering, extending their service life.

[0069] Specifically, a gearbox 5 (such as a manual gearbox 5, automatic gearbox 5, or 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 shaft 111 of the transmission wheel set 11. The gearbox 5 internally has multiple gear pairs (such as high-speed gears and low-speed gears), and the transmission ratio is adjusted through a shifting mechanism (hydraulic or electric drive). In driving mode, the low-speed gear of the gearbox 5 increases torque (suitable for starting and climbing), while the high-speed gear reduces speed (suitable for high-speed driving). In construction operation mode, the gearbox 5 adjusts the speed of the power source, causing the piston pump to operate within a corresponding range (such as rated speed ±5%).

[0070] Specifically, the gearbox 5 has a built-in overload protection device (such as a clutch slippage mechanism) that automatically cuts off power transmission when the piston pump suddenly jams, thus preventing damage to the transmission wheel set 11.

[0071] Specifically, the diameter D1 of the first driven gear 21 (connecting the drive transmission wheel set 11 and the adjacent transverse transmission wheel set 11) is greater than the diameters D2 and D3 of the second and third driven gears 23, and the number of teeth Z1 is greater than Z2 (Z2 = Z3), such as D1 = 500mm, D2 = 300mm, 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 a wheel (for low speed and high torque requirements) and a plunger pump (for high speed and medium torque requirements).

[0072] Specifically, the two transmission wheel sets 11 (see appendix for details) Figure 3 and attached Figure 6 Input terminal 12 connects to the combined power source (engine 42 and generator-motor integrated unit 41), and the other two transmission wheel sets 11 (attached) Figure 3 The input end 12 (arranged horizontally) is connected to the auxiliary drive source (integrated generator and electric motor 41) of the vehicle platform, and the output end 13 of the transmission wheel set 11 driven by the combined power source is connected to the chassis wheel system 6 of the fracturing pump truck.

[0073] The chassis's combined power source focuses on driving the wheels (requiring high power and a wide speed range), while the superstructure's combined power source and auxiliary power source focus on driving the working devices (requiring constant speed and high precision), avoiding efficiency losses caused by a single power source simultaneously meeting two working conditions. The auxiliary generator-electric integrated unit 41 can utilize electrical energy from a power storage unit (such as a battery pack) to achieve complementarity between fuel power and electric power, reducing fuel consumption during operation (especially during long-term high-pressure pumping, when primarily relying on electric drive).

[0074] The engine 42 and the generator-electric integrated unit 41 are connected via a clutch or coupler (e.g., the output shaft of the engine 42 is connected to the rotor shaft of the generator-electric integrated unit 41 via a clutch, and the stator of the generator-electric integrated unit 41 is fixed to the housing of the transmission wheel assembly 11). In driving mode, depending on the operating conditions, pure electric (generator-electric integrated unit 41 operates alone), pure fuel (engine 42 operates alone), or hybrid drive (both operate simultaneously) can be selected to improve energy efficiency and range. If either the engine 42 or the generator-electric integrated unit 41 fails, the other power source can independently drive the wheels, ensuring the basic driving function of the pump truck.

[0075] With the addition of a transmission device and an energy management system, the chassis of the fracturing pump truck of the present invention can be adjusted to two working modes. The chassis of the fracturing pump truck is in two driving modes: engaging the linkage mechanism 2 associated with the transmission wheel set 11 and disengaging the linkage mechanism 2 associated with another transmission wheel set 11. The combined power source consisting of the engine 42 and the generator-motor integrated unit 41 drives the transmission wheel set 11 connected to it. After the speed and torque are adjusted by the gearbox 5, the power is transmitted to the wheel assembly through the main shaft 111, the first gear disk 112, etc., to drive the pump truck.

[0076] Construction Operation Mode: Multiple power sources (two engines 42 and four generator-electric integrated units 41) work in conjunction with multiple transmission wheel sets 11 in parallel operation. Engines 42 and their connected generator-electric integrated units 41 work together. Under the control of the power management module and engines 42, two generator-electric integrated units 41 switch to power generation mode (clutch mechanism 3 connects the linkage path of all transmission wheel sets 11, and the power management module controls the core generator-electric integrated unit 41 to switch to power generation mode). The generator-electric integrated unit 41 shaft rotates, generating alternating current (AC). This AC is converted to direct current (DC) by an inverter and rectifier. A portion of the power is directly supplied to other generator-electric integrated units 41 to drive construction devices such as plunger pumps, while the remaining power is stored in a power storage unit. The power of the four transmission wheel sets 11 is connected in parallel through the driven gear of the linkage mechanism 2, and output to the output end 13 of one transmission wheel set 11 to drive the construction device.

[0077] Through different operating modes and transmission mechanism designs, power can be flexibly allocated according to the different needs of pump truck travel and construction operations, thereby improving power utilization efficiency. In operating mode, excess power from engine 42 is converted into electrical energy through the core generator-electric integrated unit 41, which is then used by the auxiliary generator-electric integrated unit 41, reducing fuel waste. The independent auxiliary generator-electric integrated unit 41 is powered by an energy storage unit or the power grid (if external connection is required), avoiding excessive reliance on engine 42 during operation. Especially in the event of engine 42 failure, the energy storage unit can temporarily provide power to complete emergency operations.

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

[0079] The chassis driving mode of the fracturing pump truck:

[0080] Step 1, Power Source Activation: The driver selects "Driving Mode" via the control panel. The power management module sends a command to engage only the input / output path of the drive transmission wheel set 11 via the clutch mechanism 3 (disengaging the linkage mechanism 2 of other transmission wheel sets 11). The core generator-motor integrated unit 41 switches to drive mode (directly driven by the battery pack or engine 42, depending on the energy selection).

[0081] Step 2, Power Transmission: The combined power source (engine 42 + generator-motor integrated unit 41) outputs power, the gearbox 5 adjusts the speed and torque, the main shaft 111 of the drive transmission wheel set 11, the first gear disk 112 (not meshed with the driven gear, rotating independently), the flange connector 113, the drive axle, and the wheels.

[0082] Step 3, Energy Management: The power management module adjusts the generator load by controlling the operating state (generating or driving) of the generator-motor integrated unit 41, ensuring the generator operates in its high-efficiency range and improving its working efficiency.

[0083] Construction mode of fracturing pump truck chassis:

[0084] Step 1, Power Source Activation: Select "Operating Mode" on the operation panel. The power management module sends a command to the clutch mechanism 3, which engages the linkage mechanism 2 of all transmission wheel sets 11 (all 3 driven gears are engaged). Core generator-motor integrated unit 41: Switches to generator mode (driven by engine 42 to rotate, operating as a generator).

[0085] Step 2, Power Transmission: The engine 42 outputs power to drive the plunger pump while simultaneously driving the core generator-electric integrated machine 41 to generate electricity. The inverter and rectifier convert AC to DC. The DC bus directly supplies power to the two auxiliary generator-electric integrated machines 41 (each driving one of the two working transmission wheel sets 11), the main shaft 111, the first gear disk 112, the driven gear linkage, and the power is collected and sent to a certain transmission wheel set 11 (see Appendix). Figure 3 Output terminal 13 in the upper right corner, construction devices such as plunger pump.

[0086] Energy storage and 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 energy storage unit's charge is greater than 80%, it automatically reduces the charging current to prioritize power supply to the construction equipment.

[0088] The four-axis transmission device of this invention significantly improves the smoothness, accuracy, and shock resistance of power transmission through the coordinated design of multiple transmission wheel sets 11, linkage mechanism 2, and engagement mechanism, combined with the coplanar layout of gears and differentiated gear parameter settings. A multi-stage synchronous clutch enables rapid switching of the transmission path, and the T-shaped transmission wheel set 11 layout optimizes space utilization, effectively reducing energy loss and enhancing system compactness.

[0089] The control method for the chassis of a fracturing pump truck according to the present invention specifically includes the following steps:

[0090] Step S1: Receive the driving mode or construction operation mode input from the control system;

[0091] Step S2: Driving Mode Control

[0092] In driving mode, clutch mechanism 3 engages the input end 12 and output end 13 corresponding to the transmission wheel set 11 (transmission 11 connected to the combined power source), and disconnects the input end 12 of the other transmission wheel sets 11 from the power source.

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

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

[0095] Step S3: Construction Operation Mode Control

[0096] In the construction operation mode, the clutch mechanism 3 is used to connect the input end 12 of all transmission wheel sets 11 to the power source, and at the same time connects the output end 13 of one transmission wheel set 11 (the transmission wheel set 11 located in the center of the T-shape) to the transmission path of the plunger pump.

[0097] Start the engine 42 and all generator-electric integrated units 41. The engine 42 drives the generator-electric integrated unit 41 connected to the transmission wheel set 11 to switch to the power generation mode. The generated power is converted into DC power by the inverter rectifier. Part of it is directly supplied to the plunger pump generator-electric integrated unit, and the remaining power is stored in the energy storage unit.

[0098] The power of multiple transmission 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, so that the piston pump works within the rated power range;

[0100] Step S4: Dynamic Energy Management

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

[0102] If the energy storage unit's charge is below a threshold, such as 30%, the generator 42 will be used to drive power generation first.

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

[0104] In driving mode, if the generator-motor unit 41 has insufficient power, the engine 42 drives the wheel system 6 while charging the energy storage unit.

[0105] The energy management system integrates an inverter rectifier module and an electrical storage unit. In construction operation mode, it converts the redundant power of the engine (42) into electrical energy for storage or direct drive of auxiliary equipment, achieving efficient energy recovery and dynamic distribution, and significantly improving 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 the high torque requirements of the pump truck during operation and ensuring stable output during construction operations.

[0106] This device solves the problems of uneven power distribution, sluggish mode switching, and energy waste in traditional transmission systems through structural optimization and intelligent control. It is highly efficient, energy-saving, and adaptable to multiple working conditions, significantly improving the overall performance and operating efficiency of the fracturing pump truck chassis.

[0107] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A chassis for a fracturing pump truck, characterized in that: The system includes a chassis, power source, four-axis transmission device, wheel system (6), construction device and control system that are connected to each other; the four-axis transmission device includes a transmission system (1), a linkage mechanism (2) and a clutch mechanism (3). The transmission system (1) has four transmission wheel sets (11) that are connected to the linkage mechanism (2) and the clutch mechanism (3). Each of the four transmission wheel sets (11) has an input end (12) and each of the two transmission wheel sets (11) has an output end (13). The input end (12) of the transmission wheel set (11) is used to connect with the power source, and the output end (13) of the two transmission wheel sets (11) is used to connect with 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 sets (11), the clutch mechanism (3) is used to control the engagement or disengagement of the input end (12) of the transmission wheel set (11) with the power source, and the clutch mechanism (3) is also used to control the engagement or disengagement of the output end (13) of the transmission wheel set (11) with the plunger pump. The chassis of the fracturing pump truck has two working modes: in driving mode, one power source works with one transmission wheel set (11) to drive the wheel system (6) to move; in construction operation mode, multiple power sources work with multiple transmission wheel sets (11) to drive the plunger pump to run.

2. The chassis of the fracturing pump truck according to claim 1, characterized in that: The transmission wheel set (11) includes a shaft (111), a first gear disk (112) connected to the shaft (111), and a flange connector (113) connected to the first gear disk (112). The linkage mechanism (2) is a gear mechanism with three sets. The first transmission wheel set (11) meshes with the first gear disk (112) of the remaining three transmission wheel sets (11) via the three sets of gear mechanisms.

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

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

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

6. The chassis 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 arranged parallel to each other, wherein the rotation axes of three of the transmission wheel sets (11) are arranged in the same plane.

7. The chassis of the fracturing pump truck according to claim 1, characterized in that: A gearbox (5) is provided between the transmission wheel set (11) of the four-axis transmission device and the power source. 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 of the fracturing pump truck according to claim 3, characterized in that: The diameter of the first driven gear (21) is greater than the diameter 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. 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) that are connected to the first driven gear (21) are respectively connected to the wheel system (6) and the plunger pump of the platform.

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

10. A control method for the chassis of a fracturing pump truck, characterized in that: The control method is applicable to the chassis 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 command input by the control system or manually, the operation mode command including driving mode and construction operation mode; Step S2: Driving mode control. If the control system inputs a driving mode, the clutch mechanism (3) engages the input and output ends of the first transmission wheel group (11) used to connect the wheel system (6) in the two transmission wheel groups (11), disconnects the input end (12) of the second transmission wheel group (11) used to connect the plunger pump from the power source, and disconnects the input ends (12) of the remaining two transmission wheel groups (11) from the power source; the combined power source is started, and the power of the combined power source drives the wheel system (6) to move through the output end of the first transmission wheel group; 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 end (12) of the four transmission wheel sets (11) and the power source, and engages the output end (13) of the second transmission wheel set (11) used to connect the plunger pump and the plunger pump; the engine (42) and the generator-electric integrated machine (41) are started, and the power of the multiple transmission wheel sets (11) is output to the plunger pump of the construction device after being combined by the linkage mechanism (2).

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