An automatic motor control overflow control valve system

Abstract

The application discloses a kind of motor automatic control overflow control valve systems, belong to the technical field of fluid pressure control, comprising: piston cone sleeve is integrated component, it is embedded in high-pressure valve body;High-pressure valve body, piston cone sleeve rear portion and the upper plug between the upper end of high-pressure valve body are enclosed to form hydraulic control cavity;Motor drive assembly passes through upper plug and acts on hydraulic control cavity;Position feedback component is installed on motor drive assembly, to measure piston displacement;Automatic control monitoring unit is electrically connected with motor drive assembly and position feedback component respectively, to adjust control pressure.The application combines motor drive unit, precision transmission mechanism, piston overflow valve main body, high-precision sensor and automatic controller, to replace external hydraulic pump by motor direct drive, omit independent high-pressure oil source and pipeline, make system structure compact, installation and maintenance are simple, especially suitable for limited space or required system integration experimental scene.

Description

Technical Field

[0001] This invention belongs to the technical field of fluid pressure control, specifically relating to an automatic motor control overflow control valve system. Background Technology

[0002] In the exploration and development of oil and gas reservoirs, accurate acquisition of key parameters such as downhole formation pressure, temperature, and fluid properties is crucial for reserve assessment, development planning, and production forecasting. With the increasing depletion of shallow conventional oil and gas resources, exploration and development targets have shifted to deep, ultra-deep (e.g., exceeding 10,000 meters), and unconventional oil and gas reservoirs. These reservoirs generally possess extreme environmental characteristics such as ultra-high pressure (reaching over 100 MPa) and high temperature (80°C).

[0003] To accurately guide actual mining operations, it is essential to utilize high-temperature and high-pressure simulation testing equipment in the laboratory to replicate extreme downhole conditions and conduct performance tests on rock and fluid properties, as well as drilling tools. Maintaining precise and dynamic stability of the system pressure is a core prerequisite for ensuring the continuity of the test and the validity of the data in such tests.

[0004] However, most industrial relief valves currently on the market are primarily designed for low to medium pressure applications (typically below 40 MPa), and their materials, sealing structures, and pressure regulating mechanisms are ill-suited for long-term operation under combined ultra-high pressure and high temperature conditions. Existing solutions suffer from the following significant bottlenecks: Limitations of safety valves: While safety valves can be installed in the system as an alternative, their function is essentially pressure relief protection. Once the pressure exceeds the limit, the safety valve will instantly open fully to release pressure, forcing the test to be interrupted and the data link to be broken. This not only significantly reduces test efficiency and increases costs, but also fails to meet the requirements of precision tests that require continuous, stepped loading or pressure holding.

[0005] Test risks and costs: Due to the lack of reliable ultra-high pressure and high temperature overflow control methods, the test system faces the risk of pressure runaway, and the stability, repeatability and data integrity of the test are difficult to guarantee.

[0006] Currently, the mainstream relief valves on the market can be divided into three main types according to their working principle: spring type, pilot type, and electromagnetic proportional type. Their design standards are mostly aimed at medium and low pressure and normal temperature working conditions in conventional industries.

[0007] I. Inherent Defects of Spring-Loaded Relief Valves Spring-loaded relief valves rely on the pre-compressed spring force to directly balance the system hydraulic pressure. They have a simple structure, but their disadvantages become prominent under ultra-high pressure and high temperature conditions. 1. Low pressure and flow limits: Achieving ultra-high pressure (such as 100MPa) requires springs with extremely high stiffness and size, resulting in bulky valve bodies, difficult adjustment, and easy to cause severe vibration and noise when opening under high pressure and high flow, as well as poor valve core stability.

[0008] 2. Poor regulation characteristics and stability: Under high pressure, the friction and hydraulic force of the valve core increase, causing its opening pressure to be significantly higher than the set value, and its closing pressure to be significantly lower (i.e., a serious pressure "drop"), resulting in large fluctuations in system pressure around the set point, which cannot meet the requirements of precision experiments.

[0009] 3. Short sealing reliability and lifespan: Ultra-high pressure requires extremely high valve seat contact stress, which exacerbates wear on the sealing surface; high temperature accelerates the aging of the sealing material, both leading to serious internal leakage. Springs are also prone to fatigue fracture under high temperature and high stress.

[0010] II. Limitations of Pilot-Operated Relief Valves Pilot-operated relief valves control the main valve through a small pilot valve, which improves performance to some extent, but still has shortcomings under extreme conditions: 1. Extremely sensitive to oil cleanliness and temperature: The throttling orifice and damping orifice in its pilot control oil circuit are extremely small. Changes in oil viscosity caused by high temperature and particle erosion and wear under ultra-high pressure can easily cause blockage or changes in characteristics of the oil circuit, leading to unstable operation or even failure of the main valve.

[0011] 2. High-temperature pressure drift still exists: The pilot valve itself is usually still a spring-type structure. The thermal relaxation of the pilot spring caused by high temperature will cause the set pressure of the entire valve to drift.

[0012] 3. Slow dynamic response: The main valve action depends on the pressure build-up and release of the pilot oil circuit, which has an inherent hydraulic delay. In simulation processes that require a fast response, this may lead to pressure overshoot and long recovery time.

[0013] 4. Multiple internal leakage paths: The complex structure and numerous mating surfaces amplify internal leakage under ultra-high pressure, and high temperatures further exacerbate sealing failure, affecting pressure holding performance.

[0014] III. Obstacles to the Application of Electromagnetic Proportional Relief Valves While electromagnetic proportional relief valves can achieve precise electronic control, their core electromechanical conversion components are difficult to adapt to extreme environments. 1. Core components are susceptible to high temperatures: The coil insulation material and permanent magnet in proportional electromagnets or torque motors will rapidly degrade or even burn out when exposed to temperatures consistently above 120°C. This is the fundamental obstacle to their application in high-temperature environments.

[0015] 2. Insufficient resistance to ultra-high pressure: Under system pressures above 100MPa, the electromagnetic force required to drive the valve core is enormous, resulting in a surge in the size and power consumption of the electromagnet, making structural design difficult and reducing reliability.

[0016] 3. Poor resistance to contamination and high cost: To achieve high precision, its fitting clearance is extremely precise, and ultra-high pressure fluids can easily cause wear and jamming. In addition, it is expensive to manufacture, has harsh requirements for the operating environment, and has high maintenance costs.

[0017] Traditional ultra-high pressure overflow control technology suffers from three major drawbacks: complex structure, low integration, and insufficient control precision. Most solutions rely on external hydraulic pump stations, which require complex high-pressure pipelines, valves and oil purification systems, resulting in large overall equipment size, high installation and maintenance costs, and difficulty in adapting to laboratories or industrial scenarios with limited space. Traditional electronic control solutions, such as electromagnetic proportional relief valves, are prone to pressure drift and loss of control accuracy under ultra-high pressure of 120MPa and medium temperature of 80℃. This is because the electro-mechanical conversion element is prone to pressure drift and loss of control accuracy due to insufficient driving force, thermal deformation or sealing failure, and cannot achieve stepless and linear precise pressure regulation. The existing control logic lacks multi-parameter collaborative feedback, relies solely on the pressure signal, and does not combine temperature compensation and position (displacement) feedback. It is difficult to dynamically compensate for changes in the characteristics of high-pressure liquid media and mechanical transmission errors, and it is difficult to guarantee long-term stable overflow pressure control accuracy. Summary of the Invention

[0018] The purpose of this invention is to address the aforementioned shortcomings in the prior art by providing an automatic motor control overflow control valve system, thereby solving the problems of complex structure, low integration, and insufficient control accuracy of traditional ultra-high pressure overflow control valves.

[0019] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An automatic motor control overflow control valve system includes a high-pressure valve body, a piston cone sleeve, a motor drive assembly, a position feedback assembly, and an automatic control monitoring unit. The high-pressure valve body is provided with an upper plug at the top; the piston cone sleeve is an integrated component, which is embedded in the high-pressure valve body. The front end of the piston cone sleeve is a sealing cone surface for sealing, and the rear end is a driving piston that bears the driving pressure; the high-pressure valve body, the rear part of the piston cone sleeve and the upper plug at the top of the high-pressure valve body form a hydraulic control chamber, which is filled with high-pressure liquid. The motor drive assembly passes through the upper plug and acts on the hydraulic control chamber, changing the volume of high-pressure liquid in the hydraulic control chamber through displacement; the position feedback assembly is mounted on the motor drive assembly to measure piston displacement; the automatic control monitoring unit is electrically connected to the motor drive assembly and the position feedback assembly respectively to adjust the control pressure.

[0020] Furthermore, maintaining a seal within the high-pressure valve body requires satisfying the following force balance relationship: P_control × S1≥ P_system ×S2 In the formula, P_control is the control pressure, P_system is the control valve system pressure; S1 is the effective area of ​​the piston rear end bearing surface on the piston cone sleeve, and S2 is the equivalent area of ​​the front cone surface seal of the piston cone sleeve bearing the control valve system pressure.

[0021] Furthermore, the ratio of the effective area S1 of the piston rear end bearing surface on the piston cone sleeve to the equivalent area S2 of the front cone sealing surface of the piston cone sleeve bearing the pressure of the control valve system is 10~20.

[0022] Furthermore, a piston cone sleeve sealing ring is provided in the sealing groove of the piston cone sleeve.

[0023] Furthermore, a pressure sensor and a temperature sensor are installed inside the hydraulic control chamber to collect pressure and temperature information of the high-pressure liquid in real time.

[0024] Furthermore, the upper plug is fastened to the high-pressure valve body by fixing bolts.

[0025] Furthermore, the motor drive assembly includes a motor, a thrust screw, and a thrust piston; The thrust piston is located in the hydraulic control chamber, and the thrust screw passes through the upper plug and is connected to the thrust piston to convert the rotational motion into linear motion and push the thrust piston; the output shaft of the motor is connected to the thrust screw through a precision transmission device.

[0026] Furthermore, the motor is fixed to the motor mounting cylinder, and the motor mounting cylinder is disposed on the high-pressure valve body.

[0027] Furthermore, the position feedback component includes a rotary encoder mounted on the thrust screw for accurately measuring the screw rotation angle or thrust piston displacement.

[0028] Furthermore, the automatic control monitoring unit controls the rotation angle and torque of the motor based on the signals from the pressure sensor, temperature sensor, and feedback from the rotary encoder, thereby driving the thrust piston to compress the high-pressure liquid in the hydraulic control chamber, thus steplessly and linearly generating and adjusting the control pressure.

[0029] The automatic motor control overflow control valve system provided by this invention has the following beneficial effects: 1. This invention combines a motor drive unit, a precision transmission mechanism, a piston-type overflow valve body, a high-precision sensor, and an automatic controller. It replaces the external hydraulic pump with a direct-drive motor, omitting the independent high-pressure oil source and pipelines. This makes the system structure compact and easy to install and maintain, making it especially suitable for experimental scenarios with limited space or requiring system integration.

[0030] 2. Optimized system integration: The direct-drive motor solution eliminates the need for a separate hydraulic pump station and related pipelines, reducing the system footprint and shortening installation and commissioning time; the mechanical solution completely eliminates dependence on external energy and can be deployed directly in sites without infrastructure.

[0031] 3. This invention provides a core pressure control device that can operate stably, accurately and reliably for long-term operation in ultra-high pressure and high temperature simulation experiments in fields such as deep oil and gas development, fundamentally ensuring the continuity of experiments, process stability and data integrity.

[0032] 4. Structural Innovation: It is the first to adopt an integrated structure of large-area ratio hydraulic piston drive and metal conical surface seal. The hydraulic pressure of the control chamber at the rear end of the piston cone sleeve drives the front conical surface to achieve opening and closing. The static pressure balance principle replaces the traditional direct action of the spring, eliminating the problem of thermal relaxation and fatigue failure of the spring under ultra-high pressure and high temperature from the root.

[0033] 5. Dynamic response optimization: Based on a piston design with an area ratio of 10-20, high-pressure sealing can be achieved with only 1 / 10-1 / 20 of the control pressure; combined with the automatic control system, the valve opening and closing response time is shortened to the millisecond level, the reset speed is improved, and the range of system pressure fluctuations is reduced. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the automatic motor control overflow control valve system as an example.

[0035] Among them, 2-1, high-pressure valve body; 2-2, piston cone sleeve; 2-3, piston cone sleeve sealing ring; 2-4, high-pressure liquid; 2-5, pressure sensor; 2-6, temperature sensor; 2-7, thrust piston; 2-8, thrust piston sealing ring; 2-9, upper plug; 2-10, fixing bolt; 2-11, thrust screw; 2-12, rotary encoder; 2-13, precision transmission device; 2-14, motor fixing cylinder; 2-15, motor; 2-16, automatic control monitoring unit. Detailed Implementation

[0036] The specific embodiments of the present invention are described below to enable those skilled in the art to understand the present invention. However, it should be understood that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, various changes are obvious as long as they are within the spirit and scope of the present invention as defined and determined by the appended claims. All inventions utilizing the concept of the present invention are protected.

[0037] This embodiment provides an automatic motor-controlled overflow control valve system that integrates a motor drive unit, a precision transmission mechanism, a piston-type overflow valve body, a high-precision sensor, and an automatic controller. It replaces the external hydraulic pump with a 2-15 direct-drive motor, eliminating the need for a separate high-pressure oil source and pipelines. This results in a compact system structure and simplified installation and maintenance, making it particularly suitable for experimental scenarios with limited space or requiring system integration. It is applicable to mechatronic integration solutions for environments up to 80℃ and 120MPa pressure. (See reference...) Figure 1 Specifically, it includes: High-pressure valve body 2-1, piston cone sleeve 2-2, motor drive assembly, position feedback assembly and automatic control monitoring unit 2-16; In some embodiments, the upper part of the high pressure valve body 2-1 is provided with an upper plug 2-9, and the piston cone sleeve 2-2 is an integrated component that is embedded in the high pressure valve body 2-1. The front end of the piston cone sleeve 2-2 is a sealing cone surface for sealing, and the rear end is a driving piston that bears the driving pressure. The high pressure valve body 2-1, the rear part of the piston cone sleeve 2-2 and the upper plug 2-9 at the upper end of the high pressure valve body 2-1 form a hydraulic control chamber, which is filled with high pressure liquid 2-4. The motor drive assembly passes through the upper plug 2-9 and acts on the hydraulic control chamber, changing the volume of the high-pressure liquid 2-4 in the hydraulic control chamber through displacement; the position feedback assembly is installed on the motor drive assembly to measure the piston displacement; the automatic control monitoring unit 2-16 is electrically connected to the motor drive assembly and the position feedback assembly respectively to adjust the control pressure.

[0038] In one specific embodiment, the piston cone sleeve 2-2 is an integral component, with its front end being a sealing cone surface for sealing and its rear end being a driving piston that bears the driving pressure. The key ingenuity of this design lies in the fact that the effective area S1 of the piston rear end pressure-bearing surface on the piston cone sleeve 2-2 is designed to be 10 to 20 times the equivalent area S2 of the front cone surface sealing part of the piston cone sleeve 2-2 bearing the pressure of the control valve system.

[0039] According to the principles of fluid statics, when the control valve system pressure (P_system) acts on the front conical surface, in order to maintain a seal, a control pressure (P_control) needs to be applied in the hydraulic control chamber at the rear of the piston, and the following force balance relationship must be satisfied: P_control × S1≥ P_system × S2 Since the area ratio S1 / S2 = 10~20, only a relatively small control pressure (P_control) is needed to balance or overcome extremely high system pressure (P_system). This static pressure amplification effect of "small pressure controlling large pressure" is the physical basis for this valve to achieve reliable control and rapid response under ultra-high pressure.

[0040] When the system pressure increases, causing the left side of the inequality to be less than the right side, the piston cone sleeve 2-2 moves backward, and the cone surface opens to overflow; when the system pressure decreases, the control pressure pushes the piston cone sleeve 2-2 to quickly reset and seal. The valve's opening pressure is directly determined by the control pressure (P_control).

[0041] In one specific embodiment, the high-pressure valve body 2-1 is made of high-strength steel, with a rated working pressure of 120MPa and a maximum withstand temperature of 150℃, providing pressure bearing and installation reference for the main structural components and internal precision components.

[0042] In one specific embodiment, the piston cone sleeve 2-2 is made of high-strength steel and integrates the front sealing cone surface and the rear driving piston into one unit, which has both metal hard sealing and high thrust driving functions; the piston cone sleeve sealing ring 2-3 is provided in the sealing groove of the piston cone sleeve 2-2. The piston cone sleeve sealing ring 2-3 is made of special materials that are resistant to high temperature and high pressure, and is used to realize dynamic sealing between the piston and the valve body under high pressure difference.

[0043] In one specific embodiment, the high-pressure liquid 2-4 is a hydraulic drive medium that can work stably at temperatures ranging from -20°C to 150°C and pressures up to 120 MPa. By adjusting its pressure, the piston cone sleeve 2-2 is driven to move to achieve sealing or opening.

[0044] In one specific embodiment, a pressure sensor 2-5 and a temperature sensor 2-6 are installed in the hydraulic control chamber to collect pressure and temperature information of the high-pressure liquid 2-4 in real time.

[0045] In one specific embodiment, the upper plug 2-9 serves as a detachable sealing component on the upper part of the high-pressure valve body 2-1 and is fastened to the high-pressure valve body 2-1 by fixing bolts 2-10; the function of fixing bolts 2-10 is to reliably fix the upper plug 2-9 on the high-pressure valve body 2-1.

[0046] In one specific embodiment, the motor drive assembly includes a motor 2-15, a thrust screw 2-11, and a thrust piston 2-7; The thrust piston 2-7 is located within the hydraulic control chamber. The thrust screw 2-11 passes through the upper plug 2-9 and is connected to the thrust piston 2-7 to convert rotational motion into linear motion, thus pushing the thrust piston 2-7. The output shaft of the motor 2-15 is connected to the thrust screw 2-11 via a precision transmission 2-13. The precision transmission 2-13 connects the output shaft of the motor 2-15 and the thrust screw 2-11, and is used to efficiently and accurately transmit the rotational motion and torque of the motor 2-15 to the thrust screw 2-11.

[0047] The thrust piston 2-7 changes the volume of the high-pressure liquid 2-4 in the hydraulic control chamber by its displacement, thereby changing the pressure of the internal high-pressure liquid 2-4; the thrust piston sealing ring is made of a special material that is resistant to high temperature and high pressure and is installed in the sealing groove of the thrust piston 2-7.

[0048] The thrust screw 2-11 converts the torque of the motor 2-15 into axial thrust through its own rotation, driving the thrust piston 2-7 to move and compress the liquid.

[0049] Motor 2-15 is fixed to motor mounting cylinder 2-14, which is mounted on high-pressure valve body 2-1. Motor mounting cylinder 2-14 is used to install and fix drive motor 2-15, providing it with a stable support base. Motor 2-15 serves as the system's prime mover and power source, outputting controllable rotational motion and torque.

[0050] In one specific embodiment, the position feedback component includes a rotary encoder 2-12, which is mounted on the thrust screw to measure the rotation angle of the thrust screw 2-11 in real time and feeds the position signal back to the control system to accurately control the rotation angle and number of revolutions of the motor 2-15.

[0051] In one specific embodiment, the automatic control monitoring unit 2-16 controls the rotation angle and torque of the motor 2-15 based on the signals from the pressure sensor 2-5, the temperature sensor 2-6, and the feedback from the rotary encoder 2-12, thereby driving the thrust piston 2-7 to compress the high-pressure liquid 2-4 in the hydraulic control chamber, thus steplessly and linearly generating and adjusting the control pressure.

[0052] Although specific embodiments of the invention have been described in detail with reference to the accompanying drawings, this should not be construed as limiting the scope of protection of this patent. Various modifications and variations that can be made by a person skilled in the art without inventive effort within the scope described in the claims still fall within the scope of protection of this patent.

Claims

1. An automatic motor control overflow control valve system, characterized in that, Includes a high-pressure valve body, piston cone sleeve, motor drive assembly, position feedback assembly, and automatic control monitoring unit; The high-pressure valve body is provided with an upper plug at the top; the piston cone sleeve is an integrated component, which is embedded in the high-pressure valve body. The front end of the piston cone sleeve is a sealing cone surface for sealing, and the rear end is a driving piston that bears the driving pressure; the high-pressure valve body, the rear part of the piston cone sleeve and the upper plug at the top of the high-pressure valve body form a hydraulic control chamber, which is filled with high-pressure liquid. The motor drive assembly passes through the upper plug and acts on the hydraulic control chamber, changing the volume of high-pressure liquid in the hydraulic control chamber through displacement; the position feedback assembly is mounted on the motor drive assembly to measure piston displacement; the automatic control monitoring unit is electrically connected to the motor drive assembly and the position feedback assembly respectively to adjust the control pressure.

2. The automatic motor control overflow control valve system according to claim 1, characterized in that, To maintain a seal within the high-pressure valve body, the following force balance relationship must be satisfied: P_control × S1≥ P_system ×S2 In the formula, P_control is the control pressure, P_system is the control valve system pressure; S1 is the effective area of ​​the piston rear end bearing surface on the piston cone sleeve, and S2 is the equivalent area of ​​the front cone surface seal of the piston cone sleeve bearing the control valve system pressure.

3. The automatic motor control overflow control valve system according to claim 2, characterized in that, The ratio of the effective area S1 of the piston rear end bearing surface on the piston cone sleeve to the equivalent area S2 of the front cone surface seal of the piston cone sleeve bearing the pressure of the control valve system is 10~20.

4. The automatic motor control overflow control valve system according to claim 1, characterized in that, The piston cone sleeve is provided with a piston cone sleeve sealing ring in the sealing groove.

5. The automatic motor control overflow control valve system according to claim 1, characterized in that, The hydraulic control chamber is equipped with pressure and temperature sensors to collect pressure and temperature information of the high-pressure liquid in real time.

6. The automatic motor control overflow control valve system according to claim 1, characterized in that, The upper plug is fastened to the high-pressure valve body by fixing bolts.

7. The automatic motor control overflow control valve system according to claim 1, characterized in that, The motor drive assembly includes a motor, a thrust screw, and a thrust piston; The thrust piston is located in the hydraulic control chamber, and the thrust screw passes through the upper plug and is connected to the thrust piston to convert the rotational motion into linear motion and push the thrust piston; the output shaft of the motor is connected to the thrust screw through a precision transmission device.

8. The automatic motor control overflow control valve system according to claim 7, characterized in that, The motor is fixed to the motor mounting cylinder, and the motor mounting cylinder is disposed on the high-pressure valve body.

9. The automatic motor control overflow control valve system according to claim 7, characterized in that, The position feedback component includes a rotary encoder mounted on the thrust screw for accurately measuring the screw rotation angle or thrust piston displacement.

10. The automatic motor control overflow control valve system according to claim 9, characterized in that, The automatic control and monitoring unit controls the rotation angle and torque of the motor based on the signals from the pressure sensor, temperature sensor, and feedback from the rotary encoder. This drives the thrust piston to compress the high-pressure liquid in the hydraulic control chamber, thereby steplessly and linearly generating and adjusting the control pressure.

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