Fracturing truck hydraulic end intelligent lubrication control system and method

Abstract

The application provides a fracturing truck hydraulic end intelligent lubrication control system and method, which utilizes a liquid level sensor, a particulate matter sensor and a pressure sensor to monitor key state parameters of lubricating liquid in real time, solves the problem that the prior art cannot perceive the lubrication state online, constructs a prediction model system containing a lubricating liquid residual amount prediction model, a filter screen blockage evaluation model and a comprehensive state index prediction model, can accurately quantitatively evaluate the health trend of the lubrication system, realizes a leap from passive maintenance to predictive maintenance, and based on an intelligent decision method of model calculation results and multi-stage alarm logic, can timely issue a warning before the system state deteriorates, and automatically stops the pump to protect the equipment in an extreme case, effectively avoids the hydraulic end body damage caused by lubrication failure, greatly improves the reliability and continuity of the fracturing truck operation, and reduces the equipment operation and maintenance cost.

Description

Technical Field

[0001] This invention relates to the field of fracturing equipment technology, and in particular to an intelligent lubrication control system and method for the hydraulic end of a fracturing truck. Background Technology

[0002] Fracturing trucks are core equipment in oil and gas field development operations. Their main function is to inject high-pressure, high-volume fracturing fluid into the formation to create oil and gas channels. A horizontal five-cylinder high-pressure plunger pump mounted on the fracturing truck chassis is the vehicle's power core, typically consisting of a diesel engine-driven power unit and a hydraulic unit that pressurizes the fracturing fluid. The hydraulic unit, as the component directly in contact with the fracturing fluid and performing the high-pressure output task, contains various precision components such as plungers, pump valves, and seals. These components generate intense friction and heat under high-speed reciprocating motion. Therefore, the hydraulic unit of the high-pressure plunger pump must rely on continuous lubrication, cleaning, and cooling during operation to maintain reliable operation and extend its service life. The quality of lubrication directly affects the sealing performance of the pump valves, the wear rate of the plungers, and the overall mechanical efficiency of the pump, making it a key factor in ensuring the continuity and safety of fracturing operations.

[0003] Existing hydraulic end lubrication devices for fracturing trucks, such as the one disclosed in utility model patent No. 20201293900.7, mainly include a hydraulic end body, a storage tank, a circulation pump, and inlet and outlet pipes. This device collects lubricating fluid through an inclined rectangular groove at the bottom of the pump chamber of the hydraulic end body and guides it into the storage tank through the outlet pipe. The storage tank contains a vertical baffle and a removable filter screen. After being filtered by the filter screen, the lubricating fluid flows through a flow channel on the baffle to the other side of the storage tank, and is then pumped back into the hydraulic end body by the circulation pump through the inlet pipe, thus achieving the recycling of the lubricating fluid and basic physical filtration. This mechanical circulation structure solves the problem of lubricating fluid waste to a certain extent and is a typical example of existing technology.

[0004] However, despite the fact that the aforementioned existing devices achieve lubricant circulation and physical filtration, they still suffer from several insurmountable technical defects in practical applications. First, the device only possesses basic mechanical circulation functions and lacks the ability to monitor the critical state of the lubricant in real time. Operators cannot know the remaining lubricant level in the storage tank, nor can they determine whether the lubricant being used has become contaminated or deteriorated due to long-term use, or whether the filter screen is severely clogged. They can only rely on experience or periodic shutdowns for inspection, which easily leads to the equipment operating with defects even when the lubricant is insufficient or contaminated, thus exacerbating the wear of the precision components inside the hydraulic end. Second, the device lacks an alarm mechanism. When abnormalities occur in the lubrication system (such as low fluid level or excessively dirty lubricant), it cannot promptly issue warnings to operators. Often, the problem is only discovered when obvious signs of malfunction appear (such as excessive temperature rise, abnormal noise, or pressure fluctuations), by which time irreversible damage to the hydraulic end may have already been caused. Finally, this reactive maintenance model severely impacts the continuity and efficiency of fracturing operations. Unplanned shutdowns for maintenance not only increase high maintenance costs but also delay the overall operational progress of the oil and gas field. Therefore, how to endow the existing lubrication device with the ability of state perception, intelligent decision-making and proactive early warning while retaining the main structure of the existing lubrication device, and realize the leap from "mechanical circulation" to "intelligent monitoring", is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent lubrication control system and method for the hydraulic end of a fracturing truck, so as to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution: This invention provides an intelligent lubrication control system for the hydraulic end of a fracturing truck, comprising: The physical lubrication unit includes a hydraulic end body, an outlet pipe, an inlet pipe, a reservoir, a baffle, a filter assembly, and a circulating pump. The hydraulic end body contains a pump chamber with a rectangular groove on the left side of its bottom. The right side of the rectangular groove communicates with the pump chamber, and the left side of the groove slopes downwards. The outlet pipe is fixedly installed on the left side of the bottom of the hydraulic end body, and its top end communicates with the left side of the rectangular groove. The reservoir contains a cavity with an opening at its top, and a cover is fitted at the opening. The left end of the reservoir communicates with the right end of the outlet pipe. The baffle is vertically fixedly installed in the middle of the cavity. A flow channel is provided at the center of the top of the plate. Slide rails are provided at the front end and the left side of the right end of the cavity. A frame is provided in the cavity. Slide grooves are provided at the front end and the rear end of the frame. The two sets of slide grooves are slidably connected to the two sets of slide rails respectively. A fixed plate is provided at the bottom left end of the frame. Vertical plates are provided around the top of the fixed plate. The vertical plate on the left side contacts the left end of the cavity. A filter screen is provided in the frame. The inlet pipe is fixedly installed on the right side of the bottom end of the hydraulic end body. The top end of the inlet pipe is connected to the pump chamber. The left end of the inlet pipe is connected to the right end of the cavity. The circulation pump is installed at the bottom of the inlet pipe. The data acquisition unit includes a liquid level sensor, a particulate matter sensor, and a pressure sensor. The liquid level sensor is installed on the inner wall of the storage tank to monitor the liquid level of the lubricating fluid in the cavity in real time. The particulate matter sensor is installed on the inner wall of the storage tank and located downstream of the filter screen to monitor the turbidity of the lubricating fluid in real time. The pressure sensor is installed on the front and rear sides of the frame to monitor the pressure difference across the filter screen. The control and processing unit has its signal input terminal electrically connected to the signal output terminals of the liquid level sensor, particulate matter sensor and pressure sensor, respectively, and is used to receive and process the collected status parameters. The human-computer interaction and alarm unit includes a display screen and an alarm; the communication interface of the display screen is connected to the communication interface of the control and processing unit; the control terminal of the alarm is electrically connected to the output terminal of the control and processing unit.

[0007] Preferably, the control terminal of the circulating pump is also electrically connected to the output terminal of the control and processing unit, and the control and processing unit sends start / stop control commands or speed adjustment commands to the circulating pump based on the lubrication status assessment results.

[0008] This invention also provides an intelligent lubrication control method for the hydraulic end of a fracturing truck, comprising the following steps: S1. Data Acquisition and Preprocessing: The control and processing unit acquires the liquid level signal output by the liquid level sensor, the turbidity signal output by the particulate matter sensor, and the differential pressure signal output by the pressure sensor in real time according to the preset sampling period, and performs filtering processing on the acquired raw signals to obtain preprocessed data. S2. Online assessment and model building of lubrication status: Based on the preprocessed data, the control and processing unit runs the built-in prediction model to calculate the key assessment indicators of the current lubrication status; S3. Intelligent Decision-Making and Alarm Logic: The control and processing unit compares the model calculation results with the preset threshold, executes the decision-making logic, and determines whether an alarm command needs to be generated. S4. Command Output and Execution: Based on the decision results, the control and processing unit drives the alarm to emit audible and visual alarm signals, and at the same time updates the status information on the display screen.

[0009] Preferably, step S2 specifically includes: S21. Lubricant Remaining Amount Prediction: The controller calculates the lubricant consumption rate based on the liquid level data and predicts the remaining available time; S22. Filter clogging status assessment: The controller calculates the filter clogging rate based on turbidity and differential pressure data to comprehensively assess the degree of clogging of the filter components; S23. Constructing the Comprehensive State Index (CSI): The controller constructs a dimensionless comprehensive state index to comprehensively evaluate the health of the lubrication system.

[0010] Preferably, in step S21, the formula for calculating the lubricant consumption rate is: ; in, and These are the filtered liquid level values ​​at the current time and the previous time, respectively. The sampling period is For level measurement noise; The formula for predicting the remaining available time is: ; in, It is the preset minimum safe liquid level threshold.

[0011] Preferably, in step S22, the formula for calculating the filter clogging rate is: ; in, This is the turbidity value after filtering. This is the filtered pressure difference value. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. The preset weighting coefficients satisfy 0 ≤ ≤1.

[0012] Preferably, in step S23, the formula for constructing the comprehensive state index is: ; in, This refers to the full liquid level height of the storage tank. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. , , The preset weighting coefficients satisfy... + + =1.

[0013] Preferably, the intelligent decision-making and alarm logic in step S3 specifically includes: S31. Low liquid level warning logic: If the remaining available time is less than the preset time threshold, and the filtered liquid level value at the current moment is greater than the minimum safe liquid level threshold, then a low liquid level warning command is generated. S32. Low liquid level shutdown alarm logic: If the filtered liquid level value at the current moment is less than or equal to the minimum safe liquid level threshold, a low liquid level shutdown alarm command is generated. S33. Lubricating fluid contamination alarm logic: If the turbidity is greater than or equal to the preset maximum turbidity threshold, or the pressure difference is greater than or equal to the preset maximum pressure difference threshold, or the filter clogging rate is greater than or equal to the preset clogging threshold, a lubricating fluid contamination alarm command will be generated. S34. Comprehensive Status Alarm Logic: If the comprehensive status index is greater than or equal to the preset comprehensive status index threshold, a comprehensive status alarm command is generated.

[0014] Preferably, in step S4, when the control and processing unit generates a low liquid level shutdown alarm command or a lubricant contamination alarm command, it also simultaneously sends a forced shutdown command to the circulating pump to stop the operation of the circulating pump.

[0015] Preferably, the filtering process in step S1 is a moving average filter, and its calculation formula is as follows: ; ; ; in, The width of the sliding window.

[0016] The present invention achieves the following beneficial technical effects compared to the prior art: This invention provides an intelligent lubrication control system and method for the hydraulic end of a fracturing truck. By retaining the original mechanical circulation structure, it innovatively integrates a data acquisition unit, a control and processing unit, and a human-machine interaction and alarm unit, featuring high intelligence, strong predictive capabilities, and significant protection effects. This invention utilizes level sensors, particulate matter sensors, and pressure sensors to monitor key lubricant state parameters in real time, solving the problem of existing technologies being unable to perceive lubrication status online. By constructing a predictive model system including a lubricant remaining volume prediction model, a filter clogging assessment model, and a comprehensive state index, it can accurately quantify and assess the health trend of the lubrication system, achieving a leap from passive maintenance to predictive maintenance. Based on the model calculation results and multi-level alarm logic, the intelligent decision-making method can issue timely warnings before the system state deteriorates and automatically shut down the pump to protect the equipment in extreme cases, effectively avoiding damage to the hydraulic end body due to lubrication failure. This greatly improves the reliability and continuity of fracturing truck operation and reduces equipment maintenance costs. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the main structure of the physical lubrication unit in this invention; Figure 2 For the present invention Figure 1 A partial structural diagram at point A in the middle; Figure 3 This is a schematic diagram of the partial connection structure of the liquid storage tank in this invention; Figure 4 This is a diagram illustrating the architecture of the intelligent lubrication control system for the hydraulic end of the fracturing truck in this invention. Figure 5 This is a flowchart of the intelligent lubrication control method for the hydraulic end of the fracturing truck in this invention. Detailed Implementation

[0019] The serial numbers assigned to components in this document, such as "first," "second," etc., are merely used to distinguish the described objects and have no sequential or technical meaning. The terms "connection" and "linkage" used in this application, unless otherwise specified, include both direct and indirect connections (linkages). In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0020] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The purpose of this invention is to provide an intelligent lubrication control system and method for the hydraulic end of a fracturing truck. By integrating a data acquisition unit, a control and processing unit, and a human-machine interaction and alarm unit while retaining the existing mechanical circulation structure, and by introducing a model-based intelligent decision-making algorithm, the invention achieves real-time monitoring, predictive evaluation, and graded early warning of the lubricant status. This solves the problems of the inability to perceive the lubrication status online, the lack of an early warning mechanism, and the low efficiency of post-operation maintenance in the prior art.

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] Example 1: like Figures 1 to 5As shown, the present invention provides an intelligent lubrication control system for the hydraulic end of a fracturing truck, comprising four main components: a physical lubrication unit, a data acquisition unit, a control and processing unit, and a human-machine interaction and alarm unit.

[0025] The physical lubrication unit retains the mechanical structure of the prior art (a hydraulic end lubrication device for fracturing trucks disclosed in CN202021293900.7), specifically including a hydraulic end body 1, an outlet pipe 2, an inlet pipe 3, a storage tank 4, a baffle 5, a filter assembly, and a circulation pump 6. A pump chamber 7 is provided inside the hydraulic end body 1. A rectangular groove 8 is formed on the left side of the bottom end of the pump chamber 7. The right side of the rectangular groove 8 communicates with the pump chamber 7, and the left side of the rectangular groove 8 slopes downwards. This design utilizes gravity to allow the lubricated fluid to flow smoothly into the outlet pipe 2. The outlet pipe 2 is fixedly installed on the left side of the bottom end of the hydraulic end body 1. The top end of the outlet pipe 2 communicates with the left side of the rectangular groove 8, and is used to guide the used lubricated fluid to the storage tank 4. A cavity 9 is provided inside the storage tank 4 for storing lubricated fluid. An opening is provided at the top of the cavity 9, and a cover 10 is provided at the opening for easy addition of lubricated fluid and internal maintenance. The left end of the storage tank 4 is connected to the right end of the outlet pipe 2. The baffle 5 is vertically fixed in the middle of the cavity 9. A flow channel 11 is provided at the top center of the baffle 5. The baffle 5 is used to divide the liquid storage tank 4 into two areas: the left side is the liquid inlet area and the filtration area, and the right side is the liquid storage area and the liquid outlet area. The lubricating fluid must flow from the left side to the right side through the flow channel 11 to ensure that the filtered clean lubricating fluid can enter the circulation. Slide rails 12 are provided at the front end and the left side of the right end of the cavity 9. A frame 18 is provided in the cavity 9. Slide grooves are provided at the front end and the rear end of the frame 18. The two sets of slide grooves are slidably connected to the two sets of slide rails 12 respectively. This pull-out structure facilitates the removal and maintenance of the frame 18. A fixing plate 13 is provided at the bottom left end of the frame 18. Vertical plates 14 are provided around the top of the fixing plate 13. The vertical plates 14 on the left side are in contact with the left end of the cavity 9. The fixing plate 13 and the vertical plates 14 together form a sedimentation tank for collecting large particulate impurities intercepted by the filter screen 15. A filter screen 15 is provided in the frame 18 for physical filtration of the incoming lubricating fluid. The inlet pipe 3 is fixedly installed on the right side of the bottom end of the hydraulic end body 1. The top end of the inlet pipe 3 is connected to the pump chamber 7, and the left end of the inlet pipe 3 is connected to the right end of the cavity 9, for conveying the filtered clean lubricating fluid back into the hydraulic end body 1. The circulation pump 6 is installed at the bottom of the inlet pipe 3 to provide power for the circulation of the lubricating fluid.

[0026] The data acquisition unit is the core sensing layer for intelligent monitoring in this invention, including a liquid level sensor, a particulate matter sensor, and a pressure sensor. The liquid level sensor is installed on the inner wall of the storage tank 4 to monitor the real-time liquid level of the lubricating fluid in the cavity 9. This sensor can be an ultrasonic level gauge or a float-type level gauge, and its output signal is an analog or digital signal, transmitted to the control and processing unit via a signal cable. The particulate matter sensor is installed on the inner wall of the storage tank 4 and located downstream of the filter screen 15, i.e., on the right side of the cavity 9 of the storage tank 4, to monitor the real-time turbidity of the filtered lubricating fluid. The turbidity of the lubricating fluid is directly related to the concentration of impurity particles it contains and is a key indicator for evaluating the purity of the lubricating fluid. This sensor can be an optical turbidimeter, which determines the turbidity value by measuring the intensity of transmitted or scattered light. The pressure sensors are installed on the front and rear sides of the frame 18. Specifically, one pressure measuring point is located upstream of the filter screen 15 (i.e., the inlet side), and the other pressure measuring point is located downstream of the filter screen 15 (i.e., the outlet side), to monitor the pressure difference across the filter screen 15. As more impurities are trapped on filter screen 15, its flow resistance increases, and the pressure difference across it rises accordingly. Therefore, the pressure difference is a direct indicator for assessing the degree of filter clogging. This sensor can be a differential pressure transmitter, directly outputting the upstream and downstream pressure difference signal.

[0027] The control and processing unit is the core decision-making layer of this invention and can be a programmable logic controller (PLC) or an embedded industrial computer. Its signal input terminals are electrically connected to the signal output terminals of the level sensor, particulate matter sensor, and pressure sensor, respectively, for receiving and processing the collected state parameters. The control and processing unit has pre-installed data acquisition programs, filtering algorithms, prediction models, and decision logic, enabling it to perform real-time calculations and analyses on the input raw signals and output corresponding control commands based on the analysis results. As a preferred embodiment of this invention, the control terminal of the circulating pump 6 is also electrically connected to the output terminal of the control and processing unit. This allows the control and processing unit to send start / stop control commands to the circulating pump 6 or send speed adjustment commands via a frequency converter based on the lubrication status assessment results. For example, it can force the pump to stop when the lubricating fluid is severely contaminated, or adjust the pump speed according to changes in the liquid level during normal operation to optimize the lubrication effect.

[0028] The human-machine interaction and alarm unit is the terminal layer for realizing human-machine interaction, including a display screen and an alarm. The communication interface of the display screen is connected to the communication interface of the control and processing unit, and is used to display real-time status information such as liquid level, turbidity, pressure difference, and remaining usable time, filter clogging rate, and comprehensive status index calculated by the model. The control terminal of the alarm is electrically connected to the output terminal of the control and processing unit. When the control and processing unit determines that an alarm is needed, it drives the alarm to emit an audible and visual alarm signal to remind the operator to handle the situation promptly.

[0029] Based on the above control system, the present invention also provides an intelligent lubrication control method for the hydraulic end of a fracturing truck, the method comprising the following steps.

[0030] Step S1: Data Acquisition and Preprocessing. The control and processing unit acquires the liquid level signal output by the liquid level sensor, the turbidity signal output by the particulate matter sensor, and the differential pressure signal output by the pressure sensor in real time according to a preset sampling period (e.g., 1 second). Due to electromagnetic interference and environmental noise in industrial environments, the acquired raw signals often contain noise components. Therefore, it is necessary to filter the raw signals to obtain preprocessed data that better reflects the actual state. In this embodiment, the moving average filtering method is preferably used, and its calculation formula is as follows: ; ; ; in, The sampling time number. This represents the width of the sliding window. Moving average filtering effectively smooths random noise in a signal, making subsequent model calculations more stable and reliable.

[0031] Step S2: Online assessment and model building of lubrication status. Based on the preprocessed data, the control and processing unit runs the built-in predictive model to calculate the key evaluation indicators of the current lubrication status. This step further includes three sub-steps.

[0032] S21: Lubricant Remaining Level Prediction. The controller calculates the lubricant consumption rate based on the fluid level data and predicts the remaining available time. The formula for calculating the lubricant consumption rate is: ; in, and These are the filtered liquid level values ​​at the current time and the previous time, respectively. The sampling period is The noise term for level measurement is a random variable with a mean of zero, representing the uncertainty caused by sensor measurement and environmental interference. The consumption rate reflects the height of the level drop per unit time; a positive value indicates a decreasing level, and a larger value indicates faster lubricant consumption. Based on the calculated consumption rate, the formula for predicting the remaining usable time is: ; in, This is a preset minimum safe fluid level threshold. The formula calculates the time required for the fluid level to drop from the current level to the minimum safe level, assuming the current consumption rate remains constant, in time (e.g., hours). This prediction provides operators with a clear time window for replenishing lubricant.

[0033] S22: Filter Clogging Status Assessment. The controller calculates the filter clogging rate based on turbidity and differential pressure data to comprehensively assess the degree of clogging of the filter assembly. Relying solely on turbidity or differential pressure can have limitations: turbidity reflects the purity of the lubricating fluid after passing through the filter, but when the filter is severely clogged, the flow rate through the filter decreases, which may actually lead to a decrease in turbidity; differential pressure directly reflects the resistance of the filter, but differential pressure is also affected by flow rate. Therefore, this invention constructs a comprehensive index integrating turbidity and differential pressure—the filter clogging rate, calculated using the following formula: ; in, This is the turbidity value after filtering. This is the filtered pressure difference value. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. The preset weighting coefficients satisfy 0 ≤ ≤1. Weighting coefficient The coefficient used to balance the contributions of turbidity and pressure differential to the assessment of clogging rate can be determined experimentally, for example, by simulating different degrees of clogging in experiments to find the factor that... The best linearity with the actual degree of congestion Value. Filter clogging rate. It is a dimensionless comprehensive index with a value range between [0,1]. The larger the value, the more severe the blockage.

[0034] S23: Constructing a Comprehensive State Index (CSI). To comprehensively evaluate the health of the entire lubrication system, rather than focusing on a single parameter, this invention constructs a dimensionless comprehensive state index (CSI) to integrate three key state parameters—liquid level, turbidity, and differential pressure—into a holistic health indicator. The calculation formula is as follows: ; in, This refers to the full liquid level height of the storage tank. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. , , The preset weighting coefficients satisfy... + + =1, representing the relative importance of liquid level, turbidity, and pressure difference in the overall condition assessment, respectively. For example, it can be set to... =0.3, =0.3, =0.4 indicates that the pressure difference is considered slightly more important than the liquid level and turbidity. In this formula, the first term reflects the degree of liquid level decrease; the lower the liquid level, the closer this term is to 1. The second term reflects the relative magnitude of turbidity. The third term reflects the relative magnitude of the pressure difference. Therefore, The value range is also between [0,1]. The larger the value, the worse the overall condition of the lubrication system is and the more maintenance is needed.

[0035] Step S3: Intelligent Decision-Making and Alarm Logic. The control and processing unit compares the results calculated by the model in Step S2 with a preset threshold, executes multi-level decision-making logic, and determines whether an alarm command needs to be generated and what type of alarm command should be generated. The specific alarm logic is as follows: S31: Low Liquid Level Warning Logic. If the remaining available time is less than a preset time threshold (e.g., 1 hour), and the filtered liquid level value at the current moment is still greater than the minimum safe liquid level threshold, it indicates that the lubricant is about to run out but has not yet reached a dangerous level. At this time, a low liquid level warning command is generated to remind the operator to prepare to add lubricant.

[0036] S32: Low liquid level shutdown alarm logic. If the filtered liquid level value at the current moment is less than or equal to the minimum safe liquid level threshold, it indicates that the lubricating fluid is seriously insufficient. Continuing to operate will lead to the risk of equipment damage. At this time, a low liquid level shutdown alarm command is generated, requiring immediate shutdown for inspection and replenishment of lubricating fluid.

[0037] S33: Lubricating fluid contamination alarm logic. If the turbidity is greater than or equal to the preset maximum turbidity threshold, or the differential pressure is greater than or equal to the preset maximum differential pressure threshold, or the filter clogging rate is greater than or equal to the preset clogging threshold (e.g., 0.9), it indicates that the lubricating fluid is severely contaminated or the filter is severely clogged. At this time, a lubricating fluid contamination alarm command is generated to remind the operator to clean or replace the filter.

[0038] S34: Comprehensive Status Alarm Logic. If the comprehensive status index is greater than or equal to the preset comprehensive status index threshold (e.g., 0.8), it indicates that the overall status of the lubrication system is poor. Although individual alarms may not have been triggered yet, the overall health is already in a poor state. At this time, a comprehensive status alarm command is generated, and a comprehensive system maintenance check is recommended.

[0039] Step S4: Command Output and Execution. Based on the decision result of step S3, the control and processing unit executes corresponding operations through its output module. Specifically, when any type of alarm command is generated, the controller drives the alarm to emit audible and visual alarm signals. Different types of alarms can correspond to different alarm frequencies or modes, allowing operators to quickly identify the alarm type. Simultaneously, the controller updates the latest status information to the display screen in real time for operators to view.

[0040] As a further preferred embodiment of the present invention, when a low liquid level shutdown alarm command or a lubricant contamination alarm command is generated, the control and processing unit not only drives the alarm to sound, but also simultaneously sends a forced shutdown command to the circulating pump 6. By cutting off the power supply to the circulating pump 6 or stopping its drive signal, the circulating pump 6 immediately stops operating. This protective measure can prevent the equipment from continuing to work under harsh lubrication conditions in extreme cases, thereby effectively protecting the precision components inside the hydraulic end body 1 from wear or damage.

[0041] The system and method described in this invention will be further explained below with reference to a specific workflow example.

[0042] During normal operation of the fracturing truck, the circulating pump 6 runs continuously, pumping the clean lubricating fluid from the right side of cavity 9 in the storage tank 4 through the inlet pipe 3 to the pump chamber 7 of the hydraulic end body 1 to lubricate components such as the plunger and pump valve. The lubricated fluid, under gravity, flows through the rectangular groove 8 at the bottom of the pump chamber 7 into the outlet pipe 2, and then flows back to the left side of cavity 9 in the storage tank 4. The returned fluid first undergoes physical filtration through the filter screen 15, where impurities are intercepted and precipitated onto the fixed plate 13. The filtered clean lubricating fluid overflows through the flow groove 11 at the top of the baffle 5 to the right side of cavity 9, awaiting the next circulation. Throughout the process, the data acquisition unit operates continuously: the level sensor monitors the liquid level in the storage tank 4 in real time; the particulate matter sensor monitors the turbidity of the filtered lubricating fluid in real time; and the pressure sensor monitors the pressure difference across the filter screen 15 in real time. The control and processing unit acquires these signals at a sampling period of 1 second and preprocesses them using a moving average filter with N=10. As the lubricant is gradually consumed, and the level drops from the full level of 500mm to 300mm, the controller calculates a consumption rate of 5mm / h based on historical level changes, predicting a remaining usable time of 40 hours. At this point, 40 hours is greater than the preset time threshold of 24 hours, so no alarm is triggered. As operation continues, when the level drops to 120mm, the remaining usable time is 4 hours, less than the 24-hour warning threshold. The controller immediately generates a low-level warning command, a warning message pops up on the display screen, and the alarm emits a low-frequency intermittent audible and visual signal to remind the operator to prepare to add lubricant. If the operator fails to add lubricant in time, the level continues to drop to 100mm, triggering a low-level shutdown alarm. Simultaneously, the controller drives the alarm to emit a high-frequency continuous alarm signal and sends a forced shutdown command to the circulating pump 6 to protect the equipment. Meanwhile, if the particulate matter sensor detects that the turbidity continues to rise to 90 NTU, exceeding the threshold of 80 NTU, the controller will generate a lubricant contamination alarm and calculate the filter clogging rate as 0.85 based on the differential pressure data. Although it has not yet reached the shutdown threshold of 0.9, it is close to the warning value. The alarm message will clearly indicate "Lubricant contamination, filter cleaning is recommended".

[0043] In summary, the intelligent lubrication control system and method for the hydraulic end of a fracturing truck provided by this invention integrates sensors and intelligent controllers into the existing mechanical circulation structure and introduces a model-based predictive evaluation algorithm to achieve real-time perception, quantitative evaluation, and graded early warning of lubrication status. This method can not only predict the remaining usable time of the lubricant but also comprehensively evaluate the degree of filter clogging and the overall health of the system, fundamentally solving the technical problems of "invisibility, inaccuracy, and lack of early warning" in existing technologies, and significantly improving the intelligence level and operational reliability of the hydraulic end lubrication system of the fracturing truck.

[0044] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0045] It should be noted that the components mentioned in the above embodiments are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0046] This invention has illustrated its principles and implementation methods using specific examples. The descriptions of these embodiments are merely illustrative of the method and its core ideas; furthermore, those skilled in the art will recognize that modifications may be made to the specific implementation methods and application scope based on the principles of this invention. Therefore, the content of this specification should not be construed as limiting the invention.

Claims

1. An intelligent lubrication control system for the hydraulic end of a fracturing truck, characterized in that, include: The physical lubrication unit includes a hydraulic end body (1), an outlet pipe (2), an inlet pipe (3), a storage tank (4), a baffle (5), a filter assembly, and a circulation pump (6). The hydraulic end body (1) contains a pump chamber (7). A rectangular groove (8) is formed on the left side of the bottom of the pump chamber (7). The right side of the rectangular groove (8) is connected to the pump chamber (7), and the left side of the rectangular groove (8) slopes downwards. The outlet pipe (2) is fixedly installed on the left side of the bottom of the hydraulic end body (1). The top of the outlet pipe (2) is connected to the left side of the rectangular groove (8). The storage tank (4) contains a cavity (9). An opening is formed at the top of the cavity (9), and a cover (10) is provided at the opening. The left end of the storage tank (4) is connected to the right end of the outlet pipe (2). The baffle (5) is vertically fixedly installed in the middle of the cavity (9). A flow channel (11) is provided at the top center. Slide rails (12) are provided at the front end and the left side of the right end of the cavity (9). A frame (18) is provided in the cavity (9). Slide grooves are provided at the front end and the rear end of the frame (18). The two sets of slide grooves are slidably connected to the two sets of slide rails (12). A fixing plate (13) is provided at the bottom left end of the frame (18). Vertical plates (14) are provided around the top of the fixing plate (13). The vertical plate (14) on the left side is in contact with the left end of the cavity (9). A filter screen (15) is provided in the frame (18). The inlet pipe (3) is fixedly installed on the right side of the bottom end of the hydraulic end body (1). The top end of the inlet pipe (3) is connected to the pump chamber (7). The left end of the inlet pipe (3) is connected to the right end of the cavity (9). The circulating pump (6) is installed at the bottom of the inlet pipe (3). The data acquisition unit includes a liquid level sensor, a particulate matter sensor, and a pressure sensor; the liquid level sensor is installed on the inner wall of the liquid storage tank (4) to monitor the liquid level of the lubricating fluid in the cavity (9) in real time; the particulate matter sensor is installed on the inner wall of the liquid storage tank (4) and located downstream of the filter screen (15) to monitor the turbidity of the lubricating fluid in real time; the pressure sensor is installed on the front and rear sides of the frame (18) to monitor the pressure difference on both sides of the filter screen (15); The control and processing unit has its signal input terminal electrically connected to the signal output terminals of the liquid level sensor, particulate matter sensor and pressure sensor, respectively, and is used to receive and process the collected status parameters. The human-computer interaction and alarm unit includes a display screen and an alarm; the communication interface of the display screen is connected to the communication interface of the control and processing unit; the control terminal of the alarm is electrically connected to the output terminal of the control and processing unit.

2. The intelligent lubrication control system for the hydraulic end of the fracturing truck according to claim 1, characterized in that, The control terminal of the circulating pump (6) is also electrically connected to the output terminal of the control and processing unit. The control and processing unit sends start / stop control commands or speed adjustment commands to the circulating pump (6) based on the lubrication status assessment results.

3. A method for intelligent lubrication control of the hydraulic end of a fracturing truck based on the intelligent lubrication control system of the hydraulic end of a fracturing truck as described in claim 1 or 2, characterized in that, Includes the following steps: S1. Data Acquisition and Preprocessing: The control and processing unit acquires the liquid level signal output by the liquid level sensor, the turbidity signal output by the particulate matter sensor, and the differential pressure signal output by the pressure sensor in real time according to the preset sampling period, and performs filtering processing on the acquired raw signals to obtain preprocessed data. S2. Online assessment and model building of lubrication status: Based on the preprocessed data, the control and processing unit runs the built-in prediction model to calculate the key assessment indicators of the current lubrication status; S3. Intelligent Decision-Making and Alarm Logic: The control and processing unit compares the model calculation results with the preset threshold, executes the decision-making logic, and determines whether an alarm command needs to be generated. S4. Command Output and Execution: Based on the decision results, the control and processing unit drives the alarm to emit audible and visual alarm signals, and at the same time updates the status information on the display screen.

4. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 3, characterized in that, Step S2 specifically includes: S21. Lubricant Remaining Amount Prediction: The controller calculates the lubricant consumption rate based on the liquid level data and predicts the remaining available time; S22. Filter clogging status assessment: The controller calculates the filter clogging rate based on turbidity and differential pressure data to comprehensively assess the degree of clogging of the filter components; S23. Constructing the Comprehensive State Index (CSI): The controller constructs a dimensionless comprehensive state index to comprehensively evaluate the health of the lubrication system.

5. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 4, characterized in that, In step S21, the formula for calculating the lubricant consumption rate is: ； in, and These are the filtered liquid level values ​​at the current time and the previous time, respectively. The sampling period is For level measurement noise; The formula for predicting the remaining available time is: ； in, It is the preset minimum safe liquid level threshold.

6. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 4, characterized in that, In step S22, the formula for calculating the filter clogging rate is: ； in, This is the turbidity value after filtering. This is the filtered pressure difference value. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. The preset weighting coefficients satisfy 0 ≤ ≤1.

7. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 4, characterized in that, In step S23, the formula for constructing the comprehensive state index is: ； in, This refers to the full liquid level height of the storage tank. and These are the preset maximum permissible turbidity value and maximum pressure difference value, respectively. , , The preset weighting coefficients satisfy... + + =1.

8. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 3, characterized in that, The intelligent decision-making and alarm logic in step S3 specifically includes: S31. Low liquid level warning logic: If the remaining available time is less than the preset time threshold, and the filtered liquid level value at the current moment is greater than the minimum safe liquid level threshold, then a low liquid level warning command is generated. S32. Low liquid level shutdown alarm logic: If the filtered liquid level value at the current moment is less than or equal to the minimum safe liquid level threshold, a low liquid level shutdown alarm command is generated. S33. Lubricating fluid contamination alarm logic: If the turbidity is greater than or equal to the preset maximum turbidity threshold, or the pressure difference is greater than or equal to the preset maximum pressure difference threshold, or the filter clogging rate is greater than or equal to the preset clogging threshold, a lubricating fluid contamination alarm command will be generated. S34. Comprehensive Status Alarm Logic: If the comprehensive status index is greater than or equal to the preset comprehensive status index threshold, a comprehensive status alarm command is generated.

9. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 8, characterized in that, In step S4, when the control and processing unit generates a low liquid level shutdown alarm command or a lubricant contamination alarm command, it also simultaneously sends a forced shutdown command to the circulating pump (6) to stop the operation of the circulating pump (6).

10. The intelligent lubrication control method for the hydraulic end of a fracturing truck according to claim 3, characterized in that, The filtering process in step S1 is a moving average filter, and its calculation formula is as follows: ； ； ； in, The width of the sliding window.

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