A high-temperature heavy-load high-speed thrust bearing performance testing system and method

Abstract

The application relates to the technical field of mechanical engineering, and discloses a high-temperature heavy-load high-speed thrust bearing performance testing system and method, which comprises a heavy-load simulation part, a high-temperature simulation part and a high-speed dynamic simulation part arranged in sequence; the high-temperature simulation part comprises a high-temperature box, a sealed test cabin is arranged in the high-temperature box, and the test cabin is filled with high-temperature-resistant oil to provide a high-temperature environment for the thrust bearing; the heavy-load simulation part comprises a thrust oil cylinder, an output shaft of the thrust oil cylinder is connected with a thrust shaft, the thrust shaft extends into the test cabin and is fixedly connected with a first clamp, and the first clamp is used for mounting a bearing seat of the thrust bearing; the high-speed dynamic simulation part comprises a high-speed motor, a static pressure shaft and a power shaft, the output end of the high-speed motor is connected with the power shaft through the static pressure shaft, the power shaft extends into the test cabin and is fixedly connected with a second clamp, and the second clamp is used for mounting a thrust ring of the thrust bearing. The application can realize precise reproduction of a high-temperature heavy-load high-speed coupling condition, and provides reliable equipment support for thrust bearing product development and performance determination.

Description

Technical Field

[0001] This invention relates to the field of mechanical engineering technology, specifically to a system and method for testing the performance of thrust bearings under high temperature, heavy load, and high speed conditions. Background Technology

[0002] Thrust bearings, as core components for transmitting axial loads, are widely used in high-end equipment such as submersible pump protectors, aero-engine spindles, and ultra-deep well drilling tools. Their performance directly determines the reliability and lifespan of the equipment under extreme operating conditions. In deep-sea oil and gas development, aerospace, and other fields, thrust bearings must withstand coupled operating conditions of "nearly 400°C high temperature, 30T heavy load, and 12000r / min high speed" for extended periods. For example, in ultra-deep well operations, the bottom hole temperature of a submersible pump can reach 400°C, the axial thrust exceeds 25T, and the spindle speed needs to be maintained above 10000r / min. Failure of a thrust bearing will lead to the failure of the entire machine. Therefore, accurately reproducing extreme operating conditions and testing the performance of thrust bearings has become a key aspect of equipment development and reliability assessment.

[0003] However, existing thrust bearing performance testing technologies have significant shortcomings and are difficult to meet practical application needs. The most obvious example is the insufficient ability to reproduce extreme working conditions. For instance, the maximum temperature resistance of most mainstream domestic test benches is limited to 220-250℃, dynamic load capacity ≤20T, and maximum speed ≤1500r / min. They cannot simultaneously cover the coupled working conditions of "400℃+30T+12000r / min". Although some imported equipment can improve individual parameters, it is not designed for the synergistic effect of high temperature, heavy load, and high speed, resulting in a large deviation between the test scenario and the actual service environment, and limiting the reference value of the test data. Therefore, existing thrust bearing testing platforms still have significant limitations in terms of temperature resistance, load capacity, and speed performance, and are unable to cover the operating boundaries of submersible motor thrust bearings under extreme working conditions. Summary of the Invention

[0004] To address the shortcomings of the existing technology, this invention provides a system and method for testing the performance of thrust bearings under high temperature, heavy load, and high speed conditions, so as to achieve reliable and accurate testing of thrust bearings under extreme conditions of nearly 400℃, 30T, and 12000r / min.

[0005] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: A high-temperature, heavy-load, and high-speed thrust bearing performance testing system includes a heavy-load simulation unit, a high-temperature simulation unit, and a high-speed dynamic simulation unit, wherein the heavy-load simulation unit and the high-speed dynamic simulation unit are located on both sides of the high-temperature simulation unit. The high-temperature simulation unit includes a high-temperature chamber, which contains a sealed test chamber. A high-temperature heating component is located at the bottom of the inner side of the test chamber, and a heat insulation layer is provided between the outer periphery of the test chamber and the outer shell of the high-temperature chamber. The test chamber is filled with high-temperature resistant oil to provide a high-temperature environment for the thrust bearing. The heavy-duty simulation unit includes a thrust cylinder and a thrust shaft. One end of the thrust shaft is connected to the output shaft of the thrust cylinder via a heat-insulating adapter plate, and the other end extends into the test chamber of the high-temperature chamber and is fixedly connected to a first clamp. The first clamp is used to install the bearing housing of the thrust bearing. The two ends of the thrust shaft are supported by a sliding bearing housing, and the thrust shaft is slidably sealed to the side wall of the high-temperature chamber. The thrust cylinder provides a loading force to the bearing housing through the thrust shaft. The high-speed dynamic simulation unit includes a high-speed motor, a static pressure shaft, and a power shaft. The output end of the high-speed motor is connected to one end of the static pressure shaft via a coupling, and the other end of the static pressure shaft is connected to the power shaft via a heat-insulating adapter plate. The other end of the power shaft extends into the test chamber of the high-temperature chamber and is fixedly connected to a second clamp. The second clamp is used to install the thrust ring of the thrust bearing. The two ends of the static pressure shaft are supported by a static pressure bearing seat, and the two ends of the power shaft are supported by a rotary bearing seat. The power shaft is rotatably sealed to the side wall of the high-temperature chamber. The high-speed motor drives the thrust ring to rotate through the static pressure shaft and the power shaft.

[0006] Furthermore, it also includes a signal acquisition unit, which comprises a sensor assembly including a thrust sensor, a dynamic torque sensor, a temperature sensor, a vibration sensor, and a speed sensor. The thrust sensor is located between the thrust cylinder and the thrust shaft, the dynamic torque sensor is located between the high-speed motor and the hydrostatic shaft, the temperature sensor is located inside the test chamber, and the vibration sensor is mounted on the hydrostatic bearing housing. The speed sensor is a built-in sensor of the motor. The sensor assembly also includes a wear test sensor, an oil condition sensor, and a vacuum sensor. The vacuum sensor is used to monitor the vacuum level inside the test chamber, the oil condition sensor is used to monitor the viscosity and gas content of the high-temperature resistant oil, and the wear test sensor is mounted on the bearing housing end face of the thrust bearing to monitor the wear condition of the thrust bearing. The signal acquisition unit also includes a high-frequency acquisition module and a data processing module. The high-frequency acquisition module is communicatively connected to each sensor and the data processing module, using a 16-channel acquisition frequency band, a sampling rate ≥500kS / s, a sampling range of ±10V, and a resolution of 12bit, for synchronously acquiring signals from multiple sensors. The data processing module has a built-in processing module that supports real-time curve display, data storage, trend analysis, anomaly warning, and remote data transmission.

[0007] Furthermore, a sliding sealing assembly is provided between the thrust shaft and the high-temperature chamber. The sliding sealing assembly has a through lubrication channel, and the thrust shaft is slidably connected in the lubrication channel. The sliding sealing assembly includes a CF sealing flange, which has a stepped hole inside. The small hole of the stepped hole faces the inside of the test chamber for the thrust shaft to pass through. An elastic compensation ring is provided in the large hole of the stepped hole, and a self-lubricating sealing ring is provided outside the elastic compensation ring. The self-lubricating sealing ring presses against the elastic compensation ring and is connected to the CF sealing flange by screws.

[0008] Furthermore, the self-lubricating sealing ring is made of Al2O+TiC self-lubricating ceramic matrix composite material; the elastic compensation ring is made of Inconel 718 material.

[0009] Furthermore, a rotary sealing assembly is provided between the power shaft and the high-temperature chamber. The rotary sealing assembly includes a sealing seat, a main sealing lip, a rotating bushing, and an axial retaining ring. An installation hole is provided on the side wall of the high-temperature chamber, and the sealing seat is installed within the installation hole. A stepped through hole is provided in the center of the sealing seat for the power shaft to pass through. The power shaft is a stepped shaft. The main sealing lip, rotating bushing, and axial retaining ring are sequentially fitted tightly onto the power shaft from the inside to the outside. The inner and outer sides refer to the inner and outer sides of the high-temperature chamber. The axial retaining ring is equipped with a positioning device. The outer diameter of the main sealing lip is larger than the outer diameter of the rotating bushing. The outer walls of the main sealing lip and the rotating bushing respectively abut against the inner wall of the through hole in the sealing housing. The main sealing lip, the rotating bushing, and the through hole in the sealing housing enclose and form... The mounting cavity contains an elastic sealing compensation device. The elastic sealing compensation device includes a waveform elastic compensation base, a waveform elastic compensation component, a waveform elastic compensation component push ring, and an auxiliary sealing lip. The waveform elastic compensation base is cylindrical and located on the side of the mounting cavity away from the main sealing lip. Its bottom is locked to the sealing seat by fixing screws. The waveform elastic compensation component and the waveform elastic compensation component push ring are connected sequentially inside the cylinder. The outer diameter of the waveform elastic compensation component push ring is adapted to the inner diameter of the waveform elastic compensation base cylinder. An auxiliary sealing lip is installed on the end face of the waveform elastic compensation component push ring. The auxiliary sealing lip abuts against the main sealing lip. The outer diameter of the auxiliary sealing lip is smaller than the outer diameter of the main sealing lip. A sealed cavity is formed between the elastic sealing compensation device, the main sealing lip, and the sealing seat.

[0010] Furthermore, the main sealing lip is made of ceramic fiber reinforced graphite material, the auxiliary sealing lip is made of nickel-based alloy coated with polytetrafluoroethylene composite structure, and the waveform elastic compensation component is made of Inconel 718 alloy material.

[0011] Furthermore, the sealing seat is also provided with an annular cooling cavity, which is spaced at intervals on the corresponding areas of the main sealing lip and the outer periphery of the sealed cavity, and the cooling cavity is connected to the cooling oil passage.

[0012] Furthermore, the thrust cylinder has a rated output pressure of 0-30T and an ultimate pressure of 35T, controlled by a proportional valve; the high-speed motor has a power of 45KW, a rated speed of 10000r / min, an ultimate speed of 12000r / min, and is equipped with a speed controller and a G1-level dynamic balance corrector; the coupling is a magnetic coupling, transmitting power of 45KW, adapting to an ultimate speed of 12000r / min, and realizing non-contact power transmission.

[0013] Furthermore, the high-temperature resistant oil is Moruns I-PA organic heat transfer fluid, and the heat insulation adapter plate is made of ZC800 material.

[0014] A method for testing the performance of thrust bearings under high temperature, heavy load, and high speed conditions, using the aforementioned test system for thrust bearing performance under high temperature, heavy load, and high speed conditions, includes the following steps: S1. Test piece clamping and fixing: Install the bearing seat of the thrust bearing test piece into the first clamp, install the thrust ring into the second clamp, and tighten the nut with a wrench to ensure that the test piece does not move during the test. S2. High-temperature oil injection: High-temperature resistant oil is injected into the test chamber through an automatic oil injection system; S3. Temperature control: Activate the high-temperature heating component to heat the high-temperature resistant oil in the test chamber to 400℃; S4. Pressure loading: Apply 30T axial pressure to the bearing housing of the thrust bearing via the thrust cylinder; S5, Speed ​​Adjustment: Start the high-speed motor and transmit rotational power through the static pressure shaft and the thrust ring of the thrust axial thrust bearing. The speed is 10000r / min. S6. Real-time monitoring of multiple parameters: Key parameters during the test process are collected using the signal acquisition unit, including temperature, axial pressure, vibration status, wear condition, and spindle torque. S7. Standardized shutdown: After the test, first turn off the high-speed motor, then stop the operation of the thrust cylinder and reduce the pressure to normal pressure. Turn off the high-temperature heating components. After the equipment temperature drops to normal temperature, recover the high-temperature resistant oil and disassemble the thrust bearing test piece.

[0015] The beneficial effects of this invention are: The present invention relates to a high-temperature, heavy-load, and high-speed thrust bearing performance testing system and method. The high-temperature simulation unit can provide a test environment simulating a high temperature of 400°C, the heavy-load simulation unit is used to provide a heavy-load thrust of up to 30T, and the high-speed dynamic simulation unit is used to provide a speed of up to 12000r / min. It can accurately reproduce the coupled working conditions of high temperature, heavy load, and high speed, and realize reliable and accurate testing of thrust bearings under extreme working conditions, thus providing reliable equipment support for thrust bearing product development and performance evaluation.

[0016] The high-temperature, heavy-load, and high-speed thrust bearing performance testing system and method of the present invention significantly reduces test repeatability errors and ensures the reliability of test data by clearly defining the parameters and operating standards of each simulation unit. The multi-dimensional monitoring system can comprehensively capture the performance changes of thrust bearings under extreme working conditions, providing accurate test basis for thrust bearing design optimization, life assessment, and quality screening. It is applicable to the performance testing of thrust bearings in fields such as submersible pumps, aero engines, and ultra-deep well drilling tools.

[0017] In the high-temperature, heavy-load, high-speed thrust bearing performance testing system of the present invention, the sliding seal structure adopts a self-lubricating sealing ring and an elastic compensation ring; the rotary seal structure adopts a composite design of "main sealing lip + auxiliary sealing lip + waveform elastic compensation component", which provides multiple seals and can provide stable pre-tightening force to offset the effect of thermal expansion. It effectively solves the problems of easy aging and serious leakage of traditional seals under high temperature and high speed conditions, and has the advantages of high reliability, low leakage rate and long service life. It is suitable for thrust bearing testing equipment for submersible motor protectors and similar high-temperature rotating occasions. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 This is a top view of the system of the present invention; Figure 3 This is a cross-sectional schematic diagram of the high-temperature simulation section; Figure 4 This is a schematic diagram of a sliding seal structure; Figure 5 This is a schematic diagram of a rotary seal structure.

[0020] Reference numerals: 1-Heavy-load simulation unit, 2-High-temperature simulation unit, 3-High-speed dynamic simulation unit, 4-Heat insulation connecting block, 5-First clamp, 6-Bearing housing, 7-Coupling, 8-Second clamp, 9-Thrust ring, 11-Thrust sensor, 12-Dynamic torque sensor, 101-Thrust cylinder, 102-Thrust shaft, 103-Sliding bearing housing, 201-High-temperature chamber, 202-Test chamber, 203-High-temperature heating assembly, 204-Heat insulation unit, 205-Cooling circulation pipe, 206-Sliding sealing assembly, 207-Rotary seal Components: 301-High-speed motor, 302-Hydrostatic shaft, 303-Power shaft, 304-Hydrostatic bearing housing, 305-Rotary bearing housing, 2061-CF sealing flange, 2062-Elastic compensating ring, 2063-Self-lubricating sealing ring, 2071-Sealing seat, 2072-Main sealing lip, 2073-Rotary bushing, 2074-Axial retaining ring, 2075-Mounting cavity, 2076-Wave elastic compensating component base, 2077-Wave elastic compensating component, 2078-Wave elastic compensating component push ring, 2079-Auxiliary sealing lip. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0022] A performance testing system for thrust bearings under high temperature, heavy load, and high speed conditions, such as... Figure 1 , Figure 2 As shown, it includes a heavy-load simulation unit 1, a high-temperature simulation unit 2, and a high-speed dynamic simulation unit 3. The heavy-load simulation unit 1 and the high-speed dynamic simulation unit 3 are respectively disposed on both sides of the high-temperature simulation unit 2. Furthermore, it also includes a base. The heavy-load simulation unit 1, the high-temperature simulation unit 2, and the high-speed dynamic simulation unit 3 are all fixed on the base. The heavy-load simulation unit 1 is used to provide axial loading force for the thrust bearing. The high-temperature simulation unit 2 is used to simulate a high-temperature environment exceeding 400°C. The high-speed dynamic simulation unit 3 is used to provide rotational power for the thrust bearing.

[0023] The high-temperature simulation unit 2 includes a high-temperature chamber 201, such as... Figure 3As shown, the high-temperature chamber 201 is equipped with a sealed test chamber 202. The bottom of the inner side of the test chamber 202 is equipped with a high-temperature heating component 203. A heat insulation unit 204 is provided between the outer periphery of the test chamber 202 and the outer shell of the high-temperature chamber 201. The test chamber 202 is filled with high-temperature resistant oil to provide a high-temperature environment for the thrust bearing. The heavy-load simulation unit 1 includes a thrust cylinder 101 and a thrust shaft 102. One end of the thrust shaft 102 is connected to the output shaft of the thrust cylinder 1 via a heat-insulating adapter plate 4, and the other end extends into the test chamber 202 of the high-temperature chamber and is fixedly connected to a first clamp 5. The first clamp 5 is used to install the bearing seat 6 of the thrust bearing. The two ends of the thrust shaft 102 are supported by a sliding bearing seat 103. The thrust shaft 102 is slidably and sealed to the side wall of the high-temperature chamber 201. The thrust cylinder 101 provides a loading force to the bearing seat 6 through the thrust shaft 102. The high-speed dynamic simulation unit 3 includes a high-speed motor 301, a static pressure shaft 302, and a power shaft 303. The output end of the high-speed motor 301 is connected to one end of the static pressure shaft 302 via a coupling 7, and the other end of the static pressure shaft 302 is connected to the power shaft 303 via a heat-insulating adapter plate 4. The other end of the power shaft 303 extends into the test chamber 202 of the high-temperature chamber and is fixedly connected to a second clamp 8. The second clamp 8 is used to install the thrust ring 9 of the thrust bearing. The two ends of the static pressure shaft 302 are supported by a static pressure bearing seat 304, and the two ends of the power shaft 303 are supported by a rotary bearing seat 305. The power shaft 303 is rotatably sealed to the side wall of the high-temperature chamber 201. The high-speed motor 301 drives the thrust ring 9 to rotate through the static pressure shaft 302 and the power shaft 303.

[0024] Preferably, the thrust cylinder 101 has a rated output pressure of 0-30T and an ultimate pressure of 35T, and the pressure is variablely controlled through a proportional valve; the high-speed motor has a power of 45KW, a rated speed of 10000r / min, an ultimate speed of 12000r / min, and is equipped with a speed controller and a G1-level dynamic balance corrector; the coupling and the heat-insulating coupling are magnetic couplings, transmitting power of 45KW, adapting to the ultimate speed of 12000r / min, and realizing non-contact power transmission.

[0025] Furthermore, it also includes a signal acquisition unit, which comprises a sensor assembly including a thrust sensor 11, a dynamic torque sensor 12, a temperature sensor, a vibration sensor, and a speed sensor. The thrust sensor 11 is located between the thrust cylinder 101 and the thrust shaft 102, with a maximum frequency of 2kHz and a thrust range of 30T. The dynamic torque sensor 12 is located between the high-speed motor 301 and the hydrostatic shaft 302, with a range of 0-100N·m, an accuracy of 0.1%FS, and an acquisition frequency of 1kHz. The temperature sensor is located inside the test chamber 202, with a range of 0-400℃ and an accuracy of ±0.5℃. The vibration sensor is mounted on the hydrostatic bearing seat 304; the vibration sensor is temperature resistant to 400℃. The measurement range is 0-10g, with a linearity of 1% and a sampling frequency of 1kHz. The speed sensor is a motor-embedded sensor with a range of 0-12000r / min and an accuracy of 0.1%FS. Furthermore, the sensor assembly also includes a wear test sensor, an oil condition sensor, and a vacuum sensor. The vacuum sensor is used to monitor the vacuum level in the test chamber, with a range of 0-10Pa and an accuracy of ±0.1Pa. The oil condition sensor is used to monitor the oil viscosity and gas content, with a sampling frequency of 100Hz. The wear test sensor is an ultrasonic sensor installed at the working end of the thrust bearing housing to monitor the wear condition on the thrust shaft side, with an accuracy of ±10µm, a sampling rate of 10MHz, and continuous operation of ≥500h.

[0026] The signal acquisition unit also includes a high-frequency acquisition module and a data processing module. The high-frequency acquisition module is communicatively connected to each sensor and the data processing module, using a 16-channel acquisition frequency band, a sampling rate ≥500kS / s, a sampling range of ±10V, and a resolution of 12bit, and can simultaneously acquire signals from multiple sensors. The data processing module has a built-in processing module that supports real-time curve display, data storage (supports Excel / PDF export), trend analysis, anomaly warning, and remote data transmission.

[0027] Furthermore, the high-temperature heating component 203 is a nano-rare earth electric heating element with a rated power of 10KW, a heating range of room temperature to 400℃, a maximum heating temperature of 500℃, and a heating rate of ≥5℃ / min. The heat insulation unit 204 is made of heat insulation cotton. The high-temperature chamber 201 is also equipped with a cooling component, which includes a cooling circulation pipe 205 and a cooling unit. The cooling circulation pipe 205 is arranged inside the heat insulation unit 204 and is connected to the cooling unit. Coolant is circulated into the cooling circulation pipe 205 through the cooling unit to cool the heat insulation unit 204 and prevent the outer shell temperature of the high-temperature chamber 201 from becoming too high.

[0028] A sliding sealing assembly 206 is provided between the thrust shaft 102 and the high-temperature chamber 201, such as Figure 3 , Figure 4 As shown, the sliding sealing assembly 206 has a through lubrication channel, and the thrust shaft is slidably connected within the lubrication channel. The sliding sealing assembly 206 includes a CF sealing flange 2061, which has a stepped hole inside. The smaller hole of the stepped hole faces the interior of the test chamber 202, allowing the thrust shaft 102 to pass through. An elastic compensation ring 2062 is installed inside the larger hole of the stepped hole, and a self-lubricating sealing ring 2063 is installed at the tail of the elastic compensation ring 2062. The self-lubricating sealing ring 2063 presses the elastic compensation ring 2062 and is connected to the CF sealing flange 2061 by screws. Preferably, the self-lubricating sealing ring 2063 is made of Al2O+TiC self-lubricating ceramic matrix composite material, which has wear resistance, high temperature resistance, and self-lubricating properties. The elastic compensation ring 2062 is made of Inconel 718 material, which has high elastic recovery rate and creep resistance, and can significantly reduce the risk of sealing surface peeling under thermal cycling.

[0029] A rotary sealing assembly 207 is provided between the power shaft 303 and the high-temperature chamber 201, such as Figure 3 , Figure 5As shown, the rotary sealing assembly 207 includes a sealing seat 2071, a main sealing lip 2072, a rotary bushing 2073, and an axial retaining ring 2074. An installation hole is provided on the side wall of the high-temperature chamber, and the sealing seat 2071 is installed in the installation hole. A stepped through hole is provided in the center of the sealing seat 2071 for the power shaft 303 to pass through. The power shaft is a stepped shaft. The main sealing lip 2072, rotary bushing 2073, and axial retaining ring 2074 are sequentially and tightly fitted onto the power shaft 303 from the inside out. The inner and outer sides refer to the inner and outer sides of the high-temperature chamber 201. The axial retaining ring 2074 is equipped with a positioning device. Preferably, the axial retaining ring 2074 is threadedly connected to the power shaft 303. The outer diameter of the main sealing lip 2072 is larger than the outer diameter of the rotating bushing 2073. The outer walls of the main sealing lip 2072 and the rotating bushing 2073 respectively abut against the inner wall of the through hole of the sealing seat 2071. The main sealing lip 2072, the rotating bushing 2073 and the through hole of the sealing seat 2071 enclose and form a safety barrier. The mounting cavity 2075 contains an elastic sealing compensation device. This device includes a waveform elastic compensation base 2076, a waveform elastic compensation component 2077, a waveform elastic compensation component push ring 2078, and an auxiliary sealing lip 2079. The waveform elastic compensation base 2076 is cylindrical and located on the side of the mounting cavity 2075 away from the main sealing lip 2072. Its bottom is locked to the sealing seat 2071 by fixing screws. The waveform elastic compensation components are sequentially connected inside the cylinder. 2077. Waveform elastic compensating element push ring 2078. The outer diameter of the waveform elastic compensating element push ring 2078 is adapted to the inner diameter of the waveform elastic compensating element base 2076. An auxiliary sealing lip 2079 is installed on the inner side of the waveform elastic compensating element push ring 2078. The auxiliary sealing lip 2079 abuts against the main sealing lip 2072. The outer diameter of the auxiliary sealing lip 2079 is smaller than the outer diameter of the main sealing lip 2072. A sealed cavity is formed between the elastic sealing compensation device, the main sealing lip 2072, and the sealing seat 2071. The inner wall of the mounting cavity 2075 is nitrided. The sealing seat 2071 and the main sealing lip 2072 form the main seal, and the main sealing lip 2072 and the auxiliary sealing lip 2079 form the auxiliary seal. A small amount of medium that permeates through the main seal will enter the sealing cavity and will then be intercepted by the auxiliary seal to prevent the medium from reaching the outer circumference of the rotating bushing 2073.

[0030] Preferably, the main sealing lip 2072 is made of ceramic fiber reinforced graphite material, possessing temperature resistance above 450℃ and excellent self-lubricating properties to achieve basic sealing. The auxiliary sealing lip 2079 adopts a nickel-based alloy-coated polytetrafluoroethylene (PTFE) composite structure, utilizing the high strength of the alloy and the low coefficient of friction of PTFE to compensate for minor gap leakage in the main sealing lip 2072. The wave-shaped elastic compensation component 2077 is made of Inconel 718 alloy, maintaining stable elastic deformation under high temperature even when under prolonged compression, continuously providing preload force to both lips and automatically compensating for thermal expansion and wear. The working principle of the rotary sealing structure of the present invention is as follows: the main sealing lip 2072 is located at the medium end, the power shaft 303 extends beyond the main sealing lip 2072, and the outer side of the axial retaining ring 2074 is the air end; the sealing seat 2071 and the main sealing lip 2072 form the main seal, which can isolate most of the medium. After a small amount of medium leaks, it enters the sealing cavity. The main sealing lip 2072 and the auxiliary sealing lip 2079 form the auxiliary seal, which further isolates the small amount of medium leaked from the main seal. Moreover, due to the continuous compensation effect of the elastic compensation device, it can continuously provide sufficient pre-tightening force under high temperature, high speed and heavy load conditions to ensure sealing performance.

[0031] Preferably, the sealing seat 2071 is further provided with an annular cooling chamber 20711. The annular cooling chamber 20711 is spaced apart in the corresponding area of ​​the outer periphery of the main sealing lip 2072 and the sealed cavity. The cooling chamber 20711 is connected to the cooling oil passage. By circulating and injecting cooling medium into the cooling chamber, the temperature of the sealing seat is reduced.

[0032] Furthermore, the high-temperature resistant oil can meet the requirements for use in high-temperature environments up to 400℃; preferably, the high-temperature resistant oil is Moruns I-PA organic heat transfer fluid, with a flash point of 110℃, an auto-ignition point of 620℃, a kinematic viscosity of 2.5mm² / s at 40℃, and a density (20℃) of 1056kg / m³, and can be used safely in a temperature range of 12-400℃.

[0033] The heat insulation transition plate 4 is made of ZC800 material, which can withstand high temperatures of 800℃ for a long time. It is suitable for extreme environments such as high-temperature machinery and molds. It has anti-deformation ability, and its high modulus characteristics ensure that it is not easily deformed during long-term use. It is also resistant to chemical corrosion, extending its service life. Its compressive strength reaches 500MPa, far exceeding that of ordinary heat insulation materials. The heat insulation transition plate 4 is set between the output shaft of the thrust shaft 102 and the thrust cylinder 101, and between the static pressure shaft 302 and the power shaft 303, to prevent the high temperature in the test chamber 202 from being conducted to the thrust cylinder 101 and the high-speed motor 301 through the thrust shaft 102 and the power shaft 303.

[0034] Furthermore, it also includes a control module, which comprises a temperature control unit, a pressure control unit, and a speed control unit. The high-temperature heating component and temperature sensor are electrically connected to the temperature control unit. The temperature control unit controls the activation of the high-temperature heating component to heat the high-temperature resistant oil and adjusts the power of the high-temperature heating component based on the temperature data monitored by the temperature sensor. The thrust cylinder is connected to a hydraulic station via a hydraulic pipeline. The hydraulic station and pressure sensor are electrically connected to the pressure control unit. The pressure control unit adjusts the output pressure of the thrust cylinder through the hydraulic station and adjusts the pressure of the thrust cylinder based on the pressure data monitored by the pressure sensor. The high-speed motor is electrically connected to the speed control unit. The speed control unit adjusts the speed of the high-speed motor based on the speed data monitored by the speed sensor.

[0035] A method for testing thrust bearing performance using the aforementioned high-temperature, heavy-load, high-speed performance testing system includes the following steps: S1. Test piece clamping and fixing: Install the bearing seat of the thrust bearing test piece into the first clamp, install the thrust ring into the second clamp, and tighten the nut with a wrench to ensure that the test piece does not move during the test.

[0036] S2. High-temperature oil injection: High-temperature resistant oil is injected into the test chamber through an automatic oil injection system; S3. Temperature control: The high-temperature heating component is activated to heat the high-temperature resistant oil in the test chamber. The high-temperature heating component is powered by 380V and has a power of 10KW. It can heat the temperature from room temperature to 400℃ and achieve a temperature control accuracy of ±0.5℃ through a constant temperature controller.

[0037] Specifically, the temperature value is first set according to the test requirements. Then, the temperature control unit activates the high-temperature heating component to heat the test environment. During the heating process, the temperature sensor inside the test chamber monitors the temperature of the test environment in real time and feeds the temperature signal back to the temperature control unit. Based on the set temperature value and the feedback temperature signal, the temperature control unit automatically adjusts the power of the high-temperature heating component, gradually raising the temperature of the test environment to the set value.

[0038] Once the ambient temperature reaches the set value, the temperature control unit enters the constant temperature control phase. By adjusting the power of the high-temperature heating element, it maintains the ambient temperature stable near the set value. During the test, the temperature control unit continuously monitors the ambient temperature and adjusts the power of the high-temperature heating element promptly based on temperature changes to ensure the ambient temperature meets the test requirements.

[0039] The high-temperature heating component has the following characteristics: its maximum heating temperature can reach 500°C. A heat insulation unit is filled between the outer side of the test chamber and the outer wall of the high-temperature chamber to prevent the outer shell of the high-temperature chamber from getting too hot.

[0040] S4. Pressure loading: The thrust cylinder is driven by a high-power hydraulic station to apply axial pressure to the thrust bearing test piece. The rated pressure of the high-power hydraulic station is 20MPa and the rated flow rate is 20L / min. The thrust cylinder can achieve a pressure output of 0-30T. The pressure control unit works with a proportional valve to achieve variable pressure.

[0041] Specifically, first, the axial load value is set according to the test requirements. Then, the pressure control unit activates the thrust cylinder to apply the axial load to the thrust bearing. During the loading process, the pressure sensor monitors the pressure of the thrust cylinder in real time and feeds the pressure signal back to the pressure control system. Based on the set pressure value and the feedback pressure signal, the pressure control unit automatically adjusts the pressure of the thrust cylinder so that the axial load gradually reaches the set value.

[0042] Once the axial load reaches the set value, the pressure control unit enters the constant load control phase, maintaining the axial load stable near the set value by adjusting the pressure of the thrust cylinder. During the test, the pressure control unit continuously monitors the pressure of the thrust cylinder and adjusts it promptly according to pressure changes to ensure the axial load meets the test requirements.

[0043] The hydraulic station is described as follows: the hydraulic fluid used in the hydraulic station meets the requirements of GB / T16750-2015 "Submersible Electric Pump Unit" standard, can work for a long time under ISO4406 pollution level 22 / 22 working oil source, and has a self-locking function after the oil source is lost.

[0044] S5. Speed ​​Adjustment: Start the high-speed motor and transmit power through the hydrostatic shaft and the thrust axial thrust bearing test piece. The high-speed motor meets the speed requirement of 10000r / min and the maximum speed can reach 12000r / min. The coupling transmits power of 45KW and the maximum speed can reach 12000r / min. The speed control accuracy reaches 0.1% FS through the adaptive controller.

[0045] First, the rotational speed is set according to the test requirements. Then, the speed control unit starts the motor, which transmits power to the thrust ring of the thrust bearing via the hydrostatic shaft and thrust shaft, causing the thrust ring to rotate. During rotation, the speed sensor monitors the rotational speed in real time and feeds the speed signal back to the speed control unit. Based on the set rotational speed and the feedback speed signal, the speed control unit automatically adjusts the motor speed so that the thrust bearing gradually reaches the set speed.

[0046] Once the thrust bearing reaches the set speed, the speed control unit enters the constant speed control phase, adjusting the motor speed to maintain the thrust bearing speed stable near the set value. During the test, the speed control unit continuously monitors the thrust bearing speed and adjusts the motor speed promptly based on speed changes to ensure the thrust bearing speed meets the test requirements.

[0047] The coupling is described as follows: it is a magnetic coupling, a non-contact structure, and its isolation cover is made of 316L stainless steel. The high-speed motor is equipped with a dynamic balancing corrector, which can correct the high-speed transmission components according to the dynamic balancing level G1.

[0048] S6. Real-time monitoring of multiple parameters: The signal acquisition unit collects key parameters during the test process. The temperature sensor monitors the test environment temperature, the thrust sensor collects axial pressure data, the vibration sensor monitors the vibration state of the test piece, the wear test sensor monitors the wear of the test piece, and the dynamic torque sensor detects the spindle torque.

[0049] The parameter measurement ranges are as follows: the vibration sensor has a measurement range of 0-10g and a linearity of 1%; the wear measurement accuracy of the wear testing system is ±10μm and the continuous stable working time is not less than 500h; the thrust sensor has a maximum frequency of 2KHz and a thrust measurement range of 0-30T; and the dynamic torque sensor has a range of 0-100N・m and a measurement accuracy of 0.1% FS.

[0050] S7. Standardized shutdown: After the test, first turn off the high-speed motor, then stop the operation of the thrust cylinder and reduce the pressure to normal pressure. Then turn off the high-temperature heating components. After the equipment temperature drops to normal temperature, recover the high-temperature resistant oil. Finally, disassemble the thrust bearing test piece.

[0051] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. A performance testing system for thrust bearings under high temperature, heavy load, and high speed conditions, characterized in that: It includes a heavy-load simulation section, a high-temperature simulation section, and a high-speed dynamic simulation section, with the heavy-load simulation section and the high-speed dynamic simulation section located on both sides of the high-temperature simulation section; The high-temperature simulation unit includes a high-temperature chamber, which contains a sealed test chamber. A high-temperature heating component is located at the bottom of the inner side of the test chamber, and a heat insulation layer is provided between the outer periphery of the test chamber and the outer shell of the high-temperature chamber. The test chamber is filled with high-temperature resistant oil to provide a high-temperature environment for the thrust bearing. The heavy-duty simulation unit includes a thrust cylinder and a thrust shaft. One end of the thrust shaft is connected to the output shaft of the thrust cylinder via a heat-insulating adapter plate, and the other end extends into the test chamber of the high-temperature chamber and is fixedly connected to a first clamp. The first clamp is used to install the bearing housing of the thrust bearing. The two ends of the thrust shaft are supported by a sliding bearing housing, and the thrust shaft is slidably sealed to the side wall of the high-temperature chamber. The thrust cylinder provides a loading force to the bearing housing through the thrust shaft. The high-speed dynamic simulation unit includes a high-speed motor, a static pressure shaft, and a power shaft. The output end of the high-speed motor is connected to one end of the static pressure shaft via a coupling, and the other end of the static pressure shaft is connected to the power shaft via a heat-insulating adapter plate. The other end of the power shaft extends into the test chamber of the high-temperature chamber and is fixedly connected to a second clamp. The second clamp is used to install the thrust ring of the thrust bearing. The two ends of the static pressure shaft are supported by a static pressure bearing seat, and the two ends of the power shaft are supported by a rotary bearing seat. The power shaft is rotatably sealed to the side wall of the high-temperature chamber. The high-speed motor drives the thrust ring to rotate through the static pressure shaft and the power shaft.

2. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 1, characterized in that: It also includes a signal acquisition unit, which comprises a sensor assembly including a thrust sensor, a dynamic torque sensor, a temperature sensor, a vibration sensor, and a speed sensor. The thrust sensor is located between the thrust cylinder and the thrust shaft, the dynamic torque sensor is located between the high-speed motor and the hydrostatic shaft, the temperature sensor is located inside the test chamber, and the vibration sensor is mounted on the hydrostatic bearing housing. The speed sensor is a built-in sensor in the motor. The sensor assembly also includes a wear test sensor, an oil condition sensor, and a vacuum sensor. The vacuum sensor is used to monitor the vacuum level inside the test chamber, the oil condition sensor is used to monitor the viscosity and gas content of the high-temperature resistant oil, and the wear test sensor is mounted on the bearing housing end face of the thrust bearing to monitor the wear condition of the thrust bearing. The signal acquisition unit also includes a high-frequency acquisition module and a data processing module. The high-frequency acquisition module is communicatively connected to each sensor and the data processing module, using a 16-channel acquisition frequency band, a sampling rate ≥500kS / s, a sampling range of ±10V, and a resolution of 12bit, for synchronously acquiring signals from multiple sensors. The data processing module has a built-in processing module that supports real-time curve display, data storage, trend analysis, anomaly warning, and remote data transmission.

3. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 1, characterized in that: A sliding sealing assembly is provided between the thrust shaft and the high-temperature chamber. The sliding sealing assembly has a through lubrication channel, and the thrust shaft is slidably connected in the lubrication channel. The sliding sealing assembly includes a CF sealing flange. The CF sealing flange has a stepped hole inside. The small hole of the stepped hole faces the inside of the test chamber for the thrust shaft to pass through. An elastic compensation ring is provided in the large hole of the stepped hole. A self-lubricating sealing ring is provided outside the elastic compensation ring. The self-lubricating sealing ring presses against the elastic compensation ring and is connected to the CF sealing flange by screws.

4. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 3, characterized in that: The self-lubricating sealing ring is made of Al2O+TiC self-lubricating ceramic matrix composite material; the elastic compensation ring is made of Inconel718 material.

5. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 1, characterized in that: A rotary seal assembly is provided between the power shaft and the high-temperature chamber. The rotary seal assembly includes a sealing seat, a main sealing lip, a rotating bushing, and an axial retaining ring. An installation hole is provided on the side wall of the high-temperature chamber, and the sealing seat is installed within the installation hole. A stepped through hole is provided in the center of the sealing seat for the power shaft to pass through. The power shaft is a stepped shaft. The main sealing lip, rotating bushing, and axial retaining ring are sequentially fitted tightly onto the power shaft from the inside to the outside. The inside and outside refer to the inside and outside of the high-temperature chamber, respectively. The axial retaining ring is equipped with a positioning device. The outer diameter of the main sealing lip is larger than the outer diameter of the rotating bushing. The outer walls of the main sealing lip and the rotating bushing respectively abut against the inner wall of the through hole in the sealing housing. The main sealing lip, the rotating bushing, and the through hole in the sealing housing enclose and form an installation cavity. The installation cavity is equipped with an elastic sealing compensation device. The elastic sealing compensation device includes a waveform elastic compensation base, a waveform elastic compensation component, a waveform elastic compensation component push ring, and an auxiliary sealing lip. The waveform elastic compensation base is cylindrical and located on the side of the installation cavity away from the main sealing lip. The bottom is locked to the sealing seat by fixing screws. The waveform elastic compensation component and the waveform elastic compensation component push ring are connected in sequence inside the cylinder. The outer diameter of the waveform elastic compensation component push ring is adapted to the inner diameter of the waveform elastic compensation base cylinder. An auxiliary sealing lip is installed on the end face of the waveform elastic compensation component push ring. The auxiliary sealing lip abuts against the main sealing lip. The outer diameter of the auxiliary sealing lip is smaller than the outer diameter of the main sealing lip. A sealed cavity is formed between the elastic sealing compensation device, the main sealing lip, and the sealing seat.

6. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 5, characterized in that: The main sealing lip is made of ceramic fiber reinforced graphite material, the auxiliary sealing lip is made of nickel-based alloy coated with polytetrafluoroethylene composite structure, and the waveform elastic compensation component is made of Inconel 718 alloy material.

7. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 5, characterized in that: The sealing seat is also provided with an annular cooling chamber, which is spaced at intervals around the main sealing lip and the corresponding area on the outer periphery of the sealed cavity. The cooling chamber is connected to the cooling oil passage.

8. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 1, characterized in that: The thrust cylinder has a rated output pressure of 0-30T and an ultimate pressure of 35T, and its pressure is controlled by a proportional valve. The high-speed motor has a power of 45KW, a rated speed of 10000r / min, and an ultimate speed of 12000r / min. It is equipped with a speed controller and a G1-level dynamic balance corrector. The coupling is a magnetic coupling that transmits 45KW of power and is compatible with an ultimate speed of 12000r / min, enabling non-contact power transmission.

9. The high-temperature, heavy-load, high-speed thrust bearing performance testing system according to claim 1, characterized in that: The high-temperature resistant oil is Moruns I-PA organic heat transfer fluid, and the heat insulation adapter plate is made of ZC800 material.

10. A method for testing the performance of a thrust bearing under high temperature, heavy load, and high speed, using the high temperature, heavy load, and high speed thrust bearing performance testing system according to any one of claims 1 to 9, characterized in that the steps include... include: S1. Test piece clamping and fixing: Install the bearing seat of the thrust bearing test piece into the first clamp, install the thrust ring into the second clamp, and tighten the nut with a wrench to ensure that the test piece does not move during the test. S2. High-temperature oil injection: High-temperature resistant oil is injected into the test chamber through an automatic oil injection system; S3. Temperature control: Activate the high-temperature heating component to heat the high-temperature resistant oil in the test chamber to 400℃; S4. Pressure loading: Apply 30T axial pressure to the bearing housing of the thrust bearing via the thrust cylinder; S5, Speed ​​Adjustment: Start the high-speed motor and transmit rotational power through the static pressure shaft and the thrust ring of the thrust axial thrust bearing. The speed is 10000r / min. S6. Real-time monitoring of multiple parameters: Key parameters during the test process are collected using the signal acquisition unit, including temperature, axial pressure, vibration status, wear condition, and spindle torque. S7. Standardized shutdown: After the test, first turn off the high-speed motor, then stop the operation of the thrust cylinder and reduce the pressure to normal pressure. Turn off the high-temperature heating components. After the equipment temperature drops to normal temperature, recover the high-temperature resistant oil and disassemble the thrust bearing test piece.

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