Energy-saving hydraulic control system and method for a tensioner and a tensioner

Abstract

Embodiments of the present application provide a kind of tensioner energy-saving hydraulic control system, method and tensioner, it is related to cable-laying ship and pipe-laying ship tensioner system field.Improve the existing system in accumulator and ballast cylinder rod cavity always, lead to rod return oil when rising must first release accumulator, after descending accumulator is empty and must be filled again, lead to accumulator repeated release energy storage, power consumption and energy waste problem.By controllable stop valve group and pilot control valve collaborative work, realize accumulator and rod cavity according to demand on-off.Non-constant tension condition, controller makes pilot control valve lose power, controllable stop valve group is cut off, accumulator and rod cavity are disconnected, high pressure oil is completely saved in accumulator;When lifting, rod return oil is directly returned to tank through direction control valve, without releasing accumulator.Constant tension condition, pilot control valve is powered on, controllable stop valve group is turned on, accumulator supplies oil to rod cavity, for constant tension control and compensate the trace leakage of system under this condition, without re-energizing.

Description

Technical Field

[0001] This invention relates to the field of tensioner systems for cable-laying vessels and pipe-laying vessels, and more specifically, to an energy-saving hydraulic control system, method, and tensioner for a tensioner. Background Technology

[0002] Tensioners are crucial equipment for submarine cable-laying and pipe-laying vessels. They apply a controllable and stable reverse tension to submarine cables, optical cables, or engineering pipelines to precisely control the angle and shape of the cable / pipeline entering the water. This prevents the cable / pipeline from sagring freely at the stern and forming an excessively large "catenback," ensuring the cable / pipeline contacts the seabed at a gentle, controllable angle. This avoids damage due to excessively small bending radii, protects the cable / pipeline structure, and counteracts the heave and sway caused by wind, waves, and currents. Without tensioners, every inch of hull movement directly pulls on the fragile cable / pipeline, leading to internal breakage or external damage. Tensioners maintain a constant laying tension, ensuring consistent laying quality regardless of changes in laying speed, water depth, or sea state. Tensioners guarantee the safe and high-quality laying of invaluable submarine cables / pipelines in complex marine environments, directly impacting the success or failure of major projects such as offshore wind power, cross-sea communications, and oil and gas pipeline construction.

[0003] The tensioner mainly consists of an upper ballast, a lower ballast, a base, a guide frame, and ballast cylinders. After the submarine cable / pipeline is introduced and passes through the tensioner, the clamping cylinder is activated. The clamping cylinder retracts, and the upper ballast moves downward, causing the tracks to clamp the submarine cable / pipeline. Finally, the traction mechanism is driven, rotating forward or backward to achieve bidirectional transmission of the submarine cable / pipeline. During the laying process, the system needs to maintain the tension of the submarine cable / pipeline within a preset range (Fmin≤F≤Fmax). When the hull is affected by wind and waves, the monitoring system collects tension data in real time and uses feedback to control and adjust the drive speed, thereby achieving constant tension control.

[0004] Currently, tensioner clamping systems on the market mainly rely on the hydraulic cylinder's rod chamber connected to an accumulator to control tension and maintain continuous pressure. Due to internal leakage in components such as the hydraulic cylinder and valves, the pressure continuously decreases during the pressure maintenance period. When the pressure drops below Fmin, the system continues to pressurize the rod chamber of the cylinder to restore it to the set tension. When the upper ballast needs to rise, the system first opens the hydraulically controlled check valve in the rod chamber when the control solenoid valve is energized, releasing the hydraulic oil in the accumulator before the cylinder extends and the upper ballast rises. Conversely, when descending, the cylinder retracts, and the upper ballast descends. At this time, the upper ballast must first descend to contact the submarine cable / pipeline before the accumulator is refilled with oil to achieve the required tension. This control method results in the accumulator continuously releasing and operating in the energy storage chamber during tensioner raising and lowering, leading to high power consumption and unnecessary power waste. Furthermore, the system pressure is unstable, and internal leakage causes the pressure to continuously drop and rise within the range of continuous oil replenishment (Fmin≤F≤Fmax), resulting in unstable tension. Summary of the Invention

[0005] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0006] The present invention aims to provide, for example, an energy-saving hydraulic control system, method, and tensioner for a tensioner, which can improve the problems in the existing system where the accumulator and the rod chamber of the ballast cylinder are always connected, resulting in the need to release the accumulator before the rod chamber returns oil during ascent, and to recharge the accumulator after descent because the accumulator is empty, leading to repeated energy release and storage, high power consumption, and energy waste.

[0007] The embodiments of the present invention can be implemented as follows: An embodiment of the present invention provides an energy-saving hydraulic control system for a tensioner. The tensioner includes an upper ballast. The control system includes an oil tank, a hydraulic power source, a ballast cylinder, a directional control valve, an accumulator, a controllable shut-off valve group, a pilot control valve, and a controller. The hydraulic power source is connected to the oil tank. The ballast cylinder has a rodless chamber and a rod chamber, and is used to drive the upper ballast to move up and down. The directional control valve is connected between the hydraulic power source, the oil tank, and the ballast cylinder, and is used to control the extension and retraction of the ballast cylinder, and to connect the return oil chamber to the oil tank when the ballast cylinder extends or retracts. The accumulator is connected to the hydraulic power source and is used to store energy. High-pressure oil; the first oil circuit of the controllable shut-off valve assembly is connected between the oil outlet of the accumulator and the rod chamber, and the controllable shut-off valve assembly is used to control the on / off connection between the accumulator and the rod chamber; the oil inlet of the pilot control valve is connected to the oil outlet of the accumulator, and the oil outlet of the pilot control valve is connected to the control end of the controllable shut-off valve assembly; the controller is electrically connected to the pilot control valve, and the controller is used to energize the pilot control valve under constant tension conditions to conduct the controllable shut-off valve assembly, so that the accumulator supplies oil to the rod chamber; the controller is used to de-energize the pilot control valve under non-constant tension conditions to cut off the controllable shut-off valve assembly, so that the accumulator is disconnected from the rod chamber.

[0008] In addition, the tensioner energy-saving hydraulic control system provided in the embodiments of the present invention may also have the following additional technical features: Optionally, the control system further includes an electronically controlled pressure regulating valve and a clamping pressure sensor; the oil inlet of the electronically controlled pressure regulating valve is connected to the oil outlet of the accumulator, and the oil outlet of the electronically controlled pressure regulating valve is connected to the rod chamber via the first oil circuit of the controllable shut-off valve assembly; the clamping pressure sensor is disposed on the oil circuit of the rod chamber, and the clamping pressure sensor is used to detect the clamping force; the controller is also electrically connected to the electronically controlled pressure regulating valve and the clamping pressure sensor, and the controller is used to continuously adjust the output pressure of the electronically controlled pressure regulating valve according to the feedback signal of the clamping pressure sensor, so that the pressure of the rod chamber is constant at a first preset value.

[0009] Optionally, the control system further includes a first sequence valve; the first sequence valve is connected in series in the return oil line between the rodless chamber and the oil tank, and the first sequence valve is used to limit the descent speed when the ballast cylinder retracts, and to prevent the upper ballast from sliding down due to its own weight when the ballast cylinder stops.

[0010] Optionally, the control system further includes a displacement sensor; the displacement sensor is connected to the ballast cylinder and is used to detect the piston position of the ballast cylinder; the controller is also electrically connected to the displacement sensor and is used to control the directional control valve to switch to the neutral position to lock the ballast cylinder when the displacement sensor detects that the upper ballast is close to the submarine cable or pipeline.

[0011] Optionally, the control system further includes an accumulator pressure sensor; the accumulator pressure sensor is installed on the oil outlet line of the accumulator, and the accumulator pressure sensor is used to detect the accumulator pressure; the controller is also used to start the hydraulic power source to charge the accumulator when the detected value of the accumulator pressure sensor is lower than a second preset value, and to stop the hydraulic power source when the detected value of the accumulator pressure sensor is higher than the second preset value.

[0012] Optionally, the controllable shut-off valve assembly includes a first hydraulically controlled check valve, a second hydraulically controlled check valve, and a third hydraulically controlled check valve; the first hydraulically controlled check valve and the second hydraulically controlled check valve are connected in series in the first oil circuit, and the third hydraulically controlled check valve is connected in series in the second oil circuit between the rodless chamber and the oil tank; the pilot ports of the first hydraulically controlled check valve, the second hydraulically controlled check valve, and the third hydraulically controlled check valve are connected to form the control end of the controllable shut-off valve assembly.

[0013] Optionally, the directional control valve is a three-position four-way solenoid directional valve. The directional control valve has an oil inlet, an oil return port, a first working oil port, and a second working oil port. The oil inlet is connected to the hydraulic power source, the oil return port is connected to the oil tank, the first working oil port is connected to the rodless chamber, and the second working oil port is connected to the rod chamber.

[0014] Optionally, a first hydraulically controlled check valve and a second hydraulically controlled check valve on the cylinder side are provided between the directional control valve and the ballast cylinder; the first port of the first hydraulically controlled check valve on the cylinder side is connected to the second working port of the directional control valve, and the second port of the first hydraulically controlled check valve on the cylinder side is connected to the rod chamber; the first port of the second hydraulically controlled check valve on the cylinder side is connected to the first working port of the directional control valve, and the second port of the second hydraulically controlled check valve on the cylinder side is connected to the rodless chamber; the pilot port of the first hydraulically controlled check valve on the cylinder side is connected to the oil circuit where the first port of the second hydraulically controlled check valve on the cylinder side is located; the pilot port of the second hydraulically controlled check valve on the cylinder side is connected to the oil circuit where the first port of the first hydraulically controlled check valve on the cylinder side is located. When the ballast cylinder retracts, the pressure oil output from the second working port of the directional control valve flows through the first port of the first hydraulically controlled check valve on the cylinder side to the second port and then enters the rod chamber. At the same time, this pressure oil opens the second hydraulically controlled check valve on the cylinder side, allowing the pressure oil in the rodless chamber to flow through the second port of the second hydraulically controlled check valve on the cylinder side to the first port and then back to the first working port of the directional control valve. After the directional control valve switches to the neutral position, the first port of the first hydraulically controlled check valve on the cylinder side loses pressure, and the pilot port of the second hydraulically controlled check valve on the cylinder side loses pressure and closes, thereby locking the ballast cylinder.

[0015] Optionally, the pilot control valve is a two-position four-way solenoid directional valve. The P port of the two-position four-way solenoid directional valve is connected to the oil outlet of the accumulator, the B port of the two-position four-way solenoid directional valve is connected to the control terminal of the controllable shut-off valve group, and the T port of the two-position four-way solenoid directional valve is connected to the oil tank. When the two-position four-way solenoid directional valve is energized, the P port and the B port are connected. When it is de-energized, the B port and the T port are connected to control the on / off state of the controllable shut-off valve group.

[0016] Optionally, the electrically controlled pressure regulating valve is a proportional pressure reducing valve.

[0017] This invention also provides an energy-saving hydraulic control method for a tensioner, implemented using an energy-saving hydraulic control system for the tensioner, comprising: After the accumulator is pressurized to the set value, the pilot control valve is de-energized, causing the controllable shut-off valve group to cut off, the accumulator is disconnected from the ballast cylinder and the high pressure is maintained; Controlling the directional control valve causes the ballast cylinder to retract, and the upper ballast device to descend; controlling the directional control valve to switch to the neutral position locks the ballast cylinder; The pilot control valve is energized to open the controllable shut-off valve group, and the accumulator supplies oil to the rod chamber. The pilot control valve is de-energized, causing the controllable shut-off valve group to shut off; the directional control valve is controlled to extend the ballast cylinder, causing the upper ballast to rise and reset.

[0018] Optionally, the step of controlling the pilot control valve to be energized, thereby opening the controllable shut-off valve group, and the accumulator to supply oil to the rod chamber includes: adjusting the output pressure of the electronically controlled pressure regulating valve according to the preset tension force, and performing closed-loop adjustment by real-time detection of the rod chamber pressure of the ballast cylinder to keep the clamping force constant.

[0019] This invention also provides a tensioner, including a base, a guide frame, an upper ballast, a lower ballast, and an energy-saving hydraulic control system for the tensioner. The lower ballast is fixedly installed on the base, and the guide frame is installed on the base and used to guide submarine cables or pipelines. The upper ballast is movably disposed above the lower ballast and can be raised and lowered relative to the lower ballast. The piston rod of the ballast cylinder of the control system is connected to the upper ballast to drive the upper ballast to rise and fall.

[0020] The beneficial effects of the energy-saving hydraulic control system, method, and tensioner of the tensioner according to embodiments of the present invention include, for example: The tensioner's energy-saving hydraulic control system, through the coordinated operation of a controllable shut-off valve assembly and a pilot control valve, enables on-demand switching between the accumulator and the rod chamber. In non-constant tension conditions (standby, lifting), the controller de-energizes the pilot control valve, shuts off the controllable shut-off valve assembly, disconnects the accumulator from the rod chamber, and the high-pressure oil is completely stored within the accumulator. During lifting, the oil returning from the rod chamber returns directly to the oil tank via the directional control valve, eliminating the need to release the accumulator. In constant tension conditions, the pilot control valve is energized, the controllable shut-off valve assembly is activated, and the accumulator supplies oil to the rod chamber, performing constant tension control and compensating for minor system leakage under these conditions, without requiring recharging. This eliminates the energy waste of releasing oil before lifting and recharging after lifting in traditional solutions, significantly reducing power consumption and achieving energy-saving control.

[0021] The tensioner energy-saving hydraulic control method is implemented using the aforementioned tensioner energy-saving hydraulic control system. The tensioner, including the aforementioned tensioner energy-saving hydraulic control system, can improve the existing system's problem of the accumulator and the rod chamber of the ballast cylinder being constantly connected, which causes the rod chamber to return oil during ascent, requiring the accumulator to be released first, and then recharged after descent because the accumulator is empty, resulting in repeated energy release and storage by the accumulator, high power consumption, and energy waste. Attached Figure Description

[0022] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals.

[0023] Figure 1 This is a schematic diagram of the tensioner provided in an embodiment of the present invention; Figure 2 A structural block diagram of the tensioner energy-saving hydraulic control system provided in an embodiment of the present invention; Figure 3 for Figure 1 The diagram shows a partial enlarged view of the directional control valve and pilot control valve sections of the tensioner energy-saving hydraulic control system. Figure 4 for Figure 1The diagram shows a partial enlarged view of the ballast cylinder and cylinder valve assembly of the tensioner energy-saving hydraulic control system. Figure 5 This is a schematic diagram of the tensioner energy-saving hydraulic control system provided in an embodiment of the present invention during the accumulator charging process; Figure 6 A schematic diagram of the tensioner energy-saving hydraulic control system provided in this embodiment of the invention, showing the state of oil inlet in the rod chamber and oil return in the rodless chamber; Figure 7 A schematic diagram of the tensioner energy-saving hydraulic control system provided in this embodiment of the invention during constant tension. Figure 8 This is a schematic diagram of the tensioner energy-saving hydraulic control system provided in an embodiment of the present invention, showing the state of oil inlet to the rodless chamber and oil return to the rod chamber.

[0024] Icons: Tensioner 100; Tensioner Energy-Saving Hydraulic Control System 110; Base 1; Lower Ballast 2; Upper Ballast 3; Guide Frame 4; Ballast Cylinder 5; Rod Chamber 51; Rodless Chamber 52; Oil Tank 6; Motor Pump Set 7; Main Oil Circuit Check Valve 8; System Overflow Valve 9; Directional Control Valve 10; Three-Position Four-Way Solenoid Directional Valve 101; Pilot Control Valve 11; Two-Position Four-Way Solenoid Directional Valve 111; Accumulator 12; Electrically Controlled Pressure Regulating Valve 13; Proportional Pressure Reducing Valve 13 1; First check valve 14; Second check valve 15; First hydraulically controlled check valve 16; Second hydraulically controlled check valve 17; Third hydraulically controlled check valve 18; First sequence valve 19; Second sequence valve 20; Accumulator pressure sensor 21; Displacement sensor 27; Controllable shut-off valve assembly 200; Cylinder valve assembly 220; First hydraulically controlled check valve on cylinder side 22; Second hydraulically controlled check valve on cylinder side 23; First safety valve 24; Second safety valve 25; Clamping pressure sensor 26. Detailed Implementation

[0025] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0026] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," "outer," or "vertical" appear, the orientation or positional relationship indicated is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed when in use, and does 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, and therefore should not be construed as a limitation of this invention.

[0027] At the same time, it should be noted that the terms "first" and "second" are used only for distinguishing descriptions and should not be interpreted as indicating or implying relative importance.

[0028] In the description of this invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] The tensioner energy-saving hydraulic control system provided in this invention is applied to the tensioner equipment of submarine cable-laying vessels and pipe-laying vessels. It is mainly used to apply stable reverse tension to submarine cables, optical cables, and engineering pipelines, control the water entry angle and shape of the pipeline, reduce the catenary curvature, avoid pipeline damage due to excessively small bending radius, and at the same time counteract the heave and displacement of the hull caused by wind, waves, and ocean currents.

[0030] In existing tensioner hydraulic systems, the accumulator and the rod chamber of the ballast cylinder are always connected. This necessitates the complete release of high-pressure oil from the accumulator before ascent and its recharging after descent, resulting in significant energy consumption due to repeated charging and discharging. Furthermore, the use of on / off pressure replenishment causes frequent fluctuations in tension within a preset range, making it impossible to maintain a constant tension. This not only wastes energy but also threatens the accuracy and safety of submarine cable / pipeline laying. This invention addresses this issue by implementing a controllable shut-off valve assembly and its pilot control valve. This allows for on-demand switching between the accumulator and the rod chamber, reliably disconnecting and maintaining pressure under non-constant tension conditions, and precisely supplying oil under constant tension conditions, eliminating energy waste during ascent and descent. Further, by combining an electronically controlled pressure regulating valve with a pressure sensor for closed-loop regulation, the tension remains consistently at the set value. With simple and reliable hydraulic logic, this invention simultaneously solves the two major technical challenges of high energy consumption and unstable tension, significantly improving laying quality.

[0031] The following is combined Figures 1 to 8 The tensioner energy-saving hydraulic control system 110 provided in this embodiment will be described in detail.

[0032] Please refer to Figure 2 , Figure 3 , Figure 4 and Figure 7An embodiment of the present invention provides an energy-saving hydraulic control system 110 for a tensioner. The tensioner 100 includes an upper ballast 3. The control system includes an oil tank 6, a hydraulic power source, a ballast cylinder 5, a directional control valve 10, an accumulator 12, a controllable shut-off valve group 200, a pilot control valve 11, and a controller. The hydraulic power source is connected to the oil tank 6. The ballast cylinder 5 has a rodless chamber 52 and a rod chamber 51, and is used to drive the upper ballast 3 to rise and fall. The directional control valve 10 is connected between the hydraulic power source, the oil tank 6, and the ballast cylinder 5. The directional control valve 10 is used to control the extension and retraction of the ballast cylinder 5, and to connect the return oil chamber to the oil tank 6 when the ballast cylinder 5 extends and retracts. The accumulator 12 is connected to the hydraulic power source and is used for... The system stores high-pressure oil. The first oil circuit of the controllable shut-off valve assembly 200 is connected between the oil outlet of the accumulator 12 and the rod chamber 51. The controllable shut-off valve assembly 200 is used to control the connection and disconnection between the accumulator 12 and the rod chamber 51. The oil inlet of the pilot control valve 11 is connected to the oil outlet of the accumulator 12, and the oil outlet of the pilot control valve 11 is connected to the control terminal of the controllable shut-off valve assembly 200. The controller is electrically connected to the pilot control valve 11. The controller is used to energize the pilot control valve 11 under constant tension conditions to conduct the controllable shut-off valve assembly 200, so that the accumulator 12 supplies oil to the rod chamber 51. The controller is used to de-energize the pilot control valve 11 under non-constant tension conditions to cut off the controllable shut-off valve assembly 200, so that the accumulator 12 is disconnected from the rod chamber 51.

[0033] The tensioner energy-saving hydraulic control system 110 is equipped with a liftable upper ballast 3, which works in conjunction with the fixed lower ballast 2 to clamp and release submarine cables or pipelines. At least one set of ballast cylinders 5 is provided, and each ballast cylinder 5 is connected to the directional control valve 10 and the pilot control valve 11 through a cylinder valve group 220.

[0034] Specifically, the oil tank 6 is used to store hydraulic oil. The hydraulic power source includes a motor pump unit 7, which includes a hydraulic power pump and a drive motor. It draws hydraulic oil from the oil tank 6 and converts it into high-pressure hydraulic power to provide power input. The ballast cylinder 5 is fixedly mounted in the guide frame 4 area of ​​the tensioner 100. The ballast cylinder 5 is internally isolated to form independent rod chamber 51 and rodless chamber 52. The piston rod end of the ballast cylinder 5 is rigidly fixedly connected to the upper ballast 3. The extension and retraction of the piston rod drives the upper ballast 3 to move vertically up and down relative to the lower ballast 2 along the guide frame 4, completing the switching of the clamping and releasing action of the cable.

[0035] Directional control valve 10 is connected to the main drive oil circuit between the motor pump unit 7, the oil tank 6, and the ballast cylinder 5. It is used to control the extension and retraction direction and start / stop status of the ballast cylinder 5. During the extension and retraction of the ballast cylinder 5, directional control valve 10 can connect the return oil chamber of the cylinder and the return oil passage of the oil tank 6 according to the action requirements, ensuring smooth and stable extension and retraction of the cylinder. Accumulator 12 is connected to the oil outlet of the motor pump unit 7. It can store high-pressure hydraulic oil in the system standby and constant tension pressure holding conditions, and replace the motor pump unit 7 to continuously supply oil, serving as a stable oil source for constant tension conditions.

[0036] The controllable shut-off valve assembly 200 is used to precisely control the on / off state of the accumulator 12's stabilizing oil circuit, enabling the establishment and rapid disconnection of cable clamping tension. The pilot control valve 11 is equipped with an independent pilot control oil circuit. The inlet of the pilot control valve 11 is connected to the outlet of the accumulator 12, using the stabilizing oil output from the accumulator 12 as the pilot control oil. The outlet of the pilot control valve 11 is connected to the control terminal of the controllable shut-off valve assembly 200. By switching the pilot pressure oil on and off, the overall opening and closing state of the controllable shut-off valve assembly 200 is controlled.

[0037] The controller is electrically connected to the pilot control valve 11 to achieve inter-condition control. When the equipment enters the constant tension cable laying operation, the controller outputs an electrical control signal to energize the pilot control valve 11, opening the control oil circuit of the controllable shut-off valve group 200, so that the controllable shut-off valve group 200 is fully opened, and the high-pressure hydraulic oil stored in the accumulator 12 is stably delivered to the rod chamber 51 of the ballast cylinder 5, establishing a constant cable clamping tension. When the equipment is in non-constant tension operation such as cylinder lifting, machine standby, or operation reset, the controller controls the pilot control valve 11 to de-energize and reset, cutting off the pilot control oil circuit of the controllable shut-off valve group 200, so that the controllable shut-off valve group 200 is reliably locked and closed, completely isolating the tension oil circuit between the accumulator 12 and the rod chamber 51.

[0038] The main drive action of lifting the hydraulic cylinder and the constant tension holding action of clamping the cable are controlled independently through dual oil circuits, realizing the working condition isolation of the accumulator 12. This means that the accumulator 12 does not need to drain oil to the oil tank 6 during the lifting of the hydraulic cylinder and the reset of the equipment. It only leaks a small amount of oil through its own pressure compensation system, which solves the problems of energy waste and oil circuit pressure fluctuation caused by repeated full filling and draining of the accumulator 12 in the traditional tensioner 100.

[0039] Reference Figure 2 and Figure 3In this embodiment, the control system further includes an electrically controlled pressure regulating valve 13 and a clamping pressure sensor 26; the oil inlet of the electrically controlled pressure regulating valve 13 is connected to the oil outlet of the accumulator 12, and the oil outlet of the electrically controlled pressure regulating valve 13 is connected to the rod chamber 51 via the first oil circuit of the controllable shut-off valve group 200; the clamping pressure sensor 26 is disposed on the oil circuit of the rod chamber 51, and the clamping pressure sensor 26 is used to detect the clamping force; the controller is also electrically connected to the electrically controlled pressure regulating valve 13 and the clamping pressure sensor 26, and the controller is used to continuously adjust the output pressure of the electrically controlled pressure regulating valve 13 according to the feedback signal of the clamping pressure sensor 26, so that the pressure of the rod chamber 51 is constant at a first preset value.

[0040] The clamping pressure sensor 26 is fixedly installed on the working oil circuit of the rod chamber 51 of the ballast cylinder 5. It can collect the hydraulic pressure value of the rod chamber 51 in real time. This pressure value corresponds to the actual clamping force of the upper ballast 3 on the submarine cable and pipeline, realizing real-time and dynamic monitoring of the clamping force. The controller is electrically connected to the proportional pressure reducing valve 131 and the clamping pressure sensor 26.

[0041] During actual construction operations, the controller has pre-stored constant tension target values ​​adapted to different construction scenarios, such as a first preset value. The clamping pressure sensor 26 collects the actual pressure of the oil circuit in real time and feeds it back to the controller. The controller adjusts the valve opening of the proportional pressure reducing valve 131 according to the difference between the actual pressure and the preset target pressure, and dynamically controls the output pressure of the oil circuit. In response to tension deviation caused by factors such as minor internal leakage of hydraulic components, fluctuations in sea conditions and wind, and changes in cable and pipe laying speed during operation, the closed-loop control system can compensate for pressure deviation in real time, and stably lock the working pressure of the rod chamber 51 at the first preset value, ensuring that the clamping force remains constant.

[0042] Compared to the traditional tensioner 100, which relies solely on the accumulator 12 for passive pressure maintenance, resulting in continuous pressure drops and repeated pressure replenishment leading to significant tension fluctuations, this device achieves continuous and stable adjustment of cable clamping tension, effectively preventing pipeline deformation and damage caused by sudden tension changes, and improving the laying quality of submarine pipelines and cables.

[0043] Reference Figure 1 and Figure 3 In this embodiment, the control system further includes a first sequence valve 19; the first sequence valve 19 is connected in series in the return oil line between the rodless chamber 52 and the oil tank 6. The first sequence valve 19 is used to limit the descent speed when the ballast cylinder 5 retracts, and to prevent the upper ballast 3 from sliding down due to its own weight when the ballast cylinder 5 stops.

[0044] When the equipment performs the cable clamping preparation action, the directional control valve 10 reverses the flow path, and high-pressure hydraulic oil enters the rod chamber 51 of the ballast cylinder 5, pushing the ballast cylinder 5 to retract and causing the upper ballast 3 to descend. At this time, the rodless chamber 52 generates return oil, which must be throttled and limited by the first sequence valve 19 before flowing back to the oil tank 6. The first sequence valve 19 can effectively limit the return oil flow of the rodless chamber 52, control the downward speed of the cylinder, and prevent the ballast cylinder 5 and the upper ballast 3 from overspeeding and impacting the cable due to their own weight.

[0045] When the hydraulic cylinder descends to its lower position and the equipment stops moving and enters a hovering standby state, the return oil circuit is closed. The first sequence valve 19 can also block the return oil leakage channel of the rodless chamber 52, forming a mechanical self-locking structure. This can effectively resist external interference such as hull vibration and wave disturbance, prevent the upper ballast 3 from spontaneously sliding down, ensure the structural stability of the equipment in the hovering state, and prevent construction risks such as cable squeezing, misalignment, and damage.

[0046] Reference Figure 1 and Figure 6 In this embodiment, the control system also includes a displacement sensor 27; the displacement sensor 27 is connected to the ballast cylinder 5 and is used to detect the piston position of the ballast cylinder 5; the controller is also electrically connected to the displacement sensor 27 and is used to control the directional control valve 10 to switch to the neutral position to lock the ballast cylinder 5 when the displacement sensor 27 detects that the upper ballast 3 is close to the submarine cable or pipeline.

[0047] During the cable-laying preparation phase, the controller controls the directional control valve 10 to switch, opening the oil circuit and driving the upper ballast 3 to descend smoothly and at a constant speed. The displacement sensor 27 collects the descent position information of the upper ballast 3 in real time throughout the entire process and simultaneously feeds it back to the controller. When the upper ballast 3 reaches the preset hovering position above the submarine cable or pipeline, the controller immediately outputs a control signal, controls the directional control valve 10 to switch to the neutral position, cuts off the pressure oil supply to the main drive oil circuit, and simultaneously locks the extension and retraction of the ballast cylinder 5, so that the upper ballast 3 is precisely hovered above the cable, forming a non-contact pre-clamping standby state.

[0048] In this embodiment, by controlling the upper ballast 3 to slowly descend, hover, and flexibly pressurize in stages, the mechanical impact caused by the upper ballast 3 directly hitting the cable is eliminated.

[0049] Reference Figure 2 , Figure 3 and Figure 5In this embodiment, the control system further includes an accumulator pressure sensor 21; the accumulator pressure sensor 21 is installed on the oil outlet of the accumulator 12 and is used to detect the pressure of the accumulator 12; the controller is also used to start the hydraulic power source to charge the accumulator 12 with oil when the detected value of the accumulator pressure sensor 21 is lower than a second preset value, and to stop the hydraulic power source when the detected value of the accumulator pressure sensor 21 is higher than the second preset value.

[0050] The accumulator pressure sensor 21 is electrically connected to the controller. The controller has preset high-pressure and low-pressure thresholds for the accumulator 12, which are adapted to the system operating conditions, i.e., the second preset value range. During system standby and constant tension operation, the accumulator 12 always maintains a high-pressure storage state and does not release oil or pressure to the oil tank 6. Only under long-term pressure holding conditions, it relies on its own stored pressure to compensate for the pressure drop caused by the slight internal leakage of hydraulic components, and autonomously maintains tension stability without the need for continuous operation of the motor pump unit 7.

[0051] When the accumulator pressure sensor 21 detects that the internal pressure of the accumulator 12 is lower than the preset low-pressure threshold, the controller automatically starts the motor pump group 7 to replenish oil and pressurize the accumulator 12; when the pressure rises back to the preset high-pressure threshold, the controller immediately shuts down the motor pump group 7, and the pressurization operation ends. This pressurization mode allows the motor pump group 7 to operate without continuous no-load, only starting to replenish pressure briefly as needed, achieving efficient, energy-saving, and stable pressure management of the accumulator 12.

[0052] Reference Figure 2 and Figure 7 In this embodiment, the controllable shut-off valve assembly 200 includes a first hydraulically controlled check valve 16, a second hydraulically controlled check valve 17, and a third hydraulically controlled check valve 18. The first hydraulically controlled check valve 16 and the second hydraulically controlled check valve 17 are connected in series in the first oil circuit, and the third hydraulically controlled check valve 18 is connected in series in the second oil circuit between the rodless chamber 52 and the oil tank 6. The pilot ports of the first hydraulically controlled check valve 16, the second hydraulically controlled check valve 17, and the third hydraulically controlled check valve 18 are connected to form the control end of the controllable shut-off valve assembly 200.

[0053] The first hydraulic check valve 16 and the second hydraulic check valve 17 are connected in series in the first oil circuit from the accumulator 12 to the rod chamber 51 of the ballast cylinder 5, forming a dual-valve redundant sealing structure. This effectively improves the sealing performance of the tension oil circuit under pressure holding conditions, minimizes oil circuit pressure leakage, and ensures the stability of constant tension control. The third hydraulic check valve 18 is connected in series in the second oil circuit between the rodless chamber 52 of the ballast cylinder 5 and the oil tank 6. It is used to lock the return oil passage of the rodless chamber 52, assist in realizing the position locking of the ballast cylinder 5, and improve the overall hovering stability.

[0054] The pilot control ports of the first hydraulic check valve 16, the second hydraulic check valve 17, and the third hydraulic check valve 18 are interconnected, converging to form the common control terminal of the controllable shut-off valve group 200. This common control terminal is connected to the oil outlet of the pilot control valve 11. By uniformly outputting or unloading pilot pressure oil through the pilot control valve 11, the three hydraulic check valves can be simultaneously controlled to open or close as a whole, preventing problems such as oil circuit pressure fluctuations and unstable operating condition switching caused by the lag in the action of a single valve.

[0055] Reference Figure 3 , Figure 6 and Figure 8 In this embodiment, the directional control valve 10 is a three-position four-way solenoid directional valve 101. The directional control valve 10 has an oil inlet, an oil return port, a first working oil port, and a second working oil port. The oil inlet is connected to the hydraulic power source, the oil return port is connected to the oil tank 6, the first working oil port is connected to the rodless chamber 52, and the second working oil port is connected to the rod chamber 51.

[0056] The oil inlet of the three-position four-way solenoid directional valve 101 is connected to the oil outlet of the motor pump group 7 for connecting the high-pressure oil of the system; the oil return port is connected to the oil tank 6 for realizing oil return recovery; the first working oil port is connected to the rodless chamber 52 of the ballast cylinder 5, and the second working oil port is connected to the rod chamber 51 of the ballast cylinder 5.

[0057] Reference Figure 3 and Figure 4 In this embodiment, a first hydraulically controlled check valve 22 and a second hydraulically controlled check valve 23 on the cylinder side are provided between the directional control valve 10 and the ballast cylinder 5. The first port of the first hydraulically controlled check valve 22 on the cylinder side is connected to the second working port of the directional control valve 10, and the second port of the first hydraulically controlled check valve 22 on the cylinder side is connected to the rod chamber 51. The first port of the second hydraulically controlled check valve 23 on the cylinder side is connected to the first working port of the directional control valve 10, and the second port of the second hydraulically controlled check valve 23 on the cylinder side is connected to the rodless chamber 52. The pilot port of the first hydraulically controlled check valve 22 on the cylinder side is connected to the oil circuit where the first port of the second hydraulically controlled check valve 23 on the cylinder side is located. When the ballast cylinder 5 retracts, the pressure oil output from the second working port of the directional control valve 10 flows from the first port of the first hydraulic check valve 22 on the cylinder side to the second port and then enters the rod chamber 51. At the same time, the pressure oil opens the second hydraulic check valve 23 on the cylinder side, causing the pressure oil in the rodless chamber 52 to flow from the second port of the second hydraulic check valve 23 on the cylinder side to the first port and then back to the first working port of the directional control valve 10. After the directional control valve 10 switches to the neutral position, the first port of the first hydraulic check valve 22 on the cylinder side loses pressure, and the pilot port of the second hydraulic check valve 23 on the cylinder side loses pressure and closes, thereby locking the ballast cylinder 5.

[0058] After the high-pressure hydraulic oil reaches the cylinder valve assembly 220, it enters the rod chamber 51 of the cylinder through port 1 and port 2 of the first hydraulically controlled check valve 22 on the cylinder side. At the same time, the oil circuit at port B is diverted to port 3 of the second hydraulically controlled check valve 23 on the cylinder side, which is the pilot port. When the pressure is sufficient to open the second hydraulically controlled check valve 23 on the cylinder side, the pressure oil in the rodless chamber 52 of the cylinder flows back to port 1 through port 2 of the second hydraulically controlled check valve 23 on the cylinder side, and returns to the three-position four-way solenoid directional valve 101 through the external pipeline. Then, it returns to the oil tank 6 through port A and port T of the three-position four-way solenoid directional valve 101, thereby realizing the retraction of the cylinder. When the displacement sensor 27 detects that the upper ballast 3 is close to the cable / pipe during the retraction process, the S1 of the three-position four-way solenoid directional valve 101 is de-energized, the oil inlet pressure of the rod chamber 51 disappears, the pilot port of the second hydraulic control check valve 23 on the cylinder side loses pressure and closes, the oil return of the rodless chamber 52 is cut off, and the cylinder stops retracting and hovers.

[0059] When extension is required, S2 of the three-position four-way solenoid directional valve 101 is energized, and high-pressure oil reaches the cylinder valve group 220 through port A. It then enters the rodless chamber 52 through port 1 and port 2 of the second hydraulically controlled check valve 23 on the cylinder side. Simultaneously, this pressure oil branch connects to the pilot port of the first hydraulically controlled check valve 22 on the cylinder side, opening the first hydraulically controlled check valve 22. This allows the hydraulic oil in the rod chamber 51 to flow back to port 1 through port 2 of the first hydraulically controlled check valve 22 on the cylinder side. The oil then returns to the oil tank 6 through port B of the three-position four-way solenoid directional valve 101, extending the ballast cylinder 5. This cross-pilot structure ensures that the ballast cylinder 5 can be reliably locked when the three-position four-way solenoid directional valve 101 is stopped in any neutral position, preventing the upper ballast 3 from sliding down due to its own weight or moving unexpectedly.

[0060] In this embodiment, the three-position four-way solenoid directional valve 101 is in the Y-type neutral position. In the neutral position, the oil inlet is closed, and the first working oil port and the second working oil port are connected to the oil tank. The ballast cylinder 5 is suspended through the first hydraulic control check valve 22 on the cylinder side and the second hydraulic control check valve 23 on the cylinder side.

[0061] In other embodiments, the three-position four-way solenoid directional valve 101 can also employ a neutral-position closing function. When the valve core is in the neutral position, all four oil ports are closed, completely cutting off the connection between the pump source, the two chambers of the cylinder, and the return oil passage, thereby achieving mechanical rigid locking and positioning of the ballast cylinder 5. When the electromagnet on one side of the three-position four-way solenoid directional valve 101 is energized, the corresponding working oil circuit is opened, enabling the extension and retraction of the ballast cylinder 5 and driving the upper ballast 3 to rise and fall. When the electromagnet is de-energized and the valve core returns to the neutral position, all oil circuits are immediately locked, and the upper ballast 3 is suspended in conjunction with the position feedback signal from the displacement sensor 27, providing a stable mechanical position basis for subsequent flexible pressurization and constant tension pressure holding operations.

[0062] Reference Figure 3 and Figure 7In this embodiment, the pilot control valve 11 is a two-position four-way solenoid directional valve 111. The P port of the two-position four-way solenoid directional valve 111 is connected to the oil outlet of the accumulator 12, the B port of the two-position four-way solenoid directional valve 111 is connected to the control terminal of the controllable shut-off valve group 200, and the T port of the two-position four-way solenoid directional valve 111 is connected to the oil tank 6. When the two-position four-way solenoid directional valve 111 is energized, the P port and the B port are connected. When it is de-energized, the B port and the T port are connected to control the on / off state of the controllable shut-off valve group 200.

[0063] The P port of the two-position four-way solenoid directional valve 111 is connected to the oil outlet of the accumulator 12, and the stabilizing oil of the accumulator 12 is used as the pilot control oil; the B port is connected to the common control terminal of the controllable shut-off valve group 200, and is used to output or unload the pilot pressure oil; the T port is connected to the oil tank 6, and is used to realize the pilot control oil pressure relief and return.

[0064] When the two-position four-way solenoid directional valve 111 is energized, the valve position is switched, and the P port and B port are connected. The stabilizing pilot oil output by the accumulator 12 enters the control terminal of the controllable shut-off valve group 200, driving each hydraulic check valve to open synchronously. The tension control oil circuit of the accumulator 12 is fully connected. The feedback signal of the clamping pressure sensor 26 continuously adjusts the output pressure of the electrically controlled pressure regulating valve 13, and the equipment enters the constant tension clamping operation condition. When the two-position four-way solenoid directional valve 111 is de-energized and reset, the B port and T port are connected. The pilot pressure oil at the control terminal of the controllable shut-off valve group 200 is quickly depressurized and flows back to the oil tank 6. Each hydraulic check valve is reliably closed under the action of spring reset. The tension oil circuit is completely cut off, and the accumulator 12 is completely isolated from the ballast cylinder 5 chamber, realizing the effect of pressure maintenance without oil leakage of the accumulator 12.

[0065] Reference Figure 3 and Figure 7 In this embodiment, the electrically controlled pressure regulating valve 13 is a proportional pressure reducing valve 131.

[0066] The electronically controlled pressure regulating valve 13 adopts a proportional pressure reducing valve 131. The proportional pressure reducing valve 131 is integrated into the tension control oil circuit between the accumulator 12 and the controllable shut-off valve group 200. The oil inlet of the proportional pressure reducing valve 131 is connected to the oil outlet of the accumulator 12. The oil outlet of the proportional pressure reducing valve 131 is connected to the rod chamber 51 of the ballast cylinder 5 through the first oil circuit of the controllable shut-off valve group 200.

[0067] The proportional pressure reducing valve 131 can accurately reduce and stabilize the pressure of the high-pressure energy storage oil output by the accumulator 12, converting the fixed high-pressure energy storage oil into constant low-pressure clamping oil that meets construction requirements; at the same time, in conjunction with the closed-loop feedback control of the clamping pressure sensor 26, it can correct pressure deviation in real time.

[0068] Reference Figures 5 to 8This invention also provides an energy-saving hydraulic control method for a tensioner 100, implemented using an energy-saving hydraulic control system 110 for the tensioner, comprising: Reference Figure 5 After the accumulator 12 is pressurized to the set value, the pilot control valve 11 is de-energized, causing the controllable shut-off valve group 200 to cut off, disconnecting the accumulator 12 from the ballast cylinder 5 and maintaining high pressure; the directional control valve 10 is controlled to retract the ballast cylinder 5, causing the upper ballast 3 to descend; the directional control valve 10 is controlled to switch to the neutral position, locking the ballast cylinder 5; the pilot control valve 11 is energized, causing the controllable shut-off valve group 200 to conduct, allowing the accumulator 12 to supply oil to the rod chamber 51; the pilot control valve 11 is de-energized, causing the controllable shut-off valve group 200 to cut off; the directional control valve 10 is controlled to extend the ballast cylinder 5, causing the upper ballast 3 to rise and reset.

[0069] Specifically, after the system is powered on and initialized, the motor pump unit 7 starts working, continuously charging and storing energy into the accumulator 12. When the pressure in the accumulator 12 reaches the system's preset high-pressure threshold, the motor pump unit 7 stops, completing the pre-energy storage operation, and the system enters a stable standby state. In standby mode, the controller continuously de-energizes the pilot control valve 11, and the controllable shut-off valve group 200 remains in a closed and locked state. The accumulator 12 is completely disconnected from the ballast cylinder 5, maintaining a high-pressure energy storage state throughout the process, with no oil leakage or pressure loss.

[0070] Reference Figure 6 After the operation officially starts, the controller controls the directional control valve 10 to switch, opening the oil circuit. High-pressure oil enters the rod chamber 51 of the ballast cylinder 5, driving the ballast cylinder 5 to retract and causing the upper ballast 3 to descend steadily. During the descent, the return oil from the rodless chamber 52 of the ballast cylinder 5 flows back to the oil tank 6 after being throttled and speed-limited by the first sequence valve 19, effectively preventing diving impact and ensuring smooth descent.

[0071] When the displacement sensor 27 detects that the upper ballast 3 has moved to the preset hovering position above the cable, the controller immediately controls the directional control valve 10 to switch to the neutral position, locking the extension and retraction of the ballast cylinder 5, so that the upper ballast 3 is stably hovered and the mechanical pre-positioning is completed.

[0072] Reference Figure 7 After the pre-positioning is completed, the controller controls the pilot control valve 11 to be energized and open the controllable shut-off valve group 200. The high-pressure oil stored in the accumulator 12 is precisely pressure-regulated by the proportional pressure reducing valve 131 and then delivered to the rod chamber 51 of the ballast cylinder 5 to apply a preset constant clamping force to the submarine cable or pipeline. The equipment enters a stable constant tension cable laying and pipe laying operation condition.

[0073] Reference Figure 8After the cable and pipe laying operation is completed, the controller prioritizes the de-energization reset of the pilot control valve 11, cuts off the controllable shut-off valve group 200, and isolates the oil circuit of the accumulator 12 to avoid pressure surges in the accumulator 12 during the reset process, which could impact the oil circuit. Then, the controller controls the directional control valve 10 to reverse, opening the oil inlet circuit of the rodless chamber 52 of the ballast cylinder 5, driving the ballast cylinder 5 to extend, which in turn lifts and resets the upper ballast 3. The equipment returns to the initial standby state, and a single complete operation cycle ends.

[0074] In this embodiment, the steps of controlling the pilot control valve 11 to be energized, enabling the controllable shut-off valve group 200 to be turned on, and the accumulator 12 to supply oil to the rod chamber 51 include: adjusting the output pressure of the electronically controlled pressure regulating valve 13 according to the preset tension force, and performing closed-loop regulation by real-time detection of the pressure of the rod chamber 51 of the ballast cylinder 5 to keep the clamping force constant.

[0075] In this embodiment, the step of controlling the directional control valve 10 to retract the ballast cylinder 5 and lower the upper ballast 3 includes: limiting the return oil speed of the rodless chamber 52 of the ballast cylinder 5 through a sequence valve to prevent the upper ballast 3 from stalling and falling.

[0076] In this embodiment, the step of controlling the directional control valve 10 to switch to the neutral position and locking the ballast cylinder 5 includes: detecting the piston position by means of the displacement sensor 27 built into the ballast cylinder 5, and controlling the directional control valve 10 to switch to the neutral position when the upper ballast 3 is detected to be close to the target position.

[0077] In this embodiment, the method further includes: real-time detection of the pressure of the accumulator 12, and when the pressure is lower than the first preset value, starting the hydraulic power source to replenish oil to the accumulator 12 to the second preset value and then stopping.

[0078] Reference Figure 1 This invention also provides a tensioner 100, including a base 1, a guide frame 4, an upper ballast 3, a lower ballast 2, and a tensioner energy-saving hydraulic control system 110. The lower ballast 2 is fixedly installed on the base 1, and the guide frame 4 is installed on the base 1 and is used to guide submarine cables or pipelines. The upper ballast 3 is movably arranged above the lower ballast 2 and can be raised and lowered relative to the lower ballast 2. The piston rod of the ballast cylinder 5 of the control system is connected to the upper ballast 3 to drive the upper ballast 3 to rise and fall.

[0079] The base 1 is fixedly installed on the deck of the engineering vessel; the lower ballast 2 is fixedly assembled in the middle of the base 1, serving as the lower support and positioning structure for submarine cables and pipelines; the guide frame 4 is vertically fixedly installed on both sides of the base 1, used to guide and limit submarine cables or pipelines, effectively preventing cable deviation and misalignment during operation; the upper ballast 3 is vertically movable above the lower ballast 2, and can move vertically up and down along the guide frame 4.

[0080] The ballast cylinder 5 of the hydraulic control system is vertically mounted on the top of the guide frame 4. The upper end of the piston rod of the ballast cylinder 5 is rigidly fixed to the upper ballast 3. The upper ballast 3 is driven to rise and fall by the extension and retraction of the piston rod, so as to realize the clamping and releasing action with the lower ballast 2.

[0081] According to the tensioner energy-saving hydraulic control system 110 provided in this embodiment, the working principle of the tensioner energy-saving hydraulic control system 110 includes: Reference Figure 5 When the system is closed, the motor pump set 7 starts. If no external mechanism is working, the high-pressure hydraulic oil is replenished to the accumulator 12 through the main oil circuit check valve 8 and the second check valve 15. When the accumulator pressure sensor 21 detects that the pressure has reached the set value of the hydraulic oil pressure when the accumulator 12 is full, the motor pump set 7 stops running and the system is in standby mode. The system overflow valve 9 is set to the maximum working pressure of the system to protect the safety of the pump set system.

[0082] Reference Figure 6In standby mode, input the required tension force on the operation interface, then press the start button of tensioner 100. The motor pump group 7 starts, and the S1 of the three-position four-way solenoid directional valve 101 is energized. The hydraulic oil source is connected from the motor pump group 7 through the main oil circuit check valve 8 and the three-position four-way solenoid valve PB, and then diverted through port B to the B oil circuit port of the cylinder valve group 220. After the high-pressure hydraulic oil reaches the cylinder valve group 220, it passes through the first hydraulic control check valve 22 (1) on the cylinder side. The oil flows into the rod chamber 51 of the ballast cylinder 5 (inlet 2, outlet 2) and simultaneously connects to the outlet 3 of the second hydraulically controlled check valve 23 on the cylinder side of the A oil circuit. When the rising pressure is sufficient to open the second hydraulically controlled check valve 23 on the cylinder side, the pressure in the rodless chamber 52 of the ballast cylinder 5 flows back to the outlet 1 through the outlet 2 of the second hydraulically controlled check valve 23 on the cylinder side. It then flows through an external pipeline to the directional control valve 10, and through the first sequence valve 19, from the third... The A port of the four-way solenoid directional valve 101 flows back to the oil tank 6 through the T port, forming a loop that enables the ballast cylinder 5 to retract. At this time, the upper ballast 3 retracts and descends through the rod chamber 51. During the descent, the ballast cylinder 5 detects the position signal of the upper ballast 3 through the internal displacement sensor 27. The first sequence valve 19 can prevent the upper ballast 3 from descending out of control. During the descent, when the system identifies that the track of the upper ballast 3 is close to the tensioner 100 cable / pipe through the position signal fed back by the displacement sensor 27, the S1 of the three-way four-way solenoid directional valve 101 is de-energized. At this time, since the inlet pressure of the first hydraulic control check valve 22 on the cylinder side is 0, the pressure in the rod chamber 51 of the ballast cylinder 5 is 0, and the ballast cylinder 5 stops retracting. At the same time, since the inlet pressure of the first hydraulic control check valve 22 on the cylinder side is 0, the pressure entering the port of the second hydraulic control check valve 23 on the cylinder side is 0, and the pressure in the port of the second hydraulic control check valve 23 on the cylinder side is 0. Because the pressure at port 3 is zero and therefore closed, the hydraulic oil in the rodless chamber 52 of the ballast cylinder 5 cannot flow back, restricting the descent of the upper ballast 3 and causing it to hover. The first safety valve 24 and the second safety valve 25 will overflow if the load vibration causes high pressure or the system pressure becomes too high, ensuring system safety. Because the second hydraulic control check valve 17 and the third hydraulic control check valve 18 are closed, the high-pressure oil reaching these two valves is stopped from flowing. Under these conditions, the upper ballast 3 tracks hover near the submarine cable / pipeline.

[0083] Reference Figure 7Then, the S3 switch of the two-position four-way solenoid directional valve 111 is energized. The high-pressure oil from the accumulator 12 connects to port B through port P of the two-position four-way solenoid directional valve 111 and enters port 3 of the first hydraulic control check valve 16, the second hydraulic control check valve 17, and the third hydraulic control check valve 18, putting these three hydraulic control valves in the open state with ports 1 and 2 connected. At the same time, the system automatically inputs the signal value calculated based on the input tension force to the proportional pressure reducing valve 131. At this time, the accumulator 12 releases the high-pressure oil source, which is then released through the proportional pressure reducing valve 131. The pressure at outlet 2 is maintained at the set pressure of the calculated tension force. Then, it passes through port 2 to port 1 of the first hydraulic check valve 16 and port 1 to port 2 of the second hydraulic check valve 17, entering the rod chamber 51 of the ballast cylinder 5. The rodless chamber 52 of the ballast cylinder 5 passes through port 2 to port 1 of the open third hydraulic check valve 18, and then through port 2 to port 1 of the second sequence valve 20, returning to the oil tank 6, thus forming a loop. The ballast cylinder 5 continues to retract to contact the submarine cable / pipeline, and according to the proportional pressure reducing valve 131... The input signal clamps the submarine cable / pipeline. The clamping force is fed back by the clamping pressure sensor 26, which forms a closed-loop control with the proportional pressure reducing valve 131. When the feedback force from the clamping pressure sensor 26 is too large, the input value is reduced according to the system's internal calculation. When the feedback force from the clamping pressure sensor 26 is too small, the input value is increased according to the system's internal calculation, so that the tensioner 100 clamps the submarine cable / pipeline at this tension force, thus completing the constant tension control for the submarine cable / pipeline laying. During the constant tension control period, due to system valve leakage, ballast cylinder 5 internal leakage, etc., maintaining a constant clamping force requires the accumulator 12 to continuously release high-pressure oil to compensate for the leakage. The high-pressure oil stored in the accumulator 12 will slowly decrease in pressure due to the system leakage compensation. When it falls below the low-pressure setting value, the motor pump group 7 starts to replenish oil. When the pressure reaches the high-pressure setting value, the motor pump group 7 stops working, and then the accumulator 12 continues to compensate for system leakage.

[0084] Reference Figure 3 and Figure 7 During the operation of the tensioner 100, the constant tension mode needs to be stopped. Press the stop button of the tensioner 100. At this time, the input signal of the proportional pressure reducing valve 131 returns to zero, and the output pressure of port 2 of the proportional pressure reducing valve 131 drops to 0. The S3 of the two-position four-way solenoid directional valve 111 is de-energized. Because the two-position four-way solenoid directional valve 111 is de-energized, the pressure oil at ports 3 of the first hydraulic control check valve 16, the second hydraulic control check valve 17, and the third hydraulic control check valve 18 drops to 0 through port B to port T, causing the first hydraulic control check valve 16, the second hydraulic control check valve 17, and the third hydraulic control check valve 18 to close. At this time, the tension control oil source drops to 0, and its control oil circuit is also disconnected.

[0085] Reference Figure 8Then, the motor pump unit 7 starts, the three-position four-way solenoid directional valve 101S2 is energized, and high-pressure oil flows through the solenoid valve P port to the A port, through the first check valve 14 from port 1 to port 2, through the external pipeline to the cylinder valve group 220, and through the second hydraulic control check valve 23 on the cylinder side from port 1 to port 2, into the rodless chamber 52 of the ballast cylinder 5. At the same time, a branch oil circuit is also branched off from the second hydraulic control check valve 23 on the cylinder side and connected to port 3 of the first hydraulic control check valve 22 on the cylinder side of the rod chamber 51. The pressure in the rodless chamber 52 gradually increases. When the pressure at port 3 reaches the opening pressure of the first hydraulic control check valve 22 on the cylinder side, ports 2 and 1 of the first hydraulic control check valve 22 on the cylinder side are opened. The hydraulic oil in the rod chamber 51 flows back through ports 2 to 1 of the first hydraulic control check valve 22 on the cylinder side, enters the directional control valve 10, and returns to the oil tank 6 through port B to port T of the three-position four-way solenoid directional valve 101. The entire system forms a loop, the ballast cylinder 5 extends, the upper ballast 3 rises and separates from the submarine cable / pipe. After it reaches its original position, the motor pump group 7 stops running, and the system is in standby mode.

[0086] The tensioner energy-saving hydraulic control system 110 provided in this embodiment has at least the following advantages: The controllable shut-off valve assembly 200, in conjunction with the pilot control valve 11, enables the accumulator 12 to be switched on and off with the rod chamber 51 of the hydraulic cylinder. Under non-constant tension conditions, the accumulator 12 disconnects to maintain pressure, completely eliminating the energy waste caused by repeated release and recharging during lifting and lowering processes, resulting in energy savings of approximately 30% or more in actual measurements.

[0087] The proportional pressure reducing valve 131 and pressure sensor are used for closed-loop continuous adjustment, replacing the traditional on / off pressure compensation, so that the tension is kept constant at the set value, and the fluctuation range is reduced from ±1MPa to within ±0.1MPa, effectively protecting submarine cables / pipelines.

[0088] The sequence valve is connected in series in the return oil circuit of the rodless chamber 52. It forms back pressure to limit the speed during descent and locks the cylinder when hovering to prevent the upper ballast 3 from stalling and falling or sliding due to its own weight.

[0089] The built-in displacement sensor 27 detects the piston position in real time. Once in position, it automatically controls the directional control valve 10 to switch to the neutral locking cylinder, achieving non-contact precise hovering and avoiding collision with the cable.

[0090] The accumulator pressure sensor 21 monitors the energy storage pressure and only starts the oil pump to intermittently replenish oil when the pressure is below the lower limit, and stops when the pressure reaches the upper limit, thus maintaining the oil supply capacity and further reducing energy consumption.

[0091] It automatically completes the entire process of descent, hovering, clamping, maintaining constant tension, and rising and resetting, with a high degree of intelligence, reducing the risk of human error.

[0092] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An energy-saving hydraulic control system for a tensioner, wherein the tensioner includes an upper ballast, characterized in that, The control system includes: tank; A hydraulic power source, wherein the hydraulic power source is connected to the oil tank; A ballast cylinder having a rodless chamber and a rod chamber, the ballast cylinder being used to drive the upper ballast device to rise and fall; A directional control valve is connected between the hydraulic power source, the oil tank, and the ballast cylinder. The directional control valve is used to control the extension and retraction of the ballast cylinder and to connect the return oil chamber with the oil tank when the ballast cylinder extends and retracts. An accumulator, which is connected to the hydraulic power source, is used to store high-pressure oil; A controllable shut-off valve assembly, wherein the first oil circuit of the controllable shut-off valve assembly is connected between the oil outlet of the accumulator and the rod chamber, and the controllable shut-off valve assembly is used to control the on / off state of the accumulator and the rod chamber; A pilot control valve, wherein the oil inlet of the pilot control valve is connected to the oil outlet of the accumulator, and the oil outlet of the pilot control valve is connected to the controllable shut-off valve assembly. The controller is electrically connected to the pilot control valve. Under constant tension conditions, the controller energizes the pilot control valve to open the controllable shut-off valve assembly, allowing the accumulator to supply oil to the rod chamber. Under non-constant tension conditions, the controller de-energizes the pilot control valve to disconnect the controllable shut-off valve assembly, disconnecting the accumulator from the rod chamber. The control system further includes an electrically controlled pressure regulating valve and a clamping pressure sensor; the oil inlet of the electrically controlled pressure regulating valve is connected to the oil outlet of the accumulator, and the oil outlet of the electrically controlled pressure regulating valve is connected to the rod chamber via the first oil circuit of the controllable shut-off valve group; the clamping pressure sensor is installed on the oil circuit of the rod chamber and is used to detect the clamping force; the controller is also electrically connected to the electrically controlled pressure regulating valve and the clamping pressure sensor, and the controller is used to continuously adjust the output pressure of the electrically controlled pressure regulating valve according to the feedback signal of the clamping pressure sensor, so that the pressure of the rod chamber is constant at a first preset value.

2. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The control system further includes a first sequence valve; the first sequence valve is connected in series in the return oil line between the rodless chamber and the oil tank, and the first sequence valve is used to limit the descent speed when the ballast cylinder retracts, and to prevent the upper ballast from sliding down due to its own weight when the ballast cylinder stops.

3. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The control system further includes a displacement sensor; the displacement sensor is connected to the ballast cylinder and is used to detect the piston position of the ballast cylinder; the controller is also electrically connected to the displacement sensor and is used to control the directional control valve to switch to the neutral position to lock the ballast cylinder when the displacement sensor detects that the upper ballast is close to the submarine cable or pipeline.

4. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The control system further includes an accumulator pressure sensor; the accumulator pressure sensor is installed on the oil outlet line of the accumulator and is used to detect the accumulator pressure; the controller is also used to start the hydraulic power source to charge the accumulator when the detected value of the accumulator pressure sensor is lower than a second preset value, and to stop the hydraulic power source when the detected value of the accumulator pressure sensor is higher than the second preset value.

5. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The controllable shut-off valve assembly includes a first hydraulically controlled check valve, a second hydraulically controlled check valve, and a third hydraulically controlled check valve; the first hydraulically controlled check valve and the second hydraulically controlled check valve are connected in series in the first oil circuit, and the third hydraulically controlled check valve is connected in series in the second oil circuit between the rodless chamber and the oil tank; the pilot ports of the first hydraulically controlled check valve, the second hydraulically controlled check valve, and the third hydraulically controlled check valve are connected to form the control end of the controllable shut-off valve assembly.

6. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The directional control valve is a three-position four-way solenoid directional valve. The directional control valve has an oil inlet, an oil return port, a first working oil port, and a second working oil port. The oil inlet is connected to the hydraulic power source, the oil return port is connected to the oil tank, the first working oil port is connected to the rodless chamber, and the second working oil port is connected to the rod chamber.

7. The tensioner energy-saving hydraulic control system according to claim 6, characterized in that: A first hydraulically controlled check valve and a second hydraulically controlled check valve on the cylinder side are provided between the directional control valve and the ballast cylinder. The first port of the first hydraulically controlled check valve on the cylinder side is connected to the second working port of the directional control valve, and the second port of the first hydraulically controlled check valve on the cylinder side is connected to the rod chamber. The first port of the second hydraulically controlled check valve on the cylinder side is connected to the first working port of the directional control valve, and the second port of the second hydraulically controlled check valve on the cylinder side is connected to the rodless chamber. The pilot port of the first hydraulically controlled check valve on the cylinder side is connected to the oil circuit where the first port of the second hydraulically controlled check valve on the cylinder side is located. The pilot port of the second hydraulically controlled check valve on the cylinder side is connected to the oil circuit where the first port of the first hydraulically controlled check valve on the cylinder side is located. When the ballast cylinder retracts, the pressure oil output from the second working port of the directional control valve flows through the first port of the first hydraulically controlled check valve on the cylinder side to the second port and then enters the rod chamber. At the same time, this pressure oil opens the second hydraulically controlled check valve on the cylinder side, allowing the pressure oil in the rodless chamber to flow through the second port of the second hydraulically controlled check valve on the cylinder side to the first port and then back to the first working port of the directional control valve. After the directional control valve switches to the neutral position, the first port of the first hydraulically controlled check valve on the cylinder side loses pressure, and the pilot port of the second hydraulically controlled check valve on the cylinder side loses pressure and closes, thereby locking the ballast cylinder.

8. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The pilot control valve is a two-position four-way solenoid directional valve. The P port of the two-position four-way solenoid directional valve is connected to the oil outlet of the accumulator, the B port of the two-position four-way solenoid directional valve is connected to the control terminal of the controllable shut-off valve group, and the T port of the two-position four-way solenoid directional valve is connected to the oil tank. When the two-position four-way solenoid directional valve is energized, the P port and the B port are connected. When it is de-energized, the B port and the T port are connected to control the on / off state of the controllable shut-off valve group.

9. The tensioner energy-saving hydraulic control system according to claim 1, characterized in that: The electrically controlled pressure regulating valve is a proportional pressure reducing valve.

10. A tensioner energy-saving hydraulic control method, implemented using the tensioner energy-saving hydraulic control system according to any one of claims 1-9, characterized in that, include: After the accumulator is pressurized to the set value, the pilot control valve is de-energized, causing the controllable shut-off valve group to cut off, the accumulator is disconnected from the ballast cylinder and the high pressure is maintained; Control the directional control valve to retract the ballast cylinder and lower the upper ballast; control the directional control valve to switch to the neutral position and lock the ballast cylinder; The pilot control valve is energized to open the controllable shut-off valve group, and the accumulator supplies oil to the rod chamber. The pilot control valve is de-energized, causing the controllable shut-off valve assembly to shut off; the directional control valve is controlled to extend the ballast cylinder, causing the upper ballast to rise and reset.

11. The energy-saving hydraulic control method for the tensioner according to claim 10, characterized in that, The steps of energizing the pilot control valve to open the controllable shut-off valve group and supplying oil to the rod chamber by the accumulator include: adjusting the output pressure of the electronically controlled pressure regulating valve according to the preset tension force, and performing closed-loop adjustment by real-time detection of the rod chamber pressure of the ballast cylinder to keep the clamping force constant.

12. A tensioner for use on a subsea engineering vessel, characterized in that, The system includes a base, a guide frame, an upper ballast, a lower ballast, and a tensioner energy-saving hydraulic control system as described in any one of claims 1-9. The lower ballast is fixedly installed on the base, the guide frame is installed on the base and is used to guide submarine cables or pipelines, the upper ballast is movably disposed above the lower ballast, and the upper ballast can be raised and lowered relative to the lower ballast; the piston rod of the ballast cylinder of the control system is connected to the upper ballast to drive the upper ballast to rise and fall.

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