A drive assembly for a fracturing apparatus and a fracturing apparatus

Abstract

The embodiment of the present disclosure provides a driving assembly for a fracturing device and the fracturing device, the driving assembly comprises a resultant force device and a plurality of electric motors, a parallel shaft gear structure is arranged in the resultant force device, the parallel shaft gear structure is used for outputting power to a fracturing pump, the parallel shaft gear structure comprises a third shaft and a plurality of fourth shafts, one end of the third shaft is connected with the fracturring pump or a speed reducer, a third gear is arranged on the third shaft, at least one side of the third shaft is provided with a fourth shaft, a plurality of fourth shafts are arranged in parallel with the third shaft, a fourth gear meshing with the third gear is arranged on the fourth shaft, and at least one end of the fourth shaft is connected with the electric motor. The embodiment of the present disclosure can save the number of devices and investment cost, well site equipment arrangement is more convenient, and transportation and on-site arrangement flexibility is greatly increased.

Description

Technical Field

[0001] This disclosure relates to the field of fracturing technology, and in particular to a drive assembly for fracturing equipment and fracturing equipment. Background Technology

[0002] Currently, the medium-pressure drive system, motor, and fracturing pump of the electric fracturing equipment are mounted on a semi-trailer chassis. During on-site operations, a gas generator set and energy storage equipment need to be separately located near the electric fracturing semi-trailer. The operating mode involves the gas generator producing medium-voltage electricity (e.g., 10kV or 13.8kV), which is then transformed, rectified, and inverted by the medium-pressure drive system to convert it into variable-frequency AC power required by the motor. This power drives the motor to operate at the required speed and torque, thus providing power to the fracturing pump. The energy storage system is directly connected to the DC bus of the medium-pressure drive system. In cases of power shortage, the energy storage system discharges instantaneously to supplement power and stabilize voltage. In cases of power surplus, the energy storage system absorbs energy, thereby smoothing fluctuations in the entire system and ensuring continuous and stable operation.

[0003] The main problems with the above technical solutions are as follows:

[0004] The entire system consists of gas-fired power generation, energy storage, and an electrically driven fracturing semi-trailer. It involves a large number of devices and has a high initial investment cost. The well site requires significant space and has a complex layout; laying cables between the various devices is time-consuming and inefficient in terms of manpower and resources. The system uses medium-high voltage (3.3kV-13.8kV) electricity, requiring professional electrical engineers for maintenance, and carries significant electrical safety risks. Summary of the Invention

[0005] The purpose of this disclosure is to provide a drive assembly for fracturing equipment and a fracturing equipment.

[0006] One embodiment of this disclosure provides a drive assembly for fracturing equipment. The drive assembly includes a force-combining device and multiple electric motors. A parallel shaft gear structure is provided within the force-combining device. The parallel shaft gear structure is used to output power to a fracturing pump. The parallel shaft gear structure includes a third shaft and multiple fourth shafts. One end of the third shaft is connected to the fracturing pump or a reduction gearbox. A third gear is provided on the third shaft. A fourth shaft is provided on at least one side of the third shaft. The multiple fourth shafts are arranged parallel to the third shaft. A fourth gear that meshes with the third gear is provided on the fourth shaft. At least one end of the fourth shaft is connected to the electric motor.

[0007] In some embodiments, the third gear has a gear ring structure and internal teeth, and the internal teeth of the third gear mesh with the fourth gear.

[0008] In some embodiments, a second gearbox is provided between the fourth gear and the electric motor.

[0009] In some embodiments, at least one end of the fourth shaft is connected to a plurality of motors, which are arranged in series.

[0010] In some embodiments, the plurality of the fourth axes are arranged symmetrically based on the third axis.

[0011] In some embodiments, the number of motors connected to different fourth shafts may be the same or different.

[0012] In some embodiments, a planetary gear structure is further included, which is disposed downstream of the parallel shaft gear structure and is used to output power.

[0013] In some embodiments, the planetary gear structure includes a sun gear, planet gears, a planet carrier, and a ring gear. The sun gear is connected to the third shaft of the parallel shaft gear structure, the ring gear remains fixed, and the planet carrier is connected to the fracturing pump or the gearbox.

[0014] In some embodiments, the planetary gear structure includes a sun gear, planet gears, a planet carrier, and a ring gear. The sun gear is connected to the third shaft of the parallel shaft gear structure, the planet carrier remains fixed, and the ring gear is connected to the fracturing pump or the gearbox.

[0015] One embodiment of this disclosure provides a drive assembly for fracturing equipment. The drive assembly includes a power combining device and multiple electric motors. The power combining device is equipped with a planetary gear structure and multiple fifth shafts. The planetary gear structure is used to output power to a fracturing pump. The planetary gear structure includes a sun gear, planet gears, a planet carrier, and a gear ring. The sun gear is fixed. The gear ring has external teeth. A fifth gear is provided on the fifth shaft and meshes with the external teeth of the gear ring. At least one end of the fifth shaft is connected to the electric motor. The planet carrier is connected to the fracturing pump or a gearbox.

[0016] In some embodiments, the electric motor is a generator / electric motor integrated unit used to brake the fracturing pump and recover kinetic energy when operations are stopped.

[0017] One aspect of this disclosure provides a fracturing device, which includes a drive assembly and a fracturing pump as described in any of the above embodiments, wherein the drive assembly is connected to the fracturing pump.

[0018] In some embodiments, a gearbox is further included, which is disposed between the drive assembly and the fracturing equipment or is a gearbox integrated with the fracturing pump.

[0019] In some embodiments, the fracturing equipment further includes a heat dissipation assembly, a high-pressure manifold, and a low-pressure manifold, the high-pressure manifold and the low-pressure manifold being connected to the fracturing pump.

[0020] In some embodiments, the system further includes a power generation component and a DC bus component, wherein the power generation component is connected to the drive component via the DC bus component.

[0021] In some embodiments, the power generation assembly includes an engine, a transfer case, and multiple generators. The transfer case has a parallel shaft gear structure that receives power from the engine. Alternatively, the power generation assembly includes multiple engines, each of which is connected to a corresponding generator to form a generator set.

[0022] In some embodiments, the DC bus assembly is connected to an industrial power grid and / or an external generator set.

[0023] In some embodiments, an energy storage component is further included, which is connected to the DC bus component to enable charging and discharging with the DC bus component.

[0024] In some embodiments, the fracturing equipment is carried by a semi-trailer, skid, or vehicle.

[0025] The embodiments disclosed herein can save on the number of equipment and investment costs, making the well site equipment layout more convenient and greatly increasing the flexibility of transportation and on-site arrangement; it eliminates the need for cable routing between gas-fired power generation, energy storage, and electric fracturing equipment at the well site, reducing installation costs; the use of a low-voltage platform improves the electrical safety of the work site; the power generation efficiency is 2%-5% higher than that of asynchronous motors, and it can maintain high efficiency over a wide load range, especially for fracturing under partial load conditions, where the efficiency advantage is obvious, reducing fuel consumption; in addition, the present disclosure can achieve millisecond-level torque response, precise speed control, and huge overload capacity, which is crucial for ensuring the stability of fracturing operation displacement and pressure, and can better execute complex fracturing processes. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a three-dimensional structural diagram of the fracturing equipment according to an embodiment of the present disclosure;

[0028] Figure 2This is a three-dimensional structural diagram of the power generation component in the fracturing equipment according to an embodiment of the present disclosure;

[0029] Figure 3 This is a three-dimensional structural diagram of the drive component in the fracturing equipment according to an embodiment of the present disclosure;

[0030] Figure 4 This is a side view of the power generation component in the fracturing equipment according to an embodiment of this disclosure;

[0031] Figure 5 This is a side view of the drive assembly in a fracturing device according to an embodiment of the present disclosure;

[0032] Figure 6 This is a three-dimensional structural schematic diagram of a fracturing device according to another embodiment of the present disclosure;

[0033] Figure 7 This is a schematic diagram of the arrangement of a fracturing device according to another embodiment of the present disclosure;

[0034] Figure 8 This is a schematic diagram of the arrangement of a fracturing device according to another embodiment of the present disclosure;

[0035] Figure 9 This is a schematic diagram of the arrangement of a fracturing device according to another embodiment of the present disclosure.

[0036] Figure 10 This is a schematic diagram of the arrangement of heat dissipation components in a fracturing device according to an embodiment of the present disclosure;

[0037] Figure 11 This is a schematic diagram showing the arrangement of heat dissipation components in a fracturing device according to another embodiment of the present disclosure;

[0038] Figure 12 This is a three-dimensional structural diagram of the generator set in a fracturing device according to another embodiment of the present disclosure;

[0039] Figure 13 This is a schematic diagram of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0040] Figure 14 This is a second schematic diagram of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0041] Figure 15 This is a third schematic diagram of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0042] Figure 16 This is one of the connection diagrams of multiple generators in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0043] Figure 17This is a second schematic diagram showing the connection of multiple generators in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0044] Figure 18 This is a fourth schematic diagram of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0045] Figure 19 This is the fifth schematic diagram of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0046] Figure 20 This is a schematic diagram (sixth) of the structure of the transfer device in the power generation component of a fracturing equipment according to an embodiment of the present disclosure;

[0047] Figure 21 This is a schematic diagram of the force-combining device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0048] Figure 22 This is a second schematic diagram of the combined force device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0049] Figure 23 This is a third schematic diagram of the structure of the force-combining device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0050] Figure 24 This is a fourth schematic diagram of the structure of the force-combining device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0051] Figure 25 This is the fifth schematic diagram of the combined force device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0052] Figure 26 This is a schematic diagram (sixth) of the structure of the force-combining device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0053] Figure 27 This is a schematic diagram (seventh in the series) of the force-combining device in the drive assembly of a fracturing equipment according to an embodiment of the present disclosure;

[0054] Figure 28 This is a schematic diagram of the gearbox in a fracturing device according to an embodiment of the present disclosure;

[0055] Figure 29 This is a second schematic diagram of the gearbox structure in a fracturing device according to an embodiment of the present disclosure;

[0056] Figure 30 This is a schematic diagram of the structure of Embodiment 1 of the fracturing equipment of this disclosure;

[0057] Figure 31This is a schematic diagram of the structure of Embodiment 2 of the fracturing equipment according to an embodiment of the present disclosure;

[0058] Figure 32 This is a schematic diagram of the structure of embodiment 3 of the fracturing equipment of this disclosure;

[0059] Figure 33 This is a schematic diagram of the structure of embodiment 4 of the fracturing equipment of this disclosure;

[0060] Figure 34 This is a schematic diagram of the structure of embodiment 5 of the fracturing equipment according to an embodiment of the present disclosure;

[0061] Figure 35 This is a schematic diagram of the structure of embodiment 6 of the fracturing equipment of this disclosure;

[0062] Figure 36 This is a schematic diagram of the structure of embodiment 7 of the fracturing equipment of this disclosure;

[0063] Figure 37 This is a schematic diagram of the structure of embodiment 8 of the fracturing equipment of this disclosure;

[0064] Figure 38 This is a schematic diagram of embodiment 9 of the fracturing equipment according to an embodiment of the present disclosure;

[0065] Figure 39 This is a schematic diagram of the structure of embodiment 10 of the fracturing equipment according to an embodiment of the present disclosure;

[0066] Figure 40 This is a schematic diagram of the structure of embodiment 11 of the fracturing equipment of this disclosure;

[0067] Figure 41 This is a schematic diagram of a power supply system for a fracturing device according to an embodiment of the present disclosure;

[0068] Figure 42 This is a schematic diagram of a power supply system for a fracturing device according to an embodiment of the present disclosure;

[0069] Figure 43 This is a schematic diagram of a power supply system for a fracturing device according to an embodiment of the present disclosure;

[0070] Figure 44 This is a schematic diagram of the steps of a control method for fracturing equipment according to an embodiment of the present disclosure;

[0071] Figure 45 This is a schematic diagram of the power supply system of a fracturing device according to an embodiment of the present disclosure.

[0072] Figure label:

[0073] 10-Power generation component; 11-Engine; 12-Transfer drive; 121-First shaft; 122-First gear; 123-Second shaft; 124-Second gear; 125-First gearbox; 126-Sun gear; 127-Planet gears; 128-Planet carrier; 129-Ring gear; 13-Generator; 14-First transmission component; 20-Drive assembly; 21-Resultant device; 211-Third shaft; 212-Third gear; 213-Fourth shaft; 214-Fourth gear; 215-Second gearbox; 216-Fifth shaft; 217-Fifth gear; 22-Electric motor; 23-Second transmission component; 30-DC bus assembly; 31-Rectifier; 32-Inverter Transformer; 40-Fracturing pump; 50-Heat dissipation assembly; 60-High-pressure manifold; 70-Low-pressure manifold; 80-Energy storage assembly; 81-Battery pack; 82-Battery management system; 90-Gearbox; 91-Parallel shaft gear structure; 92-Planetary gear structure; 100-Semi-trailer chassis; 110-Control system; 120-Industrial power grid; 130-Power grid transformer; 140-Power grid rectifier; 150-Bidirectional DC-DC converter; 160-External prime mover; 170-Asynchronous motor; 180-External rectifier; 200a-First generator set; 200b-Second generator set; 310-Generator-side converter unit; 320-Load-side converter unit. Detailed Implementation

[0074] Various embodiments and features of this disclosure are described herein with reference to the accompanying drawings.

[0075] It should be understood that various modifications can be made to the embodiments described herein. Therefore, the above description should not be considered as limiting, but merely as an example of embodiments. Other modifications within the scope and spirit of this disclosure will be apparent to those skilled in the art.

[0076] The accompanying drawings, which are included in and form part of this specification, illustrate embodiments of the present disclosure and, together with the general description of the disclosure given above and the detailed description of the embodiments given below, serve to explain the principles of the disclosure.

[0077] These and other features of this disclosure will become apparent from the following description of preferred forms of embodiments given as non-limiting examples, with reference to the accompanying drawings.

[0078] It should also be understood that although this disclosure has been described with reference to some specific examples, those skilled in the art can certainly implement many other equivalent forms of this disclosure, which have the features described in the claims and are therefore all within the scope of protection defined herein.

[0079] The above and other aspects, features and advantages of this disclosure will become more apparent when taken in conjunction with the accompanying drawings and in view of the following detailed description.

[0080] Specific embodiments of this disclosure are described thereafter with reference to the accompanying drawings; however, it should be understood that the claimed embodiments are merely examples of this disclosure, which may be implemented in various ways. Well-known and / or repeated functions and structures are not described in detail to avoid unnecessary or redundant details that could obscure this disclosure. Therefore, the specific structural and functional details claimed herein are not intended to be limiting, but merely to serve as the basis and representative basis for the claims to teach those skilled in the art to use this disclosure in a variety of substantially any suitable detailed structures.

[0081] This specification may use the phrases “in one embodiment,” “in another embodiment,” “in yet another embodiment,” or “in still another embodiment,” all of which may refer to one or more of the same or different embodiments according to this disclosure.

[0082] One embodiment of this disclosure provides a fracturing device, such as... Figure 1 As shown, it includes a power generation component 10, a drive component 20, a DC bus assembly (not shown), and a fracturing pump 40. The power generation component 10 is connected to the drive component 20 via the DC bus assembly, and the drive component 20 is connected to the fracturing pump 40. The power generation component 10 generates electricity and transmits it to the DC bus assembly, which in turn provides power to the drive component 20 to drive the fracturing pump 40. In some embodiments, the DC bus assembly can be further powered via an industrial power grid or an external generator set. In this disclosure, the fracturing equipment can be mounted on a semi-trailer, i.e., carried by a semi-trailer. Alternatively, the fracturing equipment can be mounted on a skid or, for example, on a vehicle. Figure 1 In the illustrated embodiment, the fracturing equipment is mounted on the semi-trailer chassis 100 of the semi-trailer.

[0083] Furthermore, the power generation assembly 10 and the drive assembly 20 can be arranged at a certain distance on the semi-trailer chassis 100. In one embodiment, the power generation assembly 10 includes an engine 11, a transfer case 12, and multiple generators 13. The engine 11 can be a gas engine, or other types of engines or power equipment, such as a fuel engine, methanol engine, hydrogen fuel engine, ammonia fuel engine, or dual-fuel engine. The generators 13 can be permanent magnet synchronous generators or asynchronous generators. The input end of the transfer case 12 is connected to the engine 11 to receive power from the engine 11, and the output end of the transfer case 12 is connected to the multiple generators 13 to provide power to the multiple generators 13. The engine 11 can drive the multiple generators 13 to generate electricity through the transfer case 12. Thus, the engine 11 connects to the multiple generators 13 through the transfer case 12 to form a first generator set 200a.

[0084] The generator 13 is connected to the DC bus assembly in the fracturing equipment, and the electrical energy generated by the generator 13 is transmitted to the DC bus assembly. Multiple generators 13 are used to transmit more electrical energy to the DC bus assembly 30; the specific number of generators 13 is determined according to actual needs.

[0085] In this embodiment, by connecting multiple generators 13 to the transfer unit 12, the output power of the engine 11 can be distributed to the multiple generators 13. On the one hand, multiple generators 13 can provide more electrical energy to the DC bus assembly; on the other hand, considering that the technology of a single high-power generator is immature, difficult to manufacture, and costly, using multiple low-power generators 11 can reduce technical difficulty and cost. Furthermore, when one generator 13 fails, the other generators 13 can still generate electricity normally, thereby improving the reliability of power supply. The generator 13 here can also be a generator / motor integrated unit used to start the engine 11.

[0086] In some embodiments, the engine 11 and the transfer case 12 can be independently configured, with the engine 11 connected to the transfer case 12 via a first transmission member 14, which can be a drive shaft. However, considering the overall structural length limitations, the connection between the engine 11 and the transfer case 12 can also utilize other structures such as couplings, in addition to a drive shaft. In other embodiments, to further reduce the overall structural length for easy, for example, placement on a semi-trailer chassis 100, the engine 11 and the transfer case 12 are connected via a housing connection, for example... Figure 2 As shown, the housing of the transfer device 12 and the flywheel housing of the engine 11 are adapted to be connected, and the internal power transmission adopts a coupling connection.

[0087] Furthermore, combined Figure 3 As shown, the drive assembly 20 includes a power combining device 21 and multiple electric motors 22. The electric motors 22 can be permanent magnet synchronous motors or asynchronous motors. The input end of the power combining device 21 is connected to the multiple electric motors 22. The electric motors 22 can be directly connected or connected to the DC bus assembly via an inverter. The output end of the power combining device 21 is connected to the fracturing pump 40. The power of the multiple electric motors 22 is combined in the power combining device 21 to drive the fracturing pump 40. Of course, the electric motors 22 are integrated generators / electric motors, used to brake the fracturing pump 40 and recover kinetic energy when operation stops; for example, braking can be achieved by reversing the direction of rotation.

[0088] The generator 13 and the motor 22 in the power generation component 10 and the drive component 20 of this disclosure are preferably permanent magnet synchronous motors. Compared with asynchronous motors, permanent magnet synchronous motors have significantly reduced size and weight, and can integrate power generation, energy storage and fracturing-related components onto a single semi-trailer.

[0089] Specifically, in the fracturing equipment, the engine 11 drives multiple generators 13 to generate electricity through the transfer device 12. The electrical energy generated by the generators 13 is supplied to the DC bus assembly and then supplied to multiple motors 22 through the DC bus assembly. If the generators 13 generate DC power, it can be directly transmitted to the DC bus assembly. If they generate AC power, it needs to be rectified before being transmitted to the DC bus assembly.

[0090] Preferably, the combined force device 21 is connected to the fracturing pump 40 via the second transmission member 23. The second transmission member 23 herein may be a transmission shaft. Certainly, besides the transmission shaft for achieving connection between the combined force device 21 and the fracturing pump 40, a coupling or other devices may also be adopted for connection.

[0091] Further, in this embodiment, direct connection between the combined force device 21 and the fracturing pump 40 can be achieved via the second transmission member 23; certainly, a reduction gearbox 90 may also be provided between the combined force device 21 and the fracturing pump 40. The reduction gearbox 90 can adjust the power input to the fracturing pump 40, thereby adjusting the rotation speed and torque of the fracturing pump 40, so that the fracturing pump 40 operates at a suitable rotation speed. The reduction gearbox 90 herein may particularly be a reduction gearbox matched with the fracturing pump 40.

[0092] In addition, when the direct connection mode between the combined force device 21 and the fracturing pump 40 is adopted, the combined force device 21 herein can have the function of a reduction gearbox, that is, it can input power of a plurality of said electric motors 22 to the fracturing pump 40, and can also play the role of speed reduction and torque increase, ensuring that the fracturing pump 40 operates within the required rotation speed and torque range. Adopting direct connection of the combined force device 21 to the fracturing pump 40 can also omit transmission members such as transmission shafts and the reduction gearbox matched with the fracturing pump 40, which can reduce the size of the transmission chain and the overall length dimension, and lower the weight and cost of the equipment.

[0093] However, the transfer case 12 can also be connected to the reduction gearbox 90 via the second transmission member 23. The advantage of adopting the second transmission member 23 such as a transmission shaft or a coupling herein is that the reduction gearbox 90 matched with the fracturing pump 40 does not need to be modified, that is, the universality of the fracturing pump 40 is relatively high.

[0094] Taking the case that four generators 13 are adopted in the power generation assembly 10 and four electric motors 22 are adopted in the driving assembly 20 as an example, the installation of the generators 13 on the transfer case 12 is as Figure 5 shown, and the installation of the electric motors 22 on the combined force device 21 is as Figure 4 shown. Those skilled in the art can understand that the number of the generators 13 in the power generation assembly 10 and the number of the electric motors 22 in the driving assembly 20 can both be set as required, wherein the generators 13 and the electric motors 22 can be in one-to-one correspondence. In some embodiments, considering that usually the power generation power of power generation is greater than or equal to the motor power of the electric motors, the generators 13 and the electric motors 22 may also be arranged without correspondence.

[0095] as Figure 6As shown, in another embodiment of the fracturing equipment, the main difference from the above embodiment is that the power generation assembly 10 does not require a transfer device. Therefore, the power generation assembly 10 includes multiple engines 11, each of which is connected to a corresponding generator 13 to form a generator set. The multiple engines 11 form multiple second generator sets 200b. Here, the engines 11 can be started in whole or in part as needed.

[0096] In this embodiment, the engine 11 is a low-power engine compared to the above embodiments. Multiple low-power engines (e.g., 400-600kW) are used instead of a high-power gas engine (e.g., 1000-2000kW). The advantage is that the technology of low-power engines is more mature and the cost is lower than that of high-power gas engines. Moreover, the number of generators 13 that can be started can be adjusted according to the working load, and the system's working load adjustment range is larger. Figure 6 The number of the second generator sets 200b shown is 5, but the number can be adjusted as needed, and all or some of the generator sets can be started as needed.

[0097] like Figure 6 As shown, in this embodiment, multiple generator sets 200b are arranged sequentially along the length of the semi-trailer chassis 100, or as shown in the diagram. Figure 7 As shown, two second generator sets 200b are arranged side-by-side in the width direction of the semi-trailer chassis 100, and then arranged in three rows along the length direction of the vehicle. The number and arrangement of the second generator sets 200b can be set according to actual needs.

[0098] It should be noted that the various power generation components 10 described above can be combined. For example, one or more high-power gas engines can be mounted on the semi-trailer chassis to drive multiple generators to form a first generator set 200a. Simultaneously, one or more low-power engines can be mounted on the semi-trailer chassis to form one or more second generator sets 200b, thereby achieving the desired effect. Figure 8 The diagram shows a power generation structure arrangement with one large and one small generator. For example, a high-power engine 11 can be used to drive multiple generators through a transfer device to form a high-power gas generator set (e.g., 1000kW), while a small-power gas generator set (400-600kW) can be added to combine them, or a large and small power generation structure arrangement can be used. Of course, it can also be arranged as follows: Figure 9 As shown, a power generation structure arrangement of two large and one small is formed, such as combining two high-power gas generator sets (e.g., each with a power of 1000kW) and a small-power gas generator set (with a power of 400-600kW).

[0099] Furthermore, such as Figure 1 As shown, the fracturing equipment also includes a heat dissipation component 50, a high-pressure manifold 60, and a low-pressure manifold 70. The heat dissipation component 50 is installed at the front of the semi-trailer chassis 100. The heat dissipation component 50 can be an integral structure, which is used to dissipate heat from the power components such as the engine 11, the electric motor 22, the fracturing pump 40, and various lubrication systems.

[0100] In some embodiments, the heat dissipation component 50 may also adopt a split heat dissipation structure, for example, Figure 10 and Figure 11 As shown, the heat dissipation assembly 50 includes a first radiator 501, a second radiator 502, and a third radiator 503, each separately configured. The first radiator is used to dissipate heat to the engine-related systems. The first radiator is separately configured and positioned closer to the engine 11 to dissipate lubricating oil heat in a high-heat environment, ensuring that the lubricating oil temperature can be continuously reduced. The second radiator 502 is used to dissipate heat to the generator 13, the electric motor 22, etc. The third radiator 503 is used to dissipate heat to the transfer case 12, the combined power device 22, the plunger pump 40, etc. The second radiator 502 is separately configured and positioned closer to the electrical components to achieve better cooling. Of course, the first radiator 501, the second radiator 502, and the third radiator 503 can also be centrally configured to reduce the number of fans in the heat dissipation device and simplify the system.

[0101] In addition, the high-pressure manifold 60 and the low-pressure manifold 70 are connected to the fracturing pump 40, thereby realizing the input of low-pressure liquid and the output of high-pressure liquid.

[0102] like Figure 12 As shown, for a power generation assembly 10 employing multiple engines 11, the generator 13 is directly connected to the engine 11 or connected via a coupling. To shorten the length of the power generation assembly 10, the heat dissipation component 50 can be installed on the upper part of the engine 11. Each engine 11 is equipped with a corresponding heat dissipation component 50, allowing for modular design of each generator set, enabling quick installation or replacement. Alternatively, multiple generator sets can share a single heat dissipation component 50. This design margin is large enough to accommodate higher operating temperatures when the equipment load is low and the number of engines 11 is small.

[0103] In addition, such as Figure 1As shown, an energy storage component 80 is also provided on the semi-trailer chassis 100. The energy storage component 80 is connected to the DC bus component, thereby enabling charging and discharging between them. Figure 1 In one embodiment, the energy storage component 80 is installed, for example, on the side of the main beam of the semi-trailer chassis 100. The energy storage component 80 can be a chemical battery (e.g., a lithium- or sodium-containing battery), a capacitor, etc., wherein the use of a capacitor can quickly absorb energy shocks.

[0104] Another embodiment of this disclosure also provides a power generation component, which can be used in the aforementioned fracturing equipment, such as... Figures 13 to 20 As shown, the power generation assembly 10 includes an engine 11, a transfer device 12, and multiple generators 13. The transfer device 12 can adopt various transmission structures, including at least a parallel shaft gear structure, and may further include a planetary gear structure.

[0105] Specifically, when the transfer device 12 adopts a parallel shaft gear structure, such as Figure 13 As shown, the transfer case 12 includes a housing, and a parallel shaft gear structure is disposed inside the housing. The parallel shaft gear structure includes a first shaft 121 and a plurality of second shafts 123. One end of the first shaft 121 serves as the input end of the transfer case 12 and is connected to the engine 11. A first gear 122 is disposed on the first shaft 121. A second shaft 123 is disposed on at least one side of the first shaft 121. The plurality of second shafts 123 are respectively disposed parallel to the first shaft 121. A second gear 124 is disposed on the second shaft 123. Here, the second gear 124 has external teeth and meshes with the first gear 122. One end of the second shaft 123 serves as the output end of the transfer case 12 and is connected to the generator 13.

[0106] The generator 13 is configured correspondingly to the second shaft 123, and the number of the second shafts 123 is not limited. Preferably, multiple second shafts 123 are symmetrically arranged based on the first shaft 121. This symmetrical arrangement is symmetrically arranged in the same plane along the axial direction of the transfer device 12, which can reduce the problems of uneven weight loading and uneven gear load.

[0107] like Figure 14As shown, in another embodiment, the difference from the above structure is that a first gearbox 125 is provided between the second gear 124 and the generator 13. The first gearbox 125 enables adjustable power transmission to the generator 13 and also allows adjustment of the matching speed of the connected generator 13, further regulating the speed difference between the engine 11 and the generator 13. Here, the first gearbox 125 can be a speed reducer or a speed-increasing gearbox.

[0108] In another embodiment, the difference from the above structure is that each of the second shafts 123 connects to a plurality of the generators 13, wherein both ends of the second shaft 123 can be respectively connected to the generators 13. In another embodiment, as shown... Figure 15 As shown, multiple generators 13 are sequentially connected in series at the ends of the second shaft 123. For a series connection of two generators 13, the two generators 13 can be coaxially arranged or non-coaxially arranged. Therefore, the two generators 13 are connected using rigid connections such as splines or flat keys, or flexible connections such as couplings, flexible discs, or vibration-damping couplings. In one embodiment, such as... Figure 16 As shown, multiple generators 13 can be connected in series via motor shafts 131; in another embodiment, as... Figure 17 As shown, the multiple generators 13 can be connected by splines 132.

[0109] It should be noted that the structure or number of each second shaft 123 in the parallel shaft gear structure described above that connects to the generator 13 may be the same or different. For example, among two parallel second shafts 123, one second shaft 123 is connected to the generator 13 through the first gearbox 125, and the other second shaft 123 connects two generators 13 connected in series. This disclosure does not limit this.

[0110] In some other embodiments, a planetary gear structure is provided upstream of the parallel shaft gear structure. The planetary gear structure receives power from the engine 11 and transmits it to the parallel shaft gear structure, and finally realizes power output through the parallel shaft gear structure. Here, the planetary gear structure and the parallel shaft gear structure have the same or different transmission ratios.

[0111] Specifically, such as Figure 18As shown, the planetary gear structure includes a sun gear 126, planet gears 127, a planet carrier 128, and a ring gear 129. Multiple planet gears 127 (typically three, four, or more) are connected to the planet carrier 128 and evenly distributed around the sun gear 126. Each planet gear 127 meshes with both the sun gear 126 and the ring gear 129. The sun gear 126 is connected to the engine 11, serving as the input end of the transfer case 12 to receive power output from the engine 11. The ring gear 129 remains fixed (e.g., connected to a housing). The planet carrier 128 is connected to the first shaft 121, serving as the output end of the planetary gear structure to transmit power to the parallel shaft gear structure.

[0112] In another implementation, such as Figure 19 As shown, the planetary carrier 128 is connected to the engine 11, and the planetary carrier 128 serves as the input end of the transfer case 12. The ring gear 129 is kept fixed (e.g., connected to the housing). The sun gear 126 is connected to the first shaft 121, and the sun gear 126 serves as the output end of the planetary gear structure to transmit power to the parallel shaft gear structure.

[0113] In another implementation, such as Figure 20 As shown, the sun gear 126 is connected to the engine 11. Here, the sun gear 126 serves as the input end of the planetary gear structure. The planet carrier 128 remains fixed (e.g., connected to the housing). The ring gear 129 is connected to the first shaft 121. The ring gear 129 serves as the output end of the planetary gear structure to transmit power to the parallel shaft gear structure.

[0114] Another embodiment of this disclosure also provides a drive assembly that can be used in the fracturing equipment described above. The drive assembly 20 includes a force-combining device 21 and a plurality of electric motors 22. The force-combining device 21 can adopt a variety of transmission structures. The transmission structure includes at least a parallel shaft gear structure, and may further include a planetary gear structure.

[0115] Specifically, when the resultant force device 21 adopts a parallel shaft gear structure, such as Figure 21As shown, the transfer device 12 includes a housing, and a parallel shaft gear structure is installed inside the housing. The parallel shaft gear structure includes a third shaft 211 and multiple fourth shafts. One end of the third shaft 211 serves as the output end of the resultant force device 21 and is connected to the fracturing pump 40 or the reduction gearbox 90. A third gear 212 is installed on the third shaft 211, and a fourth shaft 213 is installed on at least one side of the third shaft 211. Multiple fourth shafts 213 are arranged parallel to the third shaft 211, and a fourth gear 214 is installed on the fourth shaft 213. Here, the third gear 212 has external teeth, so the fourth gear 214 meshes with the external teeth of the third gear 212. One end of the fourth shaft 214 serves as the input end of the resultant force device 21 and is connected to the motor 22.

[0116] The motor 22 is correspondingly arranged with the fourth shaft 214. The number of the fourth shaft 214 is not limited. When multiple parallel fourth shafts 214 are arranged, they are symmetrically arranged based on the third shaft 211. The symmetrical arrangement is symmetrically arranged in the same plane along the axial direction of the resultant force device 21. This can reduce the problems of uneven load on the equipment weight and uneven load on the gears.

[0117] like Figure 22 As shown, in another embodiment, the difference from the above structure is that a second gearbox 215 is provided between the fourth gear 214 and the motor 22; the second gearbox 215 enables the output power of the motor 22 to be adjustable, and can also adjust the matching speed of the connected motor 22, further adjusting the speed difference between the motor 22 and the fracturing pump 40. Here, the second gearbox 215 can be a reducer or a speed-increasing gearbox.

[0118] In one embodiment, the two ends of the fourth shaft 213 can be respectively connected to the motor 22; in another embodiment, such as... Figure 23 As shown, one end of the fourth shaft 213 can be connected to multiple motors 22, which are arranged in series. Based on the series connection of two motors 22, the two motors 22 can be arranged coaxially or non-coaxially. Therefore, the two motors 22 are connected by rigid connections such as splines or flat keys, or by flexible connections such as couplings, flexible discs, or vibration-damping couplings. In one embodiment, the multiple motors 22 can be connected in series via motor shafts or by splines.

[0119] Furthermore, in another embodiment, such as Figure 24As shown, the third gear 212 adopts a gear ring structure and has internal teeth. The internal teeth of the third gear 212 mesh with the fourth gear 214. The radial dimension of the force-resulting device 21 can be reduced by the third gear 212 with the gear ring structure.

[0120] It should be noted that the structure or number of the fourth shaft 213 connected to the motor 22 in the parallel shaft gear structure described above may be the same or different. For example, among two parallel fourth shafts 213, one fourth shaft 213 is connected to the motor 13 through the second gearbox 215, and the other fourth shaft 213 is connected to two motors 22 connected in series. This disclosure does not limit this.

[0121] Furthermore, in some other embodiments, such as Figure 25 As shown, a planetary gear structure is provided downstream of the parallel shaft gear structure. The planetary gear structure can also be connected to the parallel shaft gear structure and output power to the fracturing pump 40 or the reduction gearbox 90. The planetary gear structure includes a sun gear 126, planet gears 127, a planet carrier 128, and a ring gear 129. Multiple planet gears 127 (usually 3, 4 or more) are connected to the planet carrier 128 and are evenly distributed around the sun gear 126. The planet gears 127 mesh with both the sun gear 126 and the ring gear 129. The sun gear 126 is connected to the third shaft 211 of the parallel shaft gear structure. Here, the sun gear 126 serves as the input end of the planetary gear structure to connect with the parallel shaft gear structure. The ring gear 129 remains fixed (e.g., fixedly connected to the housing). The planet carrier 128 is connected to the fracturing pump 40 (or the reduction gearbox 90). The planet carrier 128 serves as the output end of the planetary gear structure and is also the output end of the transfer device 12 to output power.

[0122] In another implementation, such as Figure 26 As shown, the sun gear 126 is connected to the third shaft 211 of the parallel shaft gear structure. Here, the sun gear 126 serves as the input end of the planetary gear structure and is connected to the parallel shaft gear structure. The planet carrier 128 is kept fixed (e.g., fixedly connected to the housing). The gear ring 129 is connected to the fracturing pump 40 (or gearbox). The gear ring 129 serves as the output end of the planetary gear structure and is also the output end of the transfer case 12 to output power.

[0123] like Figure 27As shown, another embodiment of this disclosure also provides a drive assembly that can be used in the fracturing equipment described above. The drive assembly 20 includes a force-combining device 21 and at least one electric motor 22. The transmission structure adopted by the force-combining device 21 here includes at least a planetary gear structure and a plurality of fifth shafts 216.

[0124] Specifically, the transfer device 12 includes a housing, within which a planetary gear structure is installed. The planetary gear structure includes a sun gear 126, planet gears 127, a planet carrier 128, and a ring gear 129. Multiple planet gears 127 (typically three, four, or more) are connected to the planet carrier 128 and evenly distributed around the sun gear 126. Each planet gear 127 meshes with both the sun gear 126 and the ring gear 129. The sun gear 126 remains fixed (e.g., connected to the housing), and the ring gear 129 has external teeth. A fifth gear 217 is installed on the fifth shaft 216, meshing with the external teeth of the ring gear 129. One end of the fifth shaft 216 serves as the input end of the resultant force device 21 and is connected to the electric motor 22. The planet carrier 128 is connected to the fracturing pump 40 (or the reduction gearbox 90), and serves as both the output end of the planetary gear structure and the output end of the transfer device 12 to output power.

[0125] Furthermore, in this disclosure, considering that a reduction gearbox 90 can also be provided between the combined force device 21 and the fracturing pump 40, such as... Figure 28 As shown, the gearbox 90 is equipped with a parallel shaft gear structure 91, which can also be used as follows: Figure 29 As shown, a planetary gear structure 92 is provided on the downstream side of the parallel shaft gear structure 91, and the power output by the drive assembly 20 can be adjusted and input to the fracturing pump 40 through the reduction gearbox 90.

[0126] Different implementations of the fracturing equipment can be formed by employing the power generation component 10 and the drive component 20 with different structural forms in the above embodiments. The power generation component 10 and the drive component 20 can adopt any of the above implementations, specifically selectively through the following implementations 1-11 (see...). Figures 30-40 ) Please provide a detailed explanation:

[0127] Implementation method 1:

[0128] like Figure 30As shown, in this embodiment, the engine 11 and the transfer device 12 are connected by a first transmission member 14 using a coupling or other connection method. Here, the transfer device 12 adopts a parallel shaft gear structure. The power of the engine 11 is input from the first shaft 121. Through the meshing of the first gear 122 and the second gear 124, the power is transmitted to the generator 13 for power generation through the second shaft 123 parallel to the first shaft 121. Here, the second shaft 123 and the generator 13 are arranged correspondingly, and there are two generators 13.

[0129] The alternating current generated by the generator 13 in the power generation assembly 10 is rectified by the rectifier 31 and supplied to the DC bus assembly 30. The electricity in the DC bus assembly 30 is converted into alternating current by the inverter 32 and then transmitted to the motor 22 in the drive assembly 20. Furthermore, the energy storage assembly 80 in the fracturing equipment is connected to the DC bus assembly 30, thereby enabling charging and discharging between them and stabilizing the voltage of the DC bus assembly 30.

[0130] The power output from the electric motor 22 is transmitted through the force-combining device 21 to the reduction gearbox 90 via a second transmission component 23 using a coupling or other connection method to drive the fracturing pump 40. The force-combining device 21 employs a parallel shaft gear structure. The power of the electric motor 22 is input from the fourth shaft 213. Through the meshing of the fourth gear 214 and the third gear 212, the third shaft 211, parallel to the fourth shaft 213, transmits power to the reduction gearbox 90. The fourth shaft 213 and the electric motor 22 are correspondingly arranged, and there are two electric motors 13. Furthermore, the reduction gearbox 90 is connected to the plunger pump 40 via the parallel shaft gear structure 91 and the planetary gear structure 92, thereby driving the plunger pump 40 to operate.

[0131] Implementation Method 2:

[0132] like Figure 31 As shown, in this embodiment, compared to embodiment 1, the gearbox 90 only includes the parallel shaft gear structure 91 and does not require the planetary gear mechanism 92.

[0133] Implementation Method 3:

[0134] like Figure 32As shown, in this embodiment, compared to embodiment 1, the transfer device 12 uses a planetary gear mechanism and a parallel shaft gear structure to achieve joint transmission. The planetary gear structure adopts a structure with a sun gear input, a fixed gear ring, and a planetary carrier output. The output shaft of the engine 11 is connected to the sun gear 126 via a coupling or other connection method. The gear ring 129 is fixed to the housing of the transfer device 12. Here, the planetary carrier 128 serves as an output component, transmitting its output power to the parallel shaft gear structure, which drives each generator 13 through the first shaft 121 in the parallel shaft gear structure. The structure of the resultant force device 21 in this embodiment is the same as in embodiment 1. Furthermore, it should be noted that in this embodiment, no reduction gearbox 90 is provided between the transfer device 12 and the fracturing pump 40; the speed change function is achieved through the resultant force device 21.

[0135] Implementation Method 4:

[0136] like Figure 33 As shown, in this embodiment, compared to embodiment 1, the transfer device 12 uses a planetary gear mechanism and a parallel shaft gear structure for joint transmission. The planetary gear structure has a planetary carrier input, a fixed gear ring, and a sun gear output. The output shaft of the engine 11 is connected to the planetary carrier 128, and the gear ring 129 is fixed to the housing of the transfer device 12. Here, the sun gear 126 serves as an output component, transmitting its output power to the parallel shaft gear structure, which drives each generator 13 via the first shaft 121 of the parallel shaft gear structure. The structure of the resultant force device 21 in this embodiment is the same as in embodiment 1. Furthermore, it should be noted that in this embodiment, no reduction gearbox 90 is provided between the transfer device 12 and the fracturing pump 40; the speed change function is achieved through the resultant force device 21.

[0137] Implementation Method 5:

[0138] like Figure 34As shown, in this embodiment, compared to embodiment 1, the transfer case 12 uses a planetary gear mechanism and a parallel shaft gear structure for joint transmission. The planetary gear structure has a sun gear input, a fixed planet carrier, and a ring gear output. The output shaft of the engine 11 is connected to the sun gear 126, and the planet carrier 128 is fixed to the housing of the transfer case 12. Here, the ring gear 129 serves as an output component, transmitting its output power to the parallel shaft gear structure, which drives each generator 13 via the first shaft 121 of the parallel shaft gear structure. The structure of the resultant force device 21 in this embodiment is the same as in embodiment 1.

[0139] Implementation method 6:

[0140] like Figure 35 As shown, compared to Embodiment 1, in this embodiment, a first gearbox 125 and a second gearbox 215 are respectively provided between the transfer device 12 and the generator 13, and between the motor 22 and the power combining device 21, thereby changing the transmission ratio inside the transfer device 12 and the power combining device 21 to accommodate more specifications of the generator 13 and the motor 22.

[0141] Implementation Method 7:

[0142] like Figure 36 As shown, compared to Embodiment 1, in this embodiment, the generator 13 or the motor 22 can be connected in series. By connecting two generators 13 or two motors 22 in series, the number of generators 13 or motors 22 can be increased, thereby achieving greater power output and input.

[0143] Implementation Method 8:

[0144] like Figure 37 As shown, compared to Embodiment 2, the combined force device 21 uses a planetary gear mechanism and a parallel shaft gear structure for transmission. The planetary gear structure adopts a structure with a planetary carrier input, a fixed gear ring, and a sun gear output. The gear ring 129 is fixed on the housing. Multiple motors 22 are connected to the fourth shaft 213 in the parallel shaft gear structure. The fourth gear 214 transmits power to the third gear 212. The third shaft 211 is connected to the planetary carrier 128 in the planetary gear structure to transmit power to the planetary carrier 128. The sun gear 126 in the planetary gear structure serves as an output component and is connected to the reduction gearbox 90, thereby transmitting power to the reduction gearbox 90 and ultimately driving the fracturing pump 40, thus realizing the power transmission from multiple motors 22 to the fracturing pump 40.

[0145] Implementation Method 9:

[0146] like Figure 38 As shown, compared to Embodiment 2, the combined force device 21 employs a planetary gear mechanism and a parallel shaft gear structure for joint transmission. The planetary gear structure uses a sun gear input, a fixed planetary carrier, and a ring gear output. The planetary carrier 128 is fixed to the housing. Multiple motors 22 are connected to the fourth shaft 213 in the parallel shaft gear structure. The fourth gear 214 transmits power to the third gear 212. The third shaft 211 is connected to the sun gear 126 in the planetary gear structure, transmitting power to the sun gear 126. The ring gear 129 in the planetary gear structure serves as an output component and is connected to the reduction gearbox 90, thereby transmitting power to the reduction gearbox 90 and ultimately driving the fracturing pump 40, thus realizing the power transmission from the multiple motors 22 to the fracturing pump 40.

[0147] Implementation Method 10:

[0148] like Figure 39 As shown, compared with embodiment 2, the combined force device 21 only adopts a parallel shaft gear structure. The third gear 212 has a gear ring structure and meshes with the fourth gear 214 through its internal teeth. The power output by the motor 22 is transmitted to the third gear 212 through the fourth gear 214 and then to the third shaft 211, thereby transmitting the power to the reduction gearbox 90 and finally driving the fracturing pump 40, thus realizing the power transmission from multiple motors 22 to the fracturing pump 40.

[0149] Implementation method 11:

[0150] like Figure 40As shown, compared to embodiment 2, the power combining device 21 uses a planetary gear mechanism and a transmission shaft for transmission. The planetary gear structure has an input gear ring, a fixed sun gear, and an output gear carrier. The sun gear 126 is fixed to the housing of the power combining device 21. Multiple motors 22 are connected to multiple fifth shafts 216. The fifth gear 216 meshes with the external teeth of the gear ring 129 in the planetary gear structure to transmit power to the gear ring 129. Multiple planet gears 127 are connected to the planet carrier 128 and evenly distributed around the sun gear 126. Each planet gear 127 meshes with both the sun gear 126 and the gear ring 129. Here, the planet carrier 128 serves as an output component and is connected to the reduction gearbox 90 via a second transmission component 23 such as a coupling, ultimately transmitting power to the plunger pump 40, thus realizing the power transmission from the multiple motors 22 to the fracturing pump 40.

[0151] In the fracturing equipment disclosed herein, taking the four generators 13 and four electric motors 22 as an example, the working principle of the electric drive system of the fracturing equipment is as follows: Figures 41 to 43 As shown: The control system 110 is connected to the power generation component 10, the drive component 20, the energy storage component 80, the power generation-side converter unit 310, and the load-side converter unit 320. The power generation-side converter unit 310 includes multiple rectifiers 31 corresponding to the generator 13, and the load-side converter unit 320 includes multiple inverters 32 corresponding to the motor 22. Both the generator 13 and the motor 22 are equipped with corresponding generator controllers and motor controllers. The control system 110 includes a host computer / PLC.

[0152] On the power generation side, the engine 11 drives multiple generators 13, such as permanent magnet synchronous generators, to rotate. The permanent magnet synchronous generator generates a magnetic field through permanent magnets on its rotor, inducing alternating current in the stator windings whose voltage and frequency vary with the rotational speed. This alternating current is then delivered to the corresponding rectifier 31. The rectifier 31 not only rectifies it into direct current, but also controls the amplitude of the output current or voltage through algorithms and drive modules, thereby controlling the input torque of the generator 13 and achieving precise management of the torque of the generator 13. This, in turn, ensures that the engine 11 always operates stably within the optimal fuel efficiency range.

[0153] Furthermore, all the rectified DC power is fed into the DC bus assembly 30. The energy storage assembly 80 includes a battery pack 81, which is connected to the DC bus assembly 30 through a battery management system 82.

[0154] In actual power supply, the working principle of the energy storage component 80 is to monitor the minute fluctuations of the DC bus voltage in real time: when the load power demand of the fracturing pump 40 increases sharply and the power generation side cannot meet it temporarily, the DC bus voltage tends to drop. Then the energy storage component 80 responds instantly (millisecond level) and starts the discharge mode to replenish the stored electrical energy to the DC bus component 30. Conversely, when the load drops sharply, the DC bus voltage is at risk of rising. The energy storage component 80 immediately switches to the charging state to absorb excess energy, smoothing the impact of load fluctuations on power generation and maintaining the stability of the DC bus voltage.

[0155] On the load side, multiple inverters 32 draw power in parallel from the stable DC bus assembly 30. By receiving instructions from the control system 110 (such as torque and speed setpoints), they use vector control and other algorithms to invert the DC power into three-phase AC power whose frequency, voltage, and phase can be independently and precisely controlled. These AC power drives each of the motors 22. The motors 22, with their high torque density and high efficiency, convert electrical energy into mechanical energy, directly driving the plunger in the fracturing pump 40 to reciprocate, thereby generating high-pressure fluid.

[0156] In this embodiment, the control system 110 performs advanced coordination of the entire energy flow, intelligently decides the number of generators 13 to be started and their optimal operating power points based on the total power demand, and simultaneously issues independent control commands to each inverter 32 and formulates the optimal energy storage charging and discharging strategy, so that the power generation, energy storage and power consumption are decoupled yet coordinated, thereby maximizing the overall system efficiency, dynamic response and operational stability.

[0157] The above power supply methods are used for fracturing equipment with a power range of 2000-6000hp. If the power of the fracturing pump 40, the combined power device 21 and the motor 22 are increased to 6000-10000hp, fracturing equipment with greater power can be realized. At this time, if the power generation side is insufficient to drive the fracturing pump 40 on the load side, additional generator sets or external power grids can be added to supply power.

[0158] Furthermore, such as Figure 42 As shown, the fracturing equipment can also be powered by an external power grid. The external industrial power grid 120 (e.g., 10kV / 35kV) is voltage-matched and electrically isolated by a grid transformer 130, and then converted into DC power by a grid rectifier 140. The grid rectifier 140 is an active rectifier. The rectified power is connected to the DC bus assembly 30 via a bidirectional DC-DC converter 150, thereby ensuring that the power factor on the grid side is close to 1 and the harmonic content is extremely low, meeting the grid-connected power quality requirements. Alternatively, the grid rectifier 140 can also be a passive rectifier.

[0159] In another implementing party, such as Figure 43 As shown, the DC bus assembly 30 is connected to an external generator set, which can be a three-phase asynchronous generator set. The external generator set includes an external prime mover 160, an asynchronous motor 170, and an external rectifier 180. The external prime mover 160 can be a gas generator set, an oil generator set, or a turbine, etc.

[0160] In this configuration, the AC power generated by the asynchronous generator 170, which has unstable voltage and frequency, is first converted into DC power by the external rectifier 180. This external rectifier 180 is typically an uncontrolled diode rectifier bridge or a semi-controlled thyristor rectifier; alternatively, a silicon controlled rectifier (SCR) or silicon carbide rectifier can also be used. The control system 110 needs to communicate with the control device (e.g., the throttle control device of a diesel engine) of the external prime mover 160 of the external generator set to control the frequency and active power output of the asynchronous generator 170 by adjusting its throttle.

[0161] Furthermore, the control system 110 can calculate the total power difference required to maintain the stability of the DC bus voltage based on the real-time deviation of the DC bus voltage, and then send an active power setpoint command to the ECU of the external prime mover 160 of the external generator set via Modbus or CAN bus protocol. Upon receiving the command, the ECU forms a closed loop with its own speed feedback and adjusts, for example, the fuel injection quantity or the gas valve opening through a PID algorithm, thereby changing the output torque of the external prime mover 160 and enabling the asynchronous generator 170 to achieve the target power output. Simultaneously, the control system 110 can continuously monitor the output frequency of the asynchronous generator 170 as a key feedback signal: if the frequency is lower than the rated value (e.g., 50Hz), it indicates that the external prime mover 160 is overloaded and lacks torque, and the control system 110 fine-tunes to increase the power setpoint; if the frequency is too high, the setpoint is decreased. By employing this dual closed-loop control strategy of "power setting as the main control and frequency feedback for fine-tuning", a relatively stable active power output can be achieved under the inherent limitations of the asynchronous generator 170, thereby assisting in stabilizing the DC bus voltage.

[0162] In the embodiments of this disclosure, the advantage of using permanent magnet synchronous motors for the generator 13 and the motor 22 is that: the rotor position / speed (requiring the use of position sensors such as encoders) and output voltage frequency are accurately monitored; precise control of speed and torque is achieved using a high-precision frequency converter based on vector control, resulting in higher control accuracy. For example, high-precision output can be achieved by using silicon controlled rectifiers (SCRs) or silicon carbide as frequency converter drive modules. When the load changes significantly, causing the voltage or frequency to deviate from the rated value by a gradual increase, the speed or torque of the permanent magnet synchronous motor is adjusted to ensure the stability of the generator's speed and voltage.

[0163] Another embodiment of this disclosure provides a control method for a fracturing device, which employs the fracturing device described in any of the above claims, such as... Figure 44 As shown, the control method includes:

[0164] S101, after the engine starts, the generator is controlled based on the real-time status of the engine and a torque control strategy, so that the output torque of the generator follows the output torque of the engine;

[0165] S102, the motor is controlled to operate based on a target rotational speed, the target rotational speed being determined based on the target flow rate of the fracturing pump.

[0166] Furthermore, the engine is preheated after it is started.

[0167] During the preheating process after the engine is started, the cylinder liner water temperature is compared with a preset temperature to determine whether the preheating is complete.

[0168] Furthermore, the process of preheating the engine after it starts also includes: controlling the operating mode of the heat dissipation component based on the motor temperature of the generator.

[0169] Further, in step S102, the step of controlling the motor operation based on the target rotational speed, wherein the target rotational speed is determined based on the target flow rate of the fracturing pump, includes:

[0170] When the fracturing pump experiences a load impact, the output power of the motor is controlled to follow the load change in real time and the energy is stored or released through the energy storage component.

[0171] Furthermore, when energy is stored through the energy storage component, if the energy exceeds the load-bearing limit of the energy storage component, the motor is controlled to switch to constant power mode and the output speed of the motor is reduced.

[0172] like Figure 45 As shown, the control method of the fracturing equipment provided in this disclosure is as follows:

[0173] After receiving the start command, the engine 11 starts under zero load and drives the generator 13 through the transfer case 12. After starting, the engine 11 executes a preheating command. If the engine 11 is not fully preheated, the generator 13 and its controller are shut down, ceasing power generation and drive functions. The generator 13 then rotates freely and generates heat. Simultaneously, the cooling system 50 is activated to cool the generator 13 and other components, preventing malfunctions. When the engine 11 is fully preheated, the control system 110 connects to low-voltage power and executes a self-test. If a fault is detected during the self-test, the next command is not allowed, and maintenance is prompted. If no fault is detected, the main contactor is connected, and high voltage is applied to the controller, putting the fracturing equipment in standby mode. At this time, the electric motor 22 can be started.

[0174] Specifically, after the generator 13 has started, the engine 11 will increase its speed n. ENG Increase to rated speed n s When the engine speed n ENG Reaching the preset rated speed n s At that time, the engine 11 begins to perform a preheating judgment, specifically, by detecting and judging the cylinder liner water temperature T of the engine 11. g The determination of whether the first preset temperature value T has been reached to complete preheating. Specifically, when T... g When <T, it indicates that the preheating of the engine 11 is not complete. The engine 11 needs to idle continuously for preheating. At this time, the controllers of the generator 13 and the motor 22 are all turned off and do not perform power generation and drive functions. The rotor of the generator 13 is in free rotation and will generate heat due to magnetic field, loss and other reasons.

[0175] Furthermore, during the preheating process of the engine 11, the motor temperature T of the generator 13 can also be monitored by the temperature sensor built into the generator 13. m Perform the test and record the obtained motor temperature T. m The data is uploaded in real time to the host computer / PLC of the control system 110 and compared with a second preset temperature value to activate the heat dissipation component 50. Specifically, when T... m >T 高温 When T is activated, the cooling assembly 50 is started to circulate cooling water or oil, thereby cooling the generator 13 and the electronic control system; when T m <T 低温 When T is reached, the heat dissipation component 50 stops working; when T is reached... 低温 ≤T m ≤T 高温When the generator 13 is in operation, the heat dissipation assembly 80 operates in low-power or self-circulation mode to maintain the generator 13 at its optimal operating temperature and prevent malfunctions. In one specific embodiment, the heat dissipation assembly 50 can employ the following temperature control strategy to regulate the heat dissipation power:

[0176]

[0177] When T g When T ≥ T, it indicates that the preheating of the engine 11 is complete. The motor controller of the electric motor 22 and the control system 110 are activated with the wake-up signal Key on, and a self-test program is executed. If a fault is found in the self-test, the next instruction is not allowed to be executed and a maintenance prompt is given. If there is no fault in the self-test, the main contactor is activated and high voltage is applied to the controller to control the fracturing equipment to be in standby mode.

[0178] On the generator side, since the engine 11 and the generator 13 are rigidly connected through the transfer case 12, the rotational speed n of the engine 11 is... ENG =n G =n s (Rated speed), the generator controller employs a torque control strategy and controls the generator 13 via a cable. The host computer / PLC of the control system 110 collects the real-time rotational speed n of the engine 11. ENG / Torque T ENG / Power P ENG The generator 13 uses data such as the engine 11's real-time status to set and adjust its torque control strategy, thereby ensuring that the generator 13's output torque accurately follows the engine 11's output torque and thus guaranteeing the engine 11's stable operation. The generator controller of the generator 13 controls the output voltage and current through the rectifier module, converting the AC power generated by the generator 13 into DC power and outputting it to the DC bus assembly 30. This allows it to be coupled and output to other power sources such as batteries / capacitors from the energy storage assembly 80.

[0179] For example, the torque control strategy of the generator 13 mentioned above is exemplified as follows: Due to the low load-bearing capacity of the engine 11, the load-bearing capacity increase in each power range is P. 提升 Since power P (kW) = speed n (rpm) × torque T (Nm) / 9550, the speed n of the engine 11 mentioned here is... s Given this information, the maximum torque T that the engine 11 can withstand at each power level can be calculated. 提升 Therefore, the reference torque for the i-th step boost of the generator 13 can be set to T. i =T 提升Then the output torque T of the engine 11 under the current power range can be set. 输出 = Simultaneously monitor the speed change of the engine 11, and take the speed change rate η = Δn ENG / Δt, when η > set value η 设定 When η is greater than the load-bearing capacity of the engine 11, it is considered that the torque input of the generator 13 is greater than the load-bearing capacity of the engine 11. At this time, ΔT is negative, and the torque of the generator 13 is reduced. When η ≤ the set value η 设定 When the torque input of the generator 13 is considered to be within the load-bearing capacity of the engine 11, ΔT is 0 or a positive value, thus increasing the torque of the generator 13.

[0180] The above strategies are merely examples. The torque control strategy can also be set as a function, where the output torque of the generator 13 is set as a function of time or speed, or other forms. This allows the output torque of the generator 13 to precisely follow the torque of the engine 11, ensuring stable operation of the engine 11. In this way, the generator controller controls the output voltage and current through its built-in rectifier module, converting the AC power generated by the generator 13 into DC power for output to the DC bus assembly 30. Furthermore, when the voltage of the energy storage component 80 connected to the DC bus assembly 30, such as a battery or capacitor, changes, the generator controller monitors the voltage value in real time and adjusts the output voltage value in real time through its built-in IGBT or SiC drive module, coupling it with a power source such as a battery / capacitor for output.

[0181] On the load side, since the motor 22 is rigidly connected to the fracturing pump 40 through the resultant device 21, the reducer 90, etc., the output speed of the motor 22 is directly proportional to the speed n of the fracturing pump 40. P The transmission ratio between them has a predetermined proportional relationship. The motor controller of the motor 22 obtains DC power from the DC bus assembly 30 through a cable and outputs AC power with controllable frequency and voltage through the inverter module to control the rotation output of the motor 22. At this time, the host computer / PLC of the control system 110 collects and monitors the output values ​​such as the speed and torque of the motor 22 and the fracturing pump 40 in real time through built-in sensors such as the resolver encoder and the speed sensor, pressure sensor, and flow sensor of the fracturing pump 40. The host computer / PLC control strategy adjusts the target speed / torque of the motor 22 in real time, thereby quickly driving the fracturing pump 40 to achieve the output of the fracturing pump 40.

[0182] Among them, considering the flow rate Q of the fracturing pump 40 p =Displacement V p × speed n pSince the displacement is a fixed value, the target speed n can be calculated by setting the target flow rate. p Thus, the target speed n of the motor 22 can be obtained through the transmission ratio. m The motor controller uses n m A PWM wave is output to drive the motor 22 to rotate.

[0183] Furthermore, when the fracturing pump 40 experiences a load impact, such as a rise or fall in wellhead pressure, the host computer / PLC of the control system 110 monitors the system in real time via sensors and adjusts the output power of the motor 22 to follow the load changes. The impact energy is stored in the energy storage component 80, for example, by storing energy in a battery / capacitor to smooth out peaks and valleys, thus achieving energy storage or release. Specifically, when a positive load impact occurs due to a rise in wellhead pressure, energy is stored through the energy storage component 80; when a negative load impact occurs due to a fall in wellhead pressure, energy is released through the energy storage component 80.

[0184] Specifically, when an impact occurs, the impact energy ΔP p = Pressure Δp × Flow rate Q p = Bus voltage U × Supplementary current ΔI. The energy storage components of the energy storage assembly 80, such as batteries / capacitors, need to increase or decrease the supplementary current ΔI based on the original output current, so that the output of the generator 13 remains unchanged, thereby ensuring that the engine 11 always outputs stably at the optimal operating point, achieving stable and efficient engine output.

[0185] However, when the negative load impact on the fracturing pump 40 is too large, it may exceed the storage capacity limit of energy storage components such as batteries / capacitors. At this time, the host computer / PLC of the control system 110 controls the motor 22 to switch to constant power mode according to the actual working condition, actively reducing the speed output of the motor 22 to maintain a high torque output state, thereby resisting load pressure fluctuations, and thus keeping the generator 13 and bus voltage unaffected by the load, and maintaining the stable output operation of the engine 11.

[0186] Specifically, for example, when the wellhead pressure p increases, to ensure that the fracturing pump 40 outputs the same flow rate, the power P... p = Pressure p × Flow rate Q p It can be known that the power P of the fracturing pump 40 p If the power increases, then the power P of the motor 22 will increase. m The speed increases, and according to P (kW) = speed n (rpm) × torque T (Nm) / 9550, it can be seen that if we want to stabilize the speed n of the motor 22 at this time... m Then the output torque T of the motor 22 needs to be increased.m Thus, the host computer / PLC quickly sends an increase torque command to the motor controller, which increases the drive current of the motor 22 to quickly drive the fracturing pump 40 and stabilize the output of the fracturing pump 40. Conversely, the same applies when the wellhead pressure decreases.

[0187] For example, when the fracturing pump flow rate is 10 bmp and the wellhead pressure is increased by 1000 Psi, the power P of the fracturing pump 40 is... p To increase the power output by approximately 180kW, assuming the fracturing pump 40 rotates at 1800rpm, the output torque of the motor 22 would need to increase by approximately 970Nm to balance the input and output power and stabilize the output of the fracturing pump 40.

[0188] The above is just one example of a control strategy. Other control strategies can also use PID or detect the rate of change of speed to regulate output power. The control strategy may vary depending on the actual operating conditions and the actual acquired signals.

[0189] The embodiments disclosed herein can save on the number of equipment and investment costs, making the well site equipment layout more convenient and greatly increasing the flexibility of transportation and on-site arrangement; it eliminates the need for cable routing between gas-fired power generation, energy storage, and electric fracturing equipment at the well site, reducing installation costs; the use of a low-voltage platform improves the electrical safety of the work site; the power generation efficiency is 2%-5% higher than that of asynchronous motors, and it can maintain high efficiency over a wide load range, especially for fracturing under partial load conditions, where the efficiency advantage is obvious, reducing fuel consumption; in addition, the present disclosure can achieve millisecond-level torque response, precise speed control, and huge overload capacity, which is crucial for ensuring the stability of fracturing operation displacement and pressure, and can better execute complex fracturing processes.

[0190] Furthermore, while the operations are described in a specific order, this should not be construed as requiring these operations to be performed in the specific order shown or in a sequential order. In certain environments, multitasking and parallel processing may be advantageous. Similarly, while several specific implementation details are included in the above discussion, these should not be construed as limiting the scope of this disclosure. Certain features described in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments.

[0191] Although the subject matter has been described using language specific to structural features and / or methodological logic, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or actions described above. Rather, the specific features and actions described above are merely illustrative examples of implementing the claims.

[0192] The foregoing has provided a detailed description of several embodiments of this disclosure. However, this disclosure is not limited to these specific embodiments. Those skilled in the art can make various variations and modifications based on the concept of this disclosure, and all such variations and modifications should fall within the scope of protection claimed by this disclosure.

Claims

1. A drive assembly for fracturing equipment, characterized in that, The drive assembly includes a force-combining device and multiple electric motors. The force-combining device contains a parallel shaft gear structure for outputting power to the fracturing pump. The parallel shaft gear structure includes a third shaft and multiple fourth shafts. One end of the third shaft is connected to the fracturing pump or a reduction gearbox. A third gear is mounted on the third shaft. A fourth shaft is mounted on at least one side of the third shaft. The multiple fourth shafts are arranged parallel to the third shaft. A fourth gear that meshes with the third gear is mounted on the fourth shaft. At least one end of the fourth shaft is connected to the electric motor.

2. The drive assembly for fracturing equipment according to claim 1, characterized in that, The third gear has a gear ring structure and internal teeth, and the internal teeth of the third gear mesh with the fourth gear.

3. The drive assembly for fracturing equipment according to claim 1, characterized in that, A second gearbox is provided between the fourth gear and the electric motor.

4. The drive assembly for fracturing equipment according to claim 1, characterized in that, At least one end of the fourth shaft is connected to a plurality of motors, which are arranged in series.

5. The drive assembly for fracturing equipment according to claim 1, characterized in that, The plurality of the fourth axes are arranged symmetrically based on the third axis.

6. The drive assembly for fracturing equipment according to claim 1, characterized in that, The number of motors connected to the different fourth shafts may be the same or different.

7. The drive assembly for fracturing equipment according to claim 1, characterized in that, It also includes a planetary gear structure, which is located downstream of the parallel shaft gear structure and is used to output power.

8. The drive assembly for fracturing equipment according to claim 7, characterized in that, The planetary gear structure includes a sun gear, planet gears, a planet carrier, and a gear ring. The sun gear is connected to the third shaft of the parallel shaft gear structure. The gear ring is kept fixed. The planet carrier is connected to the fracturing pump or the gearbox.

9. The drive assembly for fracturing equipment according to claim 7, characterized in that, The planetary gear structure includes a sun gear, planet gears, a planet carrier, and a gear ring. The sun gear is connected to the third shaft of the parallel shaft gear structure. The planet carrier remains fixed, and the gear ring is connected to the fracturing pump or the gearbox.

10. A drive assembly for fracturing equipment, characterized in that, The drive assembly includes a power combining device and multiple electric motors. The power combining device is equipped with a planetary gear structure and multiple fifth shafts. The planetary gear structure is used to output power to the fracturing pump. The planetary gear structure includes a sun gear, planet gears, a planet carrier, and a gear ring. The sun gear is fixed. The gear ring has external teeth. A fifth gear is provided on the fifth shaft. The fifth gear meshes with the external teeth of the gear ring. At least one end of the fifth shaft is connected to the electric motor. The planet carrier is connected to the fracturing pump or a gearbox.

11. The drive assembly for fracturing equipment according to any one of claims 1-10, characterized in that, The electric motor is a generator / electric motor integrated unit, which is used to brake the fracturing pump and recover kinetic energy when the operation is stopped.

12. A fracturing device, characterized in that, The invention includes a drive assembly and a fracturing pump as described in any one of claims 1-11, wherein the drive assembly is connected to the fracturing pump.

13. The fracturing equipment according to claim 12, characterized in that, It also includes a gearbox, which is disposed between the drive assembly and the fracturing equipment or is a gearbox integrated with the fracturing pump.

14. The fracturing equipment according to claim 12, characterized in that, The fracturing equipment also includes a heat dissipation component, a high-pressure manifold, and a low-pressure manifold, the high-pressure manifold and the low-pressure manifold being connected to the fracturing pump.

15. The fracturing equipment according to claim 12, characterized in that, It also includes a power generation component and a DC bus component, wherein the power generation component is connected to the drive component through the DC bus component.

16. The fracturing equipment according to claim 15, characterized in that, The power generation assembly includes an engine, a transfer case, and multiple generators. The transfer case is equipped with a parallel shaft gear structure, through which the power is received from the engine. Alternatively, the power generation assembly includes multiple engines, each of which is connected to a corresponding generator to form a generator set.

17. The fracturing equipment according to claim 15, characterized in that, The DC bus assembly is connected to the industrial power grid and / or an external generator set.

18. The fracturing equipment according to claim 15, characterized in that, It also includes an energy storage component, which is connected to the DC bus assembly to enable charging and discharging with the DC bus assembly.

19. The fracturing equipment according to claim 12, characterized in that, The fracturing equipment is carried by a semi-trailer, skid, or vehicle.

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