A large flow high pressure unloading valve for an emulsion pump station

Abstract

The utility model discloses an emulsion pump station high -pressure unloading valve of large flow, including valve body, main valve core, deputy valve core, main valve core and deputy valve core constitute dual -path main valve structure, pilot control valve inlet communicates with the liquid inlet of valve body, be equipped with control liquid path in the valve body with the spring cavity of main valve core and the spring cavity of deputy valve core communication, be equipped with throttle hole on control liquid path, the working export of pilot control valve is communicated with the spring cavity of main valve core and deputy valve core through control liquid path, when system pressure reaches the set value, pilot control valve opens, makes the spring cavity of main valve core and deputy valve core unloading pressure through control liquid path, realizes dual -path unloading, the utility model discloses through dual -path main valve structure, under the premise of not increasing single body valve core size greatly, realize the multiplication of total unloading flow, and the flow rate, pressure drop and liquid power that single valve port bears are reduced significantly, and the sealing reliability, pressure stability and anti -scouring ability under the high -pressure large -flow working condition are improved significantly.

Description

Technical Field

[0001] This utility model relates to the technical field of coal mine emulsion pump stations, specifically a high-flow-rate, high-pressure unloading valve for emulsion pump stations. Background Technology

[0002] In underground coal mining, emulsion pump stations serve as the power source for hydraulic equipment such as hydraulic supports and hydraulic pillars, and their performance directly impacts the working face's advancing efficiency and safe production. An emulsion pump station typically consists of an electric motor, an emulsion pump, and an unloading valve, with the unloading valve playing a crucial role.

[0003] The main function of the unloading valve is to automatically open when the discharge pressure of the emulsion pump exceeds the rated pressure, connecting the pump's discharge port to the oil tank, thus putting the pump into an unloading state, preventing pump overload and stabilizing system pressure. With the increasing intensity of coal mining and the faster advance speed of the working face, higher requirements are placed on the flow rate and pressure of emulsion pump stations. To meet the demands of high flow rate and high pressure, existing technologies typically use a single valve with an increased pipe diameter to increase flow rate. However, this traditional method has the following problems:

[0004] While increasing the valve diameter can theoretically increase flow rate, in practical applications, limitations imposed by valve structure and sealing performance lead to decreased sealing performance after the valve opening widens, making leakage and pressure instability more likely. Furthermore, large-diameter unloading valves are structurally more complex, require higher machining and assembly precision, and significantly increase costs.

[0005] Furthermore, under high pressure and high flow conditions, traditional unloading valves experience accelerated wear on the valve core and seat, and the sealing surface is easily eroded and damaged, leading to reduced valve reliability and lifespan. Moreover, the rapid movement of the valve core during opening and closing of existing unloading valves can easily generate impacts and vibrations, affecting the valve's stability and sealing performance.

[0006] In summary, traditional high-flow-rate, high-pressure unloading valves have shortcomings in terms of performance and reliability. There is a need for a new type of unloading valve that is simple in structure, can handle large flow rates, can maintain high-pressure sealing stability, and has a long service life to meet the needs of coal mining. Summary of the Invention

[0007] The technical problem to be solved by this utility model is to provide a high-flow-rate, high-pressure unloading valve for emulsion pump stations that is compact in structure, stable in operation, and has a long service life, in order to overcome the shortcomings of the prior art. This high-flow-rate, high-pressure unloading valve for emulsion pump stations achieves a doubling of the total unloading flow rate without significantly increasing the size of the individual valve core through an innovative dual-path parallel main valve structure. The dual valves share the system pressure and flow, and the flow velocity, pressure drop, and hydraulic force borne by a single valve port are significantly reduced, which significantly improves the sealing reliability, pressure stability, and erosion resistance under high pressure and high flow conditions.

[0008] To achieve the above-mentioned technical objectives, the technical solution adopted by this utility model is as follows:

[0009] A high-flow-rate, high-pressure unloading valve for an emulsion pump station includes a valve body, a main valve core, a secondary valve core, a pilot control valve, and an inlet, a high-pressure outlet, and an unloading port located on the valve body.

[0010] The main valve core and the auxiliary valve core are independently and symmetrically arranged in the valve body, respectively controlling the two parallel main liquid paths that flow out from the liquid inlet, forming a dual-path main valve structure; when the main valve core and the auxiliary valve core are opened, both parallel main liquid paths are connected to the unloading port.

[0011] The pilot control valve is installed on the valve body, and its inlet is connected to the liquid inlet.

[0012] The valve body is provided with a control fluid path that communicates with the spring cavity of the main valve core and the spring cavity of the auxiliary valve core simultaneously, and a throttling orifice is provided on the control fluid path;

[0013] The working outlet of the pilot control valve is connected to the control fluid circuit and simultaneously to the spring chamber of the main valve core and the spring chamber of the auxiliary valve core.

[0014] When the system pressure reaches the set value, the pilot control valve opens, and the spring chambers of the main valve core and the auxiliary valve core are simultaneously depressurized through the control fluid circuit. The main valve core and the auxiliary valve core open synchronously under the action of the pressure difference at their respective ends, realizing simultaneous unloading of both circuits.

[0015] As a further improvement to this utility model, it also includes an overflow valve;

[0016] The oil inlet of the overflow valve is connected to the liquid inlet on the valve body; the oil outlet of the overflow valve is connected to the unloading port on the valve body.

[0017] When the system pressure exceeds the unloading set pressure, or when at least one of the main valve core and the auxiliary valve core fails to open normally, the relief valve opens, forming an additional unloading channel.

[0018] As a further improvement of this utility model, the technical solution also includes an upper valve cover, a main valve spring, a secondary valve spring, a main valve housing, and a secondary valve housing;

[0019] The valve body has two independent and symmetrically arranged upper valve chambers;

[0020] The main valve core is housed in a main valve housing installed in the upper valve chamber on one side, and the auxiliary valve core is housed in an auxiliary valve housing installed in the upper valve chamber on the other side.

[0021] The main valve spring is disposed between the main valve core and the upper valve cover, and the auxiliary valve spring is disposed between the auxiliary valve core and the upper valve cover;

[0022] The upper valve cover is fixedly installed on the top of the valve body, and the main valve shell, the auxiliary valve shell, the main valve spring and the auxiliary valve spring are pressed and fixed in their respective upper valve chambers, so that the main valve spring and the auxiliary valve spring are in a pre-compressed state.

[0023] The lower end face of the main valve core forms the unloading valve port of the first main liquid path, and its opening and closing controls the connection and disconnection between the first main liquid path and the first unloading passage; wherein, the first main liquid path is connected to the liquid inlet on the valve body, and the first unloading passage is connected to the unloading port on the valve body.

[0024] The lower end face of the auxiliary valve core forms the unloading valve port of the second main liquid path, and its opening and closing controls the connection and disconnection between the second main liquid path and the second unloading passage; wherein, the second main liquid path is connected to the liquid inlet on the valve body, and the second unloading passage is connected to the unloading port on the valve body.

[0025] As a further improvement of this utility model, a main valve seat is provided on the main valve housing along the movement path of the main valve core. When the main valve core is in the closed position, its lower sealing surface fits against the main valve seat to form a seal. The lower sealing surface of the main valve core adopts a chamfered sealing structure.

[0026] Along the movement path of the secondary valve core, a secondary valve seat is provided on the secondary valve housing. When the secondary valve core is in the closed position, its lower sealing surface fits against the secondary valve seat to form a seal. The lower sealing surface of the secondary valve core adopts a chamfered sealing structure.

[0027] As a further improvement of this utility model, the stiffness coefficient of the main valve spring and the auxiliary valve spring is 6.2 N / mm, and the preload is 140N.

[0028] As a further improvement of the present invention, the main valve core, the main valve shell, the main valve seat on the main valve shell, the auxiliary valve core, the auxiliary valve shell, the auxiliary valve seat on the auxiliary valve shell, and the overflow valve core and overflow valve seat in the overflow valve are all made of TA4 material.

[0029] As a further improvement of the present invention, the control fluid path provided in the valve body that is connected to the spring cavity of the main valve core and the spring cavity of the auxiliary valve core is referred to as control fluid path one. The upper valve cover is provided with control fluid path two. The control fluid path one of the valve body is connected to the control fluid path two of the upper valve cover. A throttling orifice is provided at one end of the control fluid path one of the valve body that is connected to the control fluid path two of the valve body. A throttling orifice is provided at one end of the control fluid path two of the upper valve cover that is connected to the control fluid path one of the valve body. The two throttling orifices are connected to each other.

[0030] The working outlet of the pilot control valve is connected in sequence to the spring cavity of the main valve core and the spring cavity of the auxiliary valve core through the control fluid circuit control fluid circuit one, the throttling orifice at one end of the control fluid circuit control fluid circuit one, the throttling orifice at one end of the control fluid circuit control fluid circuit two, and the control fluid circuit control fluid circuit two.

[0031] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0032] 1. High Flow Capacity: This utility model adopts a dual-path parallel main valve structure, with the total unloading flow area equivalent to the sum of the two valve ports. Without increasing the size of a single valve core or sacrificing sealing performance, the unloading valve can discharge more emulsion per unit time, achieving a doubling of the unloading flow rate and meeting the unloading requirements of pumping stations under high flow conditions. This is particularly beneficial for high-speed working faces, enabling timely unloading of the pump's high pressure, avoiding prolonged high-pressure operation, and improving the working efficiency and reliability of the pumping station.

[0033] 2. High-Pressure Stability and Sealing Performance: The dual-path main valve structure not only increases the flow area and improves the unloading flow rate, but also allows the two hydraulic paths to operate in parallel, reducing the flow and pressure load on a single valve, lowering the flow velocity and pressure drop at the valve port, which is beneficial for improving valve stability and lifespan. The dual valves share system pressure and flow, reducing the flow velocity and pressure gradient at each valve port, minimizing wear and impact between the valve core and seat, and significantly reducing the flow velocity, pressure drop, and hydraulic force on a single valve port. Combined with a precision chamfered sealing structure and wear-resistant materials such as TA4, the valve's wear resistance and erosion resistance are improved. Individual valve ports provide more reliable sealing under high pressure, with less leakage and significantly reduced system pressure fluctuations. This avoids the problem of decreased sealing performance caused by excessive opening of a single valve port.

[0034] 3. High Reliability and Long Lifespan: The pilot control valve's working outlet is simultaneously connected to the spring chambers of both the main valve core and the auxiliary valve core via the control fluid circuit, ensuring the synchronicity of the main and auxiliary valve core movements and preventing single-valve overload and system shock caused by sequential opening. The relief valve serves as an independent backup, providing fail-safe protection. Dual-path flow diversion reduces erosion and wear on individual valves, extending overall lifespan.

[0035] 4. Compact Structure and Smooth Operation: Although employing dual valves (main valve core and auxiliary valve core), the overall structure is compact with minimal increase in size and weight thanks to symmetrical design and integrated layout. The symmetrical design and integrated layout ensure coordinated operation of all components, reducing external piping connections and improving system reliability and ease of installation. Pilot control combined with throttling damping (throttling orifice) ensures smooth opening and closing of the main and auxiliary valve cores, effectively reducing hydraulic shock and vibration, resulting in smoother system operation, higher stability, and better sealing performance.

[0036] 5. Long service life and maintenance: The valve adopts pilot valve control, and the main valve core moves smoothly, avoiding the impact and vibration caused by high-speed operation, thus extending the service life of the valve. The spring parameters of the main valve spring and the auxiliary valve spring are consistent, which facilitates debugging and replacement. Attached Figure Description

[0037] Figure 1 This is a front view of the high-flow-rate, high-pressure unloading valve for the emulsion pump station of this utility model.

[0038] Figure 2 for Figure 1 Sectional view of AA.

[0039] Figure 3 This is a left view of the high-flow-rate, high-pressure unloading valve for the emulsion pump station of this utility model.

[0040] Figure 4 for Figure 3 BB cross-section diagram.

[0041] Figure 5 This is a front view of the pilot control valve of the high-flow-rate, high-pressure unloading valve for the emulsion pump station of this utility model.

[0042] Figure 6 for Figure 5 CC cross-section view.

[0043] Figure 7 This is a schematic diagram of the pressure flow of the internal control fluid circuit of the valve body of this utility model. Detailed Implementation

[0044] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings:

[0045] A high-flow, high-pressure unloading valve for emulsion pump stations, such as Figure 1 As shown, it includes unloading valve main valve 1, pilot control valve 2 and relief valve 3.

[0046] like Figure 2As shown, the unloading valve main valve 1 includes an upper valve cover 5, a valve body 6, a lower valve cover 7, a secondary valve housing 8, a main valve housing 9, a secondary valve core 10, a secondary valve spring 11, a main valve core 12, a main valve spring 13, a one-way secondary valve housing 14, a one-way secondary valve seat 15, a one-way secondary valve core 16, a one-way secondary valve spring 17, a one-way main valve housing 18, a one-way main valve seat 19, a one-way main valve core 20, and a one-way main valve spring 21. The upper valve cover 5 is connected and fixed to the valve body 6 by top bolts, pressing the secondary valve housing 8, main valve housing 9, secondary valve core 10, secondary valve spring 11, main valve core 12, and main valve spring 13 into the valve cavity of the valve body 6. The lower valve cover 7 is connected and fixed to the valve body 6 by bottom bolts, pressing the one-way auxiliary valve housing 14, one-way auxiliary valve seat 15, one-way auxiliary valve core 16, one-way auxiliary valve spring 17, one-way main valve housing 18, one-way main valve seat 19, one-way main valve core 20, and one-way main valve spring 21 into the lower valve cavity of the valve body 6.

[0047] like Figure 2 As shown, the structure of the overflow valve 3 can adopt existing technology, including an upper overflow valve cover 22, an overflow spring seat 23, an overflow spring 24, an overflow valve sleeve 25, an overflow valve stem 26, an overflow valve core 27, an overflow valve seat 28, and an lower overflow valve cover 29. The spring seat 23 is fixed to the upper overflow valve cover 22 by a threaded connection, and the upper overflow valve cover 22 is fixed to the overflow valve body by cover bolts, pressing the spring seat 23, overflow spring 24, overflow valve sleeve 25, overflow valve stem 26, overflow valve core 27, and overflow valve seat 28 into the overflow valve cavity.

[0048] like Figure 3-6As shown, the pilot control valve 2 can adopt an existing structure, including a pilot valve body 30, a pilot plug 31, a filter element positioning post 32, a filter element 33, a flange 34, an M10 plug 35, an M24 plug 36, a piston rod 37, a piston sleeve 38, a pilot valve seat 39, a pilot valve core 40, a pilot valve sleeve 41, a pilot spring seat 42, a pilot spring 43, a pressure regulating seat 44, a clamping plug 45, a pressure regulating screw 46, an M16 locking nut 1 47, an M28 plug 48, an M12 screw 49, a shut-off valve core 50, an A inner nest 51, an M30 clamping plug 52, a pressure regulating screw 53, an M16 locking nut 2 54, a hydraulic circuit switching valve core 55, a B inner nest 56, a C inner nest 57, and a hydraulic circuit switching spring 58. An O-ring is fitted onto the pilot valve body 30 via a threaded connection to seal the process orifice. The piston sleeve 38 houses the piston rod 37, and the M24 plug 36 presses the piston sleeve 38 and piston rod 37 into the pilot valve body 30 via its bottom thread. The clamping plug 45 presses the pilot valve seat 39, pilot valve core 40, pilot valve sleeve 41, pilot spring seat 42, pilot spring 43, and pressure regulating seat 44 into the pilot valve body 30. The pressure regulating screw 46 is threaded to the clamping plug 45. Adjusting the depth of the pressure regulating screw 46 causes the pressure regulating seat 44 to deform the pilot spring 43, thereby adjusting the stroke of the pilot spring seat 42 to regulate the unloading pressure of the large-flow unloading valve. The M16 locking nut 47 is threaded to the pressure regulating screw 46 and serves to fix the pressure regulating screw 46 after pressure adjustment. M28 plug 48 is threaded to pilot valve body 30, pressing shut-off valve core 50 and A inner nest 51 inside pilot valve body 30. Two M12 screws 49 are threaded to the middle thread of M28 plug 48. By removing one M12 screw 49 and loosening it until it is flush with the end face of M28 plug 48, the stroke of shut-off valve core 50 is adjusted to mechanical unloading mode. M30 clamping plug 52 is threaded to pilot valve body 30, pressing hydraulic switching valve core 55, B inner nest 56, C inner nest 57, and hydraulic switching spring 58 into pilot valve body 30. Pressure adjusting screw 53 is threaded to M30 clamping plug 52. By loosening pressure adjusting screw 53, hydraulic switching spring 58 pushes hydraulic switching valve core 55 outward, thereby manually switching to mechanical unloading mode; tightening switches to electromagnetic mode.

[0049] like Figure 2 and Figure 4 As shown, the valve body 6 is provided with an inlet 601, a high-pressure outlet 603, and an unloading port 602.

[0050] like Figure 2As shown, the main valve core 12 and the auxiliary valve core 10 are independently and symmetrically arranged within the valve body 6. They control the two parallel main liquid paths that branch off from the inlet 601, forming a dual-path main valve structure. When the main valve core 12 and the auxiliary valve core 10 are opened, both parallel main liquid paths are connected to the unloading port 602.

[0051] The pilot control valve 2 is installed on the valve body 6, and its inlet is connected to the liquid inlet 601.

[0052] The valve body 6 is provided with a control fluid path that communicates with both the spring cavity of the main valve core 12 and the spring cavity of the auxiliary valve core 10. The working outlet of the pilot control valve 2 is connected to both the spring cavity of the main valve core 12 and the spring cavity of the auxiliary valve core 10 through the control fluid path.

[0053] When the system pressure reaches the set value, the pilot control valve 2 opens, and the spring chambers of the main valve core 12 and the auxiliary valve core 10 are simultaneously depressurized through the control fluid circuit. The main valve core 12 and the auxiliary valve core 10 open synchronously under the action of the pressure difference at their respective ends, realizing simultaneous unloading of both circuits.

[0054] Specifically, the valve body 6 has two independent and symmetrically arranged upper valve chambers. The main valve core 12 is housed in the main valve housing 9 installed in one upper valve chamber, and the auxiliary valve core 10 is housed in the auxiliary valve housing 8 installed in the other upper valve chamber. The main valve spring 13 is disposed between the main valve core 12 and the upper valve cover 5, and the auxiliary valve spring 11 is disposed between the auxiliary valve core 10 and the upper valve cover 5. The upper valve cover 5 is fixedly installed on the top of the valve body 6, and presses and fixes the main valve housing 9, the auxiliary valve housing 8, the main valve spring 13, and the auxiliary valve spring 11 into their respective upper valve chambers, so that the main valve spring 13 and the auxiliary valve spring 11 are in a pre-compressed state.

[0055] The lower end face of the main valve core 12 forms an unloading valve port for the first main liquid path, and its opening and closing controls the connection and disconnection between the first main liquid path and the first unloading passage. The first main liquid path is connected to the inlet 601 on the valve body 6, and the first unloading passage is connected to the unloading port 602 on the valve body 6. The lower end face of the auxiliary valve core 10 forms an unloading valve port for the second main liquid path, and its opening and closing controls the connection and disconnection between the second main liquid path and the second unloading passage. The second main liquid path is connected to the inlet 601 on the valve body 6, and the second unloading passage is connected to the unloading port 602 on the valve body 6.

[0056] Along the movement path of the main valve core 12, a main valve seat is provided on the main valve housing 9. When the main valve core 12 is in the closed position, its lower sealing surface fits against the main valve seat to form a seal; the lower sealing surface of the main valve core 12 adopts a chamfered sealing structure. Along the movement path of the auxiliary valve core 10, a secondary valve seat is provided on the secondary valve housing 8. When the auxiliary valve core 10 is in the closed position, its lower sealing surface fits against the secondary valve seat to form a seal; the lower sealing surface of the secondary valve core 10 adopts a chamfered sealing structure.

[0057] like Figure 7 As shown, the control fluid path provided in the valve body 6, which is connected to the spring cavity of the main valve core 12 and the spring cavity of the auxiliary valve core 10, is denoted as control fluid path one a. The upper valve cover 5 is provided with control fluid path two b. The tail end of control fluid path two b includes two branch oil paths that are respectively connected to the spring cavity of the main valve core 12 and the spring cavity of the auxiliary valve core 10. The control fluid path one a of the valve body 6 is connected to the control fluid path two b on the upper valve cover 5. A throttling orifice a1 is provided at the end of the valve body 6 where control fluid path one a is connected to control fluid path two b. A throttling orifice a1 is provided at the end of the upper valve cover 5 where control fluid path two b is connected to control fluid path one a. The two throttling orifices a1 are connected to each other. The diameter of the throttling orifice a1 is the size of a pinhole. The working outlet of the pilot control valve 2 is connected to the spring cavity of the main valve core 12 and the spring cavity of the auxiliary valve core 10 in sequence through the control fluid circuit control fluid circuit one a, the throttle orifice a1 at one end of the control fluid circuit control fluid circuit one a, the throttle orifice a1 at one end of the control fluid circuit control fluid circuit two b, and the control fluid circuit control fluid circuit two b.

[0058] Within the lower valve chamber of the valve body 6, a one-way valve assembly is installed, consisting of a one-way main valve core 20, a one-way main valve seat 19, a one-way auxiliary valve core 16, and a one-way auxiliary valve seat 15, and is enclosed by a lower valve cover 7. This assembly allows liquid to flow from the inlet 601 to the outlet and prevents reverse flow.

[0059] An overflow valve 3 is installed on the valve body 6. The oil inlet of the overflow valve 3 is connected to the liquid inlet 601 on the valve body 6; the oil outlet of the overflow valve 3 is connected to the unloading port 602 on the valve body 6. When the system pressure exceeds the unloading set pressure, or when at least one of the main valve core 12 and the auxiliary valve core 10 fails to open normally, the overflow valve 3 opens, forming an additional unloading channel.

[0060] The pilot control valve 2 is mounted on the side of the valve body 6 via a flange or threads. Its internal core includes: a control piston consisting of a piston rod 37 and a piston sleeve 38, used to sense system pressure from the inlet 601; a pilot valve core 40 and a pilot valve seat 39, used to control the opening and closing of the pilot oil circuit; a pressure regulating spring 43, used to set the pressure; and a pressure regulating mechanism including a pressure regulating screw 46 and a locking nut 47. In addition, a manual / automatic mode switching mechanism composed of a liquid circuit switching valve core 55 is integrated.

[0061] Work process:

[0062] 1. Loading and Supplying Liquid: The pump station is started. The pressurized emulsion enters the valve body 6 through inlet 601, dividing into two main liquid paths. It then flows through the internal oil passage of valve body 6 to the inlet of pilot control valve 2. From there, it passes through oil passage c within pilot control valve 2 into the chamber containing pilot plug 31. After filtration by filter element 33, it flows through oil passage 2 within pilot control valve 2 into shut-off valve core 50. At this point, one M12 screw 49 has been removed. Shut-off valve core 50 moves under hydraulic pressure. The liquid inside shut-off valve core 50 flows through oil passage 3 within pilot control valve 2 into the chamber containing M24 plug 36. It then flows through the internal oil passage of M24 plug 36 into the chamber containing piston rod 37, applying hydraulic pressure to piston rod 37. Simultaneously, liquid flows from inlet 601 into the inlet of overflow valve 3. When the pressure in the main and auxiliary hydraulic circuits (system pressure) does not reach the set pressure of the pilot control valve 2 (i.e., the thrust of the piston rod 37 is insufficient to overcome the force of the pressure regulating spring 43), the pilot control valve 2 does not work and is in the closed state. At this time, the pressure in the spring chambers of the auxiliary valve core 10 and the main valve core 12 is maintained equal to the inlet pressure by the throttle orifice a1. The auxiliary valve core 10 and the main valve core 12 are closed under the action of the spring force. Under the action of the pressurized emulsion, the one-way auxiliary valve spring 17 and the one-way main valve spring 21 are squeezed and contracted by the one-way auxiliary valve core 16 and the one-way main valve core 20, and the one-way auxiliary valve core 16 and the one-way main valve 20 are opened. The high-pressure emulsion is supplied to the hydraulic system from the high-pressure outlet 603.

[0063] 2. Unloading State: When the system pressure rises to the set value of pilot control valve 2 (by pre-loosening the pressure regulating screw 53, the hydraulic switching spring 58 can push the hydraulic switching valve core 55 outward, thus achieving mechanical unloading mode), the hydraulic pressure acting on the piston rod 37 pushes the pilot valve core 40 open. After the pilot control valve 2 opens, the pressure in the spring chambers of the main valve core 12 and the auxiliary valve core 10 can be quickly released through control hydraulic circuit two b, control hydraulic circuit one a, and the opened pilot valve port (i.e., the pressure is quickly released to the high-pressure outlet through control hydraulic circuit two b, control hydraulic circuit one a, the chamber where the opened pilot valve core 40 is located, oil circuit four d, the chamber where the hydraulic switching valve core 55 is located, and oil circuit five e). The pressure in the spring chamber drops sharply, while the lower ends of the main valve core 12 and the auxiliary valve core 10 still bear the system high pressure. Under this pressure difference, the main valve core 12 and the auxiliary valve core 10 move upward synchronously, opening the two main unloading channels. The high-flow-rate, high-pressure emulsion discharged by the pump then flows directly into the unloading passage of valve body 6 through these two open channels, and is quickly discharged back to the oil tank from the unloading port 602, and the pump enters the low-pressure unloading operation state.

[0064] 3. Safety Backup: If a malfunction, such as jamming of the main valve core 12, prevents the unloading valve 10 from opening properly, the system pressure will continue to rise. This high pressure is transmitted to the oil inlet of the relief valve 3. When the pressure exceeds the set force of the relief spring 24, the relief valve core 27 opens, forming an additional pressure relief channel to ensure system safety.

[0065] 4. Resumption of Loading: When the system pressure drops below the set pressure of pilot control valve 2 (i.e., the thrust of piston rod 37 is insufficient to overcome the force of pressure regulating spring 43), pilot valve core 40 closes under the action of pressure regulating spring 43, and piston rod 37 returns to its original position. The spring chambers of main valve core 12 and auxiliary valve core 10 are repressurized. When the pressure in the upper and lower chambers returns to equilibrium, main valve core 12 and auxiliary valve core 10 reset and close under the action of their respective springs, cutting off the two main unloading channels. The pump output pressure opens the check valve again and supplies liquid to the system through the high-pressure outlet, starting a new working cycle. This process realizes the automatic switching between pump unloading and loading, reducing power consumption during system standby.

[0066] Key parameters and materials:

[0067] Main valve spring 13 and auxiliary valve spring 11: stiffness 6.2 N / mm, preload 140N, to ensure consistent opening pressure of the two valves.

[0068] Pilot spring 43: stiffness 20 N / mm, with a certain preload, used to set the system unloading pressure.

[0069] Overflow spring 24: stiffness 6.5 N / mm, with a certain preload, used to set safety pressure.

[0070] Liquid inlet size: φ50, depth 100mm. High pressure outlet size: φ45, depth 50mm. Overflow outlet size: φ45, depth 50mm.

[0071] The main pressure-bearing and wear-resistant parts, such as: auxiliary valve housing 8, main valve housing 9, auxiliary valve core 10, main valve core 12, one-way auxiliary valve housing 14, one-way auxiliary valve seat 15, one-way auxiliary valve core 16, one-way main valve housing 18, one-way main valve seat 19, one-way main valve core 20, overflow valve sleeve 25, overflow valve stem 26, overflow valve core 27, overflow valve seat 28, etc., can all be made of TA4 titanium alloy.

[0072] Components such as pilot valve sleeve 41, B inner nest 56, C inner nest 57, and A inner nest 51 are all made of H62 brass.

[0073] All springs are made of 1Cr18Ni9Ti stainless steel.

[0074] Through the above-described specific design, this utility model achieves a high-flow, high-pressure, stable, and highly reliable unloading function, and is particularly suitable for emulsion pump station systems in modern high-yield and high-efficiency coal mines.

[0075] The scope of protection of this utility model includes, but is not limited to, the above embodiments. The scope of protection of this utility model is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art shall fall within the scope of protection of this utility model.

Claims

1. A high-flow-rate, high-pressure unloading valve for an emulsion pump station, comprising a valve body (6), a main valve core (12), a secondary valve core (10), a pilot control valve (2), and an inlet (601), a high-pressure outlet (603), and an unloading port (602) disposed on the valve body (6). Its features are: The main valve core (12) and the auxiliary valve core (10) are independently and symmetrically arranged in the valve body (6), respectively controlling the two parallel main liquid paths that flow out from the liquid inlet (601), forming a dual-path main valve structure; when the main valve core (12) and the auxiliary valve core (10) are opened, the two parallel main liquid paths are connected to the unloading port (602); The pilot control valve (2) is installed on the valve body (6), and its inlet is connected to the liquid inlet (601); The valve body (6) is provided with a control fluid path that is connected to the spring cavity of the main valve core (12) and the spring cavity of the auxiliary valve core (10) at the same time. A throttling orifice (a1) is provided on the control fluid path. The working outlet of the pilot control valve (2) is simultaneously connected to the spring cavity of the main valve core (12) and the spring cavity of the auxiliary valve core (10) through the control fluid circuit; When the system pressure reaches the set value, the pilot control valve (2) opens, and the spring chambers of the main valve core (12) and the auxiliary valve core (10) are simultaneously depressurized through the control fluid circuit. The main valve core (12) and the auxiliary valve core (10) open synchronously under the action of the pressure difference at their respective ends, realizing simultaneous unloading of both circuits.

2. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 1, characterized in that, It also includes an overflow valve (3); The oil inlet of the overflow valve (3) is connected to the liquid inlet (601) on the valve body (6); the oil outlet of the overflow valve (3) is connected to the unloading port (602) on the valve body (6). When the system pressure exceeds the unloading set pressure, or when at least one of the main valve core (12) and the auxiliary valve core (10) fails to open normally, the overflow valve (3) opens to form an additional unloading channel.

3. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 2, characterized in that, It also includes an upper valve cover (5), a main valve spring (13), a secondary valve spring (11), a main valve housing (9), and a secondary valve housing (8). The valve body (6) has two independent and symmetrically arranged upper valve chambers; The main valve core (12) is housed in the main valve housing (9) installed in the upper valve chamber on one side, and the auxiliary valve core (10) is housed in the auxiliary valve housing (8) installed in the upper valve chamber on the other side. The main valve spring (13) is disposed between the main valve core (12) and the upper valve cover (5), and the auxiliary valve spring (11) is disposed between the auxiliary valve core (10) and the upper valve cover (5); The upper valve cover (5) is fixedly installed on the top of the valve body (6), and the main valve shell (9), the auxiliary valve shell (8), the main valve spring (13) and the auxiliary valve spring (11) are pressed and fixed in their respective upper valve chambers, so that the main valve spring (13) and the auxiliary valve spring (11) are in a pre-compressed state. The lower end face of the main valve core (12) forms the unloading valve port of the first main liquid path, and its opening and closing controls the connection and cut-off between the first main liquid path and the first unloading passage; wherein, the first main liquid path is connected to the liquid inlet (601) on the valve body (6), and the first unloading passage is connected to the unloading port (602) on the valve body (6). The lower end face of the secondary valve core (10) forms the unloading valve port of the second main liquid path, and its opening and closing controls the connection and cut-off between the second main liquid path and the second unloading passage; wherein, the second main liquid path is connected to the liquid inlet (601) on the valve body (6), and the second unloading passage is connected to the unloading port (602) on the valve body (6).

4. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 3, characterized in that, On the movement path of the main valve core (12), a main valve seat is provided on the main valve housing (9). When the main valve core (12) is in the closed position, its lower sealing surface is in contact with the main valve seat to form a seal. The lower sealing surface of the main valve core (12) adopts a chamfered sealing structure. On the movement path of the secondary valve core (10), a secondary valve seat is provided on the secondary valve housing (8). When the secondary valve core (10) is in the closed position, its lower sealing surface fits against the secondary valve seat to form a seal. The lower sealing surface of the secondary valve core (10) adopts a chamfered sealing structure.

5. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 3, characterized in that, The stiffness coefficient of the main valve spring (13) and the auxiliary valve spring (11) is 6.2 N / mm, and the preload is 140 N.

6. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 3, characterized in that, The main valve core (12), main valve housing (9), main valve seat on the main valve housing (9), auxiliary valve core (10), auxiliary valve housing (8), auxiliary valve seat on the auxiliary valve housing (8), and the overflow valve core and overflow valve seat in the overflow valve (3) are all made of TA4 material.

7. The high-flow-rate, high-pressure unloading valve for emulsion pump stations according to claim 3, characterized in that, The control fluid path provided in the valve body (6) that is connected to the spring cavity of the main valve core (12) and the spring cavity of the auxiliary valve core (10) is called control fluid path one (a). The upper valve cover (5) is provided with control fluid path two (b). The control fluid path one (a) of the valve body (6) is connected to the control fluid path two (b) on the upper valve cover (5). The end of the valve body (6) where control fluid path one (a) is connected to control fluid path two (b) is provided with a throttling orifice (a1). The end of the upper valve cover (5) where control fluid path two (b) is connected to control fluid path one (a) is provided with a throttling orifice (a1). The two throttling orifices (a1) are connected to each other. The working outlet of the pilot control valve (2) is connected to the spring cavity of the main valve core (12) and the spring cavity of the auxiliary valve core (10) in sequence through the control fluid path one (a), the throttle hole (a1) at one end of the control fluid path one (a), the throttle hole (a1) at one end of the control fluid path two (b) and the control fluid path two (b).

Images