Rotary Drilling Rig Test Bench for Dynamic Load Commissioning
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Solution Overview
Problem
Existing rotary drilling rig commissioning methods fail to accurately simulate actual working conditions, particularly in terms of load changes and parameter monitoring, and lack comprehensive performance testing capabilities.
Innovation Solution
A test device incorporating dynamometer motors, torque transmission gearboxes, speed-increasing gearboxes, and a hydraulic loading system, connected to a computer software control system, simulates actual working conditions with high-frequency load changes and monitors multiple parameters, including torque, rotational speed, and hydraulic pressures, while recycling energy through power feedback technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hydraulic dynamometer is used for commissioning, then torque, rotational speed, and power parameters can be detected online, but the load is relatively stable with slow loading speed and cannot simulate abrupt load changes due to stratigraphic fluctuations
Solution Approach 1:
The patent replaces the traditional hydraulic dynamometer with an electric dynamometer that uses electromagnetic braking force to simulate load. This substitution enables the system to rapidly adjust loading conditions and simulate abrupt load changes that occur during actual drilling operations, while maintaining the capability to accurately measure torque, rotational speed, and power parameters.
Solution Approach 2:
The patent implements a dynamic loading system that can rapidly change load conditions to simulate actual working conditions including high-frequency alternating loads and abrupt load changes. The electric dynamometer with electromagnetic braking can adjust loading speed and magnitude dynamically, unlike the stable but slow-response hydraulic system.
2Area of stationary object
If borehole commissioning is used, then space occupation is reduced, but the torque is limited to only 20% of designed value and cannot determine whether technical parameters meet design requirements
Solution Approach 1:
The patent creates an integrated test bed that combines multiple functions: it can apply full design torque loads (unlike borehole commissioning limited to 20%), simulate various working conditions including abrupt load changes, and comprehensively test technical parameters. This multi-functional system eliminates the need for separate commissioning methods while providing superior testing capability.
3Reliability
If comprehensive parameter monitoring is implemented during commissioning, then the complete machine performance can be evaluated, but the device complexity and data processing requirements increase significantly
Solution Approach 1:
The patent implements a computer-based control and monitoring system that collects data from multiple sensors measuring torque, rotational speed, power, hydraulic parameters, and engine performance. The system provides real-time feedback and processes comprehensive data to evaluate complete machine performance, making the complexity manageable through automated control and analysis.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device accurately simulates actual working conditions, monitors critical parameters, and recycles energy, providing high-frequency load simulation and energy savings, thus optimizing product design and improving performance and reliability.
Implementation Method 1
a hydraulic loading cylinder connected to a hydraulic station through a hydraulic pipe
Implementation Method 2
a torque sensor connected to the computer software control system
Implementation Method 3
a tension-pressure sensor connected to the computer software control system
Implementation Method 4
dynamometer motors provided on a foundation
Implementation Method 5
a water-cooling resistance box connected to the power grid in parallel with the dynamometer motors
Data Source
AI summary
A test device for testing and commissioning comprehensive performance of a rotary drilling rig is provided. Dynamometer motors in the test device are provided on a foundation. A torque transmission gearbox is fixed on a gearbox anchoring plate through a gearbox adapter plate. A speed-increasing corner gearbox is provided on the torque transmission gearbox and connected to the dynamometer motors through a transmission shaft, a torque sensor, and a motor coupling sequentially. A drive sleeve is provided in a connecting shaft of the torque transmission gearbox. A lower end of the drive sleeve is connected to a hydraulic loading cylinder through a rotating bearing, a rotating support, and a tension-pressure sensor. The rotating support is fixed in the foundation. The hydraulic loading cylinder is connected to a hydraulic station through a hydraulic pipe. The tension-pressure sensor and a pressure control valve are connected to a computer software control system.