CN113431769A - Reciprocating pump quick-wear part life test device - Google Patents
Reciprocating pump quick-wear part life test device Download PDFInfo
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- CN113431769A CN113431769A CN202110624043.7A CN202110624043A CN113431769A CN 113431769 A CN113431769 A CN 113431769A CN 202110624043 A CN202110624043 A CN 202110624043A CN 113431769 A CN113431769 A CN 113431769A
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- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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Abstract
The invention relates to the technical field of service life detection of reciprocating pumps, in particular to a service life testing device for quick-wear parts of a reciprocating pump. The stepped plug body comprises a small-head plug, a working plug, an energy storage plug and an additional plug rod; the cylinder sleeve cavity is divided into a pressure exchange transition cavity, a simulation pump cavity, a cavity discharging cavity and a high-pressure energy storage cavity; the evacuation cavity has a normal pressure environment; a high-pressure energy storage liquid inlet valve and a high-pressure energy storage liquid outlet valve are arranged at the high-pressure energy storage cavity; a high-pressure liquid inlet valve and a high-pressure liquid outlet valve which forms a tested piece are arranged at the simulated pump cavity; the high-pressure energy-storage liquid inlet valve and the high-pressure liquid outlet valve are communicated with each other through a pump cavity discharge high-pressure pipe, and the high-pressure energy-storage liquid outlet valve and the high-pressure liquid inlet valve are communicated with each other through a pump cavity suction high-pressure pipe. The invention can completely simulate the actual flow condition in the pump cavity, and the valve group, the column/piston, the corresponding cylinder sleeve and the corresponding filler which are used as the tested piece are not or only rarely influenced by the flow, the pressure and especially the power of the pump, thereby finally realizing the purpose of accurately, quickly and cheaply completing the service life test.
Description
Technical Field
The invention relates to the technical field of service life detection of reciprocating pumps, in particular to a service life testing device for quick-wear parts of a reciprocating pump.
Background
The stability and the service life of the one-way valve group and the column/piston in the reciprocating pump are directly determined by the performance and the reliability of the pump as core parts and wearing parts of the one-way valve group and the column/piston. Once the valve block and the column/piston fail, they can cause pump pressure and flow to drop, resulting in pump failure. So far, due to the limitation of various factors and conditions such as life test cost, verification method and the like, in most cases, no effective method and means for obtaining the service life of the valve bank and the column/piston are available. At present, most of service life data of the check valve group and the column/piston of the reciprocating pump are obtained by theoretical analysis and comparison, field tests and other methods, and the data sources are either insufficient in accuracy and fuzzy in guidance, or too high in cost, long in period and incapable of being generally implemented. The factors seriously restrict the effect of attack and development and the application thereof, even seriously affect the effective improvement of the service life of the reciprocating pump and the development of other related new technologies, and even restrict the progress of the industry of reciprocating pump products in a certain sense. Taking the most commonly used application field test method and object prototype test method at present as examples:
1) using field test methods
The testing method is that the service life and the working state of the pump valve group and the column/piston are tracked and recorded and finally the service life testing data of the valve group and the column/piston are obtained in the pump process for process production by means of the reciprocating pump application field and the production device and the convenient conditions of the pump application field. The test method has the outstanding advantages that the existing production equipment, power dragging, process and personnel conditions are completely utilized, and the test cost can be greatly saved.
However, the disadvantages of this test method are also very significant:
in the process application field, the primary premise and goal is to ensure safe production, and valve block and column/piston life testing is an additional task. In the actual production process, the production process is constantly changed, factors such as the operation conditions (flow, pressure, rotating speed, temperature and conveying medium) of the pump are determined to be changed, so that the boundary conditions of the service life testing process of the valve bank and the column/piston are always deviated from the preset conditions and cannot be adjusted, and the testing result cannot objectively reflect the actual working conditions of the valve bank and the column/piston. Even due to the restriction of conditions, the change often lacks effective statistical records, and when data are analyzed, necessary actual operation conditions and operation boundary conditions are lacked as the basis for change analysis. Therefore, many of the methods only obtain the life data, and the life data can only be used as the direction reference of the life data due to the lack of a plurality of necessary prerequisite supports, and cannot be used for guiding the fine production and accurate life basis. Meanwhile, the uncertainty of the test data is increased due to the influence of various factors such as the professional ability of a field operator, difficulty in system participation of professional technicians, insufficient precision of field production type instruments and equipment and the like. So many times, the same valve set and column/piston, different channels get data with large differences, even with multiple deviations. In addition, the accidental shutdown maintenance of most production lines can bring about great economic loss. The method is directly used for actual production to carry out test verification without test verification, and is easy to cause unexpected fault shutdown. In most cases, the valve block and the column/piston, which are not verified by testing, do not allow direct testing at the production site.
2) Method for testing sample machine
The test method of the sample machine is to install the sample machine with the tested valve group and the column/piston on a special test bed system, to continuously run the pump under the actual design condition, and to test the actual running life of the pump valve group and the column/piston. Compared with the application of a field test method, the test method has the obvious advantages that the service life test always meets the test boundary of the standard requirement and the technical specification and always runs under the design working condition, and the accuracy of test data and test results can be fully guaranteed.
However, the disadvantages of this test method are also very significant: i.e. high power consumption, especially for high power units.
1) The test cost is huge, and a large amount of electric energy (or diesel oil) cost and test medium cost are consumed.
The physical prototype testing method requires that the valve block and the post/piston are assembled in a physical sample pump and continuously run under the actual working condition of the pump until the valve block and the post/piston are damaged. Taking a 315kW step plug pump of medium power as an example, if the valve block and column/piston life is estimated at 2000 hours over time and the electricity rate is estimated at 0.75 yuan/kw.h, the test electricity rate is about: 315 × 2000 × 0.75/10000 ═ 47.25 ten thousand yuan. The above estimation is only for 1 group of inlet and outlet valves and 1 working condition, if the valve group and the column/piston need to carry out the comparative test of a plurality of working conditions, the test cost is undoubtedly great expense; this test method requires a significant cost expenditure for support. In fact, the test has the construction expenses of water cost, huge test system and the like besides the payment of the electric expenditure, and the test cost is huge.
2) The test period is long, and test data cannot be obtained quickly.
The test mode is to test the pump, and the rotating speed of the pump is in a first order relation with the flow rate and the power of the pump according to the structure and the working principle of the reciprocating pump. If the speed-up test is increased, the flow rate and the driving power of the pump are increased, and the test is impossible, so that the service life test can only be the original speed test or the speed-down test.
Experience shows that the service life of the reciprocating pump valve bank and the column/piston is generally about 1-6 months, and the service life of the large pump valve bank and the column/piston is relatively short. If high-power and original-speed tests are carried out, the testing capability of most enterprises can only ensure one large-pump test, which means that if a high-power pump valve bank and a column/piston service life test are carried out, a large number of pumps cannot be tested normally, and cannot be borne by any enterprise for a long time, so that the long-period test is not only the problem of slow test data, but also the problem that enterprises cannot bear the heavy load. Moreover, manufacturers of valve sets and column/piston machines of reciprocating pumps do not have test conditions of a little high power at all.
Of course, the above problems also exist in the life test of the cylinder liner and the filler which are both wearing parts, so that the problem needs to be solved.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a reciprocating pump service life testing device with a reasonable and practical structure, which can not only completely simulate the actual flow condition in a pump cavity, but also ensure that a high-pressure liquid discharge valve, a stepped plug body, a corresponding cylinder sleeve and a corresponding filler which are used as a tested piece are not or hardly influenced by the flow, pressure and especially power of the pump, and finally realize the purpose of accurately, quickly and inexpensively completing the service life test of a set object.
In order to achieve the purpose, the invention adopts the following technical scheme:
the utility model provides a reciprocating pump vulnerable part life test device, includes the cylinder liner and arranges the ladder cock body that is used for constituting piston or plunger in cylinder liner cover intracavity which characterized in that:
the stepped plug body comprises a small head plug, a working plug and an energy storage plug, wherein the small head plug, the working plug and the energy storage plug are coaxially arranged from front to back along the axial direction in sequence, and the diameters of the small head plug, the working plug and the energy storage plug are gradually increased; an additional plug rod is coaxially arranged on the rear end face of the energy storage plug so as to be connected with an external power source, and therefore the stepped plug body is driven to perform linear reciprocating motion along the axial direction of the cylinder sleeve cavity;
the cylinder sleeve cavity is sequentially divided into a pressure exchange transition cavity, a simulation pump cavity, a middle section matching cavity, a rear section matching cavity and a tail cavity from front to back along the axial direction, wherein the pressure exchange transition cavity is used for forming sealing sliding fit with the outer wall of the small-head plug so as to seal the front end of the cylinder sleeve cavity; the axial length of the rear-section matching cavity is greater than that of the energy storage plug, so that the rear-end matching cavity is divided into a cavity discharging cavity at the front and a high-pressure energy storage cavity at the rear through the energy storage plug;
the evacuation cavity is provided with a normal pressure environment; the high-pressure energy storage cavity is provided with a high-pressure energy storage liquid inlet valve and a high-pressure energy storage liquid outlet valve which are communicated with each other; a high-pressure liquid inlet valve communicated with the simulation pump cavity and a high-pressure liquid outlet valve forming a tested piece are arranged at the simulation pump cavity, and an outlet of the high-pressure liquid inlet valve is positioned at an inlet of the pressure exchange transition cavity; the high-pressure energy-storage liquid inlet valve and the high-pressure liquid outlet valve are communicated with each other through a pump cavity discharge high-pressure pipe, and the high-pressure energy-storage liquid outlet valve and the high-pressure liquid inlet valve are communicated with each other through a pump cavity suction high-pressure pipe;
the device also comprises a detection component for monitoring the working information of the stepped plug body, the cylinder sleeve and the medium;
the tested object is one or more of a high-pressure drain valve, a stepped plug body forming a plunger or a piston, a filler forming a friction pair with the stepped plug body and a cylinder sleeve forming a friction pair with the stepped plug body.
Preferably, a low-pressure liquid inlet valve communicated with the simulation pump cavity is further arranged in the simulation pump cavity; the device also comprises a circulation auxiliary assembly used for providing media and cooling media, wherein the inlet of the circulation auxiliary assembly is respectively communicated with the pump cavity discharge high-pressure pipe and the pump cavity suction high-pressure pipe, and the inlet of the circulation auxiliary assembly is communicated with the inlet end of the low-pressure liquid inlet valve.
Preferably, the circulation auxiliary assembly comprises a liquid storage tank for storing media, the media are discharged from the high-pressure pipe through the pump cavity and sucked into the high-pressure pipe through the pump cavity and then enter the liquid storage tank through the overflow valve and the liquid inlet pipeline, and the media at the liquid outlet end of the liquid storage tank are cooled through the first water-cooling heat exchanger and then enter the liquid outlet pipeline and finally enter the low-pressure liquid inlet valve and the simulation pump cavity; temperature sensors for monitoring the temperature of the medium when the medium enters and flows out are respectively arranged on the liquid inlet pipeline and the liquid outlet pipeline; the signal output end of the temperature sensor is connected with the signal input end of the acquisition and control module.
Preferably, a liquid replenishing pipe is arranged on the liquid storage tank, and a liquid replenishing valve is arranged on the liquid replenishing pipe.
Preferably, the device further comprises a forced one-way valve disposed within the pressure exchange transition chamber; when the small-head plug is scheduled to enter the pressure exchange transition cavity and form sealing fit between the small-head plug and the pressure exchange transition cavity, the medium flows back to the pump cavity through the forced one-way valve and is discharged out of the high-pressure pipe; the sum of the liquid inlet flow of the low-pressure liquid inlet valve and the liquid inlet flow of the pressure exchange transition cavity is equal to the sum of the passing discharge capacities of the high-pressure liquid discharge valve and the forced one-way valve.
Preferably, the detection assembly comprises a stroke frequency sensor for monitoring the reciprocating times of the stepped plug body, a rotating speed sensor for monitoring the rotating speed of the stepped plug body and a pressure sensor for monitoring the hydraulic pressure in the simulated pump cavity; and the signal output ends of the stroke frequency sensor and the pressure sensor are connected to the signal input end of the acquisition and control module.
Preferably, the device also comprises a pressure boosting and stabilizing component, wherein the liquid outlet end of the pressure boosting and stabilizing component is communicated with the pump cavity discharge high-pressure pipe and the pump cavity suction high-pressure pipe through a group of overflow valves respectively; the energy accumulators are uniformly arranged on the pump cavity discharge high-pressure pipe and the pump cavity suction high-pressure pipe.
Preferably, an overflow valve is arranged between the outlet of the high-pressure liquid discharge valve and the inlet of the liquid storage tank; an overflow valve is arranged between the high-pressure energy-storage liquid discharge valve and the inlet of the liquid storage tank.
Preferably, a second water-cooled heat exchanger is arranged on the pump chamber suction high-pressure pipe.
Preferably, the power source is a rotary reciprocating conversion mechanism driven by a variable frequency motor, and the tail end of the rotary reciprocating conversion mechanism is fixedly connected with the rear end of the additional plug rod.
The invention has the beneficial effects that:
1) compared with the traditional test mode, the invention can ensure that the power for driving the stepped plug body to move is not necessarily related to the design flow and pressure of the pump; the influence of pump performance parameters is eliminated under the condition that the relative motion between the stepped plug body and the cylinder sleeve is completely simulated, so that the driving power required by the test is extremely low no matter how large and powerful valve groups matched with the pump, the stepped plug body, the corresponding cylinder sleeve and the corresponding filler are subjected to the service life test, the test cost is greatly saved, and the aims of saving energy and reducing consumption are achieved for enterprises. Meanwhile, the medium needed by the test is very little, so that the method is a great saving for special, rare and precious test media. In addition, because the stepped plug body of the invention hardly applies work to the medium, the stepped plug body hardly bears any axial force, so that the reciprocating frequency of the stepped plug body can be very high, namely the reciprocating frequency of the stepped plug body can be greatly increased in unit time, thereby completing the detection of the service life of the valve bank, the column/piston, the corresponding cylinder sleeve and the corresponding filler more quickly, greatly shortening the test and testing period, saving a large amount of time cost and providing sufficient preparation for the development of new technology.
Therefore, the scheme of the invention simulates the running state of the pump body under the actual working condition by creatively designing the structural style of a multi-cavity, a stepped plug body and a multi-valve body. When the device is practically applied, the device can be suitable for the test environment of the piston pump and can also be suitable for the test environment of the plunger pump; the device can simulate the stress and working state of the valve bank, the column/piston and the corresponding cylinder sleeve and the corresponding filler under the actual working condition, can also greatly reduce the required power and the test duration of the test, and is very flexible in test. In addition, the invention has carried on the field test of the life-span of corresponding valves and columns/pistons under the full-automatic test system, systematic assistance of self-error correction of key parameter. The test result also proves that the invention has the working characteristics of energy saving and high efficiency, can ensure the accurate, reliable, rapid and automatic service life test, and is particularly suitable for the service life test of valve banks, columns/pistons, corresponding cylinder sleeves and corresponding fillers in high-power units.
Drawings
FIG. 1 is a schematic view of the present invention in an assembled state;
FIG. 2 is a diagram of the working state of the present invention;
fig. 3 is a schematic structural diagram of the stepped plug body.
The actual correspondence between each label and the part name of the invention is as follows:
a-pressure exchange transition cavity b-simulation pump cavity c-row cavity d-high pressure energy storage cavity
10-cylinder sleeve
20-step plug body 21-small head plug 22-working plug 23-energy storage plug 24-additional plug rod
30-power source 41-high pressure energy storage liquid inlet valve 42-high pressure energy storage liquid outlet valve
43-high pressure liquid inlet valve 44-low pressure liquid inlet valve 45-forced one-way valve
50-high pressure drain valve 61-Pump Chamber Drain high pressure tube
62-Pump Chamber suction high pressure tube 62 a-second Water cooled Heat exchanger
70-circulation auxiliary assembly 71-liquid storage tank 72-first water-cooled heat exchanger 73-liquid supplementing valve
80-overflow valve 91-temperature sensor 92-acquisition and control module
93-stroke frequency sensor 94-rotating speed sensor 95-pressure sensor
100-supercharging pressure-stabilizing component 110-energy accumulator
Detailed Description
The structure of the specific embodiment of the invention is shown in reference to fig. 1-3. For the sake of understanding, the following description will be made by taking the test object as the tested object in the drawing, that is, the high-pressure drain valve 50 located above the simulated pump chamber b as an example:
in the actual design, it should be noted that: the invention is different from the traditional straight-through sleeve cavity structure, and is creatively provided with four functional cavities, and the functions of low driving force, low power consumption and rapid service life test of the reciprocating pump valve group are realized through the functions of transmission, energy storage, balance and the like of the four functional cavities on high-pressure media. The four functional cavities are respectively: the specific arrangement positions of the pressure exchange transition cavity a, the simulation pump cavity b, the cavity discharge cavity c and the high-pressure energy storage cavity d are shown in the figure 1. And for the middle section matching cavity and the tail cavity, the purpose of separating the functional cavities is achieved, and the separation mode is also realized by injecting a sealing ring or packing seal and the like.
When assembled, as shown in fig. 2, the simulation pump chamber b is located at the front end of the jacket chamber of the cylinder liner 10, i.e., the second position from the left, and has a function of simulating the hydraulic cylinder chamber of the conventional reciprocating pump. The simulation pump cavity b is provided with a low-pressure liquid inlet valve 44 and a high-pressure liquid outlet valve 50, and the main functions of the two valves are low-pressure liquid inlet and high-pressure liquid outlet during the test. Meanwhile, a high-pressure liquid inlet channel is drilled at the position where the cavity wall of the simulated pump cavity b is coaxial with the plunger, namely a pressure exchange transition cavity a which is positioned at the leftmost end of the cylinder sleeve shown in the figure 2; and a high-pressure liquid inlet valve 43 is arranged in the pressure exchange transition cavity a, most of high-pressure medium discharged from the simulation pump cavity b is guided into the simulation pump cavity b in a high-pressure mode after flowing through a high-pressure energy storage cavity d and the pump cavity sucks high-pressure pipe 62, and thus the discharged high-pressure medium is recycled to the simulation pump cavity b, and the purpose of an energy-saving test is achieved.
Because the high-pressure liquid inlet channel forms the pressure exchange transition cavity a, in the suction process of the simulation pump cavity b, the small-head plug 21 can be used for temporarily plugging the cavity and temporarily closing the high-pressure liquid inlet channel, so that the low-pressure liquid inlet valve 44 at the simulation pump cavity b is opened, low-pressure medium enters the simulation pump cavity b, and the simulation pump cavity b has a low-pressure liquid inlet state at the moment. The pressure exchange transition cavity a is provided with a forced check valve 45, and the opening pressure of the forced check valve 45 is slightly higher than the set pressure of each overflow valve 80. Therefore, in the process of simulating the scheduling of the pump cavity b, when the small head plug 21 is scheduled to block the pressure exchange transition cavity a, the cavity medium is discharged to the pump cavity discharge high-pressure pipe 61 through the forced one-way valve 45, and also when the small head plug 21 is blocked in a suction stroke, the cavity medium is not discharged to the pump cavity discharge high-pressure pipe 61, so that the working pressure difference of the high-pressure liquid discharge valve 50 is completely simulated.
At the rear, namely the rightmost side, of the structure shown in fig. 2, the invention is provided with an annular high-pressure energy storage cavity d, a high-pressure energy storage liquid inlet valve 41 and a high-pressure energy storage liquid outlet valve 42 are arranged in the cavity, the specific installation positions can be actually determined according to the convenience of field arrangement, and both the valves belong to the structural type of one-way valves. The high-pressure energy-storage liquid inlet valve 41 is connected with the high-pressure liquid outlet valve 50 through a pump cavity discharge high-pressure pipe 61; when the simulation pump cavity b is in a liquid discharging state, namely the high-pressure energy storage cavity d is in a liquid inlet state, the high-pressure energy storage liquid inlet valve 41 is opened, and high-pressure media of the simulation pump cavity b are discharged from the high-pressure pipe 61 through the pump cavity and guided into the high-pressure energy storage cavity d to be stored; when the simulation pump cavity b is in a liquid inlet state, namely the high-pressure energy storage cavity d is in a liquid discharge state, the high-pressure energy storage liquid inlet valve 41 is closed, the channel is cut off, and backflow is prevented. The high-pressure energy-storage drain valve 42 is connected with a high-pressure liquid inlet valve 43 in the simulation pump cavity b through a pump cavity suction high-pressure pipe 62; when the simulation pump cavity b is in a liquid inlet state, namely the high-pressure energy storage cavity d is in a liquid discharge state, the high-pressure energy storage liquid discharge valve 42 is opened, and high-pressure media in the high-pressure energy storage cavity d are discharged. In actual design, part of high-pressure medium in the high-pressure energy storage cavity d at the initial stage can be emptied through the overflow valve 80, and then the high-pressure medium enters the simulation pump cavity b to start energy storage conversion. When the simulation pump cavity b is in a liquid discharge state, namely the high-pressure energy storage cavity d is in a liquid inlet state, the high-pressure energy storage liquid discharge valve 42 is closed, the channel is cut off, and backflow is prevented.
In fig. 1-2, an annular cavity c, which is an auxiliary cavity, is also arranged between the simulation pump cavity b and the high-pressure energy storage cavity d. The upper part of the exhaust cavity c is provided with an exhaust hole communicated with the atmosphere, so that the pressure in the cavity is kept constant and the normal pressure state is kept, and a new plunger force is not generated. The lower part of the cavity c can be provided with a liquid discharge hole so as to collect the leakage liquid.
Thus, it can be seen that: according to the invention, through designing the stepped plug body 20, the volumes of the medium cavities are correspondingly changed through the reciprocating motion of the stepped plug body, the functions of orderly inflow, discharge, plugging, energy storage and the like of the media among the cavities are realized, and finally, the service life test which can be realized only by large plunger force and high power can be completed by small plunger force and micropower. More specifically, the stepped plug body 20 of the present invention is shown in fig. 3, which mainly includes four functional steps, and for the convenience of description, the following reference is made to fig. 2 as an embodiment: the step plug 20 has a stroke S2(ii) a The steps of the step plug 20 are sequentially from left to right: the small head plug 21 has a diameter d1The longest stroke of the pressure exchange transition cavity a is S1(ii) a The working plug 22 at the simulated pump chamber b has a diameter d2(ii) a The diameter of the energy storage plug 23 is d3(ii) a The additional plug 24 has a diameter d4。
In fig. 2-3, the far left end is a small head plug 21 having a nominal outer diameter dimension that is the same as the nominal inner diameter dimension of the pressure exchange transition chamber a. In the process of the suction stroke of the simulated pump cavity b, when the small head plug 21 is positioned in the pressure exchange transition cavity a, the high-pressure medium discharged from the high-pressure energy storage cavity d is blocked in the left area of the end face of the small head plug 21, namely the pressure exchange transition cavity a, so that the high-pressure medium can not enter the simulated pump cavity b temporarily, and the simulated pump cavity b is kept in a transient low-pressure state. When the small head plug 21 is completely moved out of the pressure exchange transition cavity a, high-pressure medium starts to enter the simulation pump cavity b, and energy storage conversion is started; and after the suction stroke of the simulated pump cavity b is finished, energy storage conversion is finished. In the process of scheduling the simulated pump cavity b, when the small head plug 21 enters the pressure exchange transition cavity a, the pressure in the pressure exchange transition cavity a rises, the forced one-way valve 45 is opened, and the medium in the cavity is discharged to the pump cavity discharge high-pressure pipe 61 through the forced one-way valve 45.
Immediately to the right of the small head plug 21 is the working plug 22, which generates a flow rate in the dummy pump chamber b by its reciprocating motion and discharges a test demand flow rate through the discharge high-pressure discharge valve 50, the full stroke of which is equal to the stroke S of the stepped plug body 202And (5) the consistency is achieved. 1) The initial stage of the simulated pump cavity b suction (i.e. the high pressure accumulator cavity d schedule): the pressure exchange transition cavity a is moved from the beginning to the small head plug 21, the simulation pump cavity b is fed by the low-pressure liquid inlet valve 44, and the input flow is
2) The conventional stage of simulating the suction stroke of the pump cavity b (i.e. scheduling of the high-pressure energy storage cavity d): from the moving of the head plug 21 out of the pressure exchange transition cavity a to the end of the suction stroke, the simulation pump cavity b sucks the high-pressure pipe 62 to feed liquid from the pump cavity, and the input flow rate is
The sum of the two is the passing displacement of the high-pressure drain valve 50, which is totally
The design satisfies this formula, just can guarantee the flow of complete simulation valve. In the process of scheduling the simulated pump chamber b, except for the discharge amount of the high-pressure drain valve 50
In addition, the discharge valve is also discharged from the pressure exchange transition cavity a
The medium thus co-discharged to the pump chamber discharge high-pressure pipe 61 is
As shown in fig. 1-2, immediately to the right of the working plug 22 is an accumulator plug 23, by means of whose piston ring a left-hand sealing of the high-pressure accumulator chamber d is achieved; the right side of the energy storage plug 23 is provided with an additional plug rod 24, and the sealing purpose of a rear cavity at the right side of the high-pressure energy storage cavity d is realized by means of sealing packing. The stroke of the energy storage plug 23 is identical to that of the stepped plug body 20, which is S2. When the stepped plug body 20 reciprocates, liquid feeding and discharging of the high-pressure energy storage cavity d are realized by annular volume changes of the energy storage plug 23 and the additional plug rod 24. The design is carried out according to a one-way liquid discharge method, the discharge capacity of the pump cavity at the position of discharging the high-pressure pipe 61 is kept consistent with the liquid inlet capacity of the high-pressure energy storage cavity d, so that the method comprises the following steps:
so that the two step diameters satisfy the condition
The consistency of the scheduling medium of the simulation pump cavity b and the medium sucked by the high-pressure energy storage cavity d can be ensured; the amount of the high-pressure energy storage chamber d discharged to the pump chamber suction high-pressure pipe 62 is also
1) The high-pressure energy storage chamber d schedules (i.e. simulates the suction stroke of the pump chamber b) in the initial stage: the pressure exchange transition chamber a is moved from the beginning to the small head plug 21, the high-pressure energy storage chamber d is discharged to the pump chamber suction high-pressure pipe 62 by the amount
The pump chamber suction high-pressure pipe 62 is discharged to the pressure exchange transition chamber a by an amount
Thus is provided with
The amount of the relief valve 80 configured by the pump chamber suction high pressure pipe 62 is evacuated to the circulation assistance assembly 70. 2) The high pressure reservoir d schedules (i.e. simulates the suction stroke of the pump chamber b) the conventional phase: the high-pressure energy storage cavity d is discharged to the pump cavity to suck the high-pressure pipe 62 by the amount from the small head plug 21 moving out of the pressure exchange transition cavity a to the end of the suction stroke
The suction quantity of the pump cavity is completely consistent, and the stable operation of the system can be ensured.
In order to realize maximum energy saving, the invention generally adopts a single mechanism working mode, so that the outlet medium of the valve in the mechanism has stronger fluidity. In order to reduce pulsation and stabilize operation, the present invention provides a set of accumulators 110 on each of the pump chamber discharge high-pressure pipe 61 and the pump chamber suction high-pressure pipe 62, and the size and number of the accumulators 110 are specifically determined by the flow rate according to the design of the high-pressure drain valve 50. While the accumulator 110 can also properly compensate for small differences in actual flow due to manufacturing tolerances.
As shown in the formulas of figures 1-2, the invention is also communicated with a pressurizing and pressure stabilizing assembly 100 at the periphery of the whole set of high-pressure pipelines through a relief valve 80. The pressure boosting and stabilizing assembly 100 is mainly composed of a small reciprocating booster pump, connecting pipelines and valves, and the structure is commercially available. The main functions are as follows: 1) in the initial stage of the test, the system is pressurized to the test pressure, 2) in the test process, the leakage loss of a piston or a plunger cannot be avoided, the pressure and the high-pressure medium are gradually reduced, the reduction is available no matter how small the reduction is, the reduction in a certain range can be compensated, and the pressurization and pressure stabilization component needs to be started to supplement the high-pressure medium into the system to maintain the stability of the pressure and the flow of the system when the reduction exceeds the certain range. An overflow valve 80 is provided in the pump chamber discharge high pressure pipe 61 to release the elevated pressure of the mechanism due to a pipe blockage or other accident, ensuring safe operation of the mechanism.
For the power source 30, the driving form still adopts a crank connecting rod structure form or other rotary reciprocating conversion mechanisms to convert the rotary motion output by the variable frequency motor into the reciprocating motion of the step plug body 20, and the rotating speed of the driving end is adjustable. The driving end is connected with the step plug body 20 and provides power for the reciprocating motion of the step plug body 20; the driving force of the device only needs to provide the friction force for overcoming the reciprocating motion of the stepped plug body 20, and the power and the strength for overcoming the work of the stepped plug body 20 by the high-pressure medium in a very short time before the pressures in the left pump chamber and the right pump chamber are not balanced when the device is initially operated.
The selection of the sealing ring, the packing seal and the like is selected according to the actual situation, the completeness is ensured, and the flow is ensured to meet the design requirement.
The circulation auxiliary assembly 70 comprises a liquid storage tank 71, a first water-cooled heat exchanger 72, a liquid supplementing valve 73 and the like, and aims to provide a circulation medium and cool a test medium for a test. The circulation assistance assembly 70 is a universal system that is designed scientifically to meet substantially all of the valve train testing needs.
To facilitate a further understanding of the invention, the actual workflow of the invention is given here as follows:
before the test is started, high-pressure media which are consistent with the test working condition and have the same pressure as the working pressure of the high-pressure drain valve 50 are injected into the pump cavity, the simulation pump cavity b and the high-pressure energy storage cavity d through the externally-connected pressure-increasing and pressure-stabilizing component 100, and the test media can adopt actual media according to the design and development requirements to complete the early-stage preparation work of the test.
As shown in fig. 1, when the stepped plug 20 moves to the right, the simulated pump chamber b is in a suction state (i.e., the high-pressure energy storage chamber d is in a scheduled state); this process can be divided into two stages, an initial stage and a conventional stage:
simulating the initial stage of the suction stroke of the pump cavity b: the small head plug 21 is located in the pressure exchange transition chamber a. The volume in the right high-pressure energy storage cavity d is reduced, so that the high-pressure energy storage liquid inlet valve 41 at the cavity is closed, the high-pressure energy storage liquid outlet valve 42 at the cavity is opened, and high-pressure medium is sucked into the high-pressure pipe 62 through the pump cavity and flows towards the direction of the simulated pump cavity b. At this time, because the left small head plug 21 is not completely moved out of the pressure exchange transition cavity a, the high-pressure liquid inlet channel at the simulated pump cavity b is closed by the plugging action of the small head plug 21, the high-pressure liquid cannot enter the simulated pump cavity b, only part of the high-pressure liquid enters the channel, and the rest part of the high-pressure liquid is discharged by the overflow valve 80. Meanwhile, as the volume of the dummy pump chamber b at the left side is increased, the low pressure liquid inlet valve 44 at the dummy pump chamber b is opened, and the low pressure medium flows into the dummy pump chamber b through the valve to enter the low pressure liquid suction process. At this stage, the step plug body 20 needs to work against the high-pressure medium, and the power consumption is related to the length of the small head plug 21, and the shorter the length of the small head plug 21 is, the lower the power consumption is. After the small head plug 21 is completely moved out of the pressure exchange transition cavity a, the initial stage is finished, and the suction stroke conventional stage is entered.
Simulating the suction lift conventional stage of the pump cavity b: the small head plug 21 is completely removed from the pressure exchange transition chamber a. As the stepped plug body 20 continues to move rightward, at this time, the small-head plug 21 moves out of the pressure exchange transition cavity a completely, the high-pressure liquid inlet channel in the simulation pump cavity b is opened, high-pressure fluid flows into the simulation pump cavity b through the channel, the pressure of the simulation pump cavity b rises, the low-pressure liquid inlet valve 44 is closed, and the pressures of the simulation pump cavity b and the high-pressure energy storage cavity d tend to be balanced. At this time, the power source 30 only needs to provide work to overcome the friction force of the step plug body 20, so that the step plug body 20 can complete the whole suction stroke.
When the stepped plug body 20 moves leftwards, the simulated pump cavity b is in a scheduled state (namely the high-pressure energy storage cavity d is in a suction state); this process can also be divided into two stages, an initial stage and a later stage:
simulation pump cavity b scheduling initial stage: the small head plug 21 is located completely within the dummy pump chamber b. Because the volume of the simulated pump cavity b is reduced, the high-pressure drain valve 50 at the simulated pump cavity b is opened, other valves in the cavity are closed, and high-pressure fluid is drained from the high-pressure pipe 61 through the pump cavity and flows to the direction of the right high-pressure energy storage cavity d; at this time, as the volume of the high-pressure energy storage cavity d is increased, the high-pressure energy storage liquid inlet valve 41 at the high-pressure energy storage cavity d is opened, the high-pressure energy storage liquid outlet valve 42 is closed, the high-pressure medium flows into the high-pressure energy storage cavity d, the pressure of the left and right cavities tends to balance again, and at this time, the power source 30 only needs to provide work for overcoming the friction force of the stepped plug body 20, so that the stepped plug body 20 can complete the whole scheduling action.
Simulation of the later stage of pump cavity b scheduling: the small head plug 21 is located in the pressure exchange transition chamber a. The volume of the simulation pump chamber b is continuously reduced, and high-pressure fluid is discharged from the high-pressure pipe 61 through the pump chamber and flows to the direction of the high-pressure energy storage chamber d on the right side. The volume of the pressure exchange transition cavity a is reduced, the pressure in the cavity is increased, the one-way valve 45 is forced to be opened, and high-pressure fluid in the pressure exchange transition cavity a is discharged from the high-pressure pipe 61 through the pump cavity and flows to the direction of the right high-pressure energy storage cavity d; the sum of the flow rates is the same as that in the initial stage, and the flow rate continues to flow to the high-pressure energy storage cavity d until the scheduling is finished.
In the process of simulating the suction stroke scheduling of the pump cavity b, the fluid medium can generate pressure pulsation to be reduced; meanwhile, due to actual machining errors, the suction stroke scheduled flow has small errors to be compensated, and the problem is solved by adding the energy accumulators 110 in two high-pressure pipes respectively.
The stepped plug body 20 generates friction heat in the reciprocating process, energy is released when the overflow valve 80 is discharged in a normal overflow mode, the temperature of a medium is increased, and in order to keep the temperature of the medium stable within a test allowable range, the first water-cooling heat exchanger 72 and the second water-cooling heat exchanger 62a are added in the system for heat exchange, so that the cooling purpose is achieved.
In conclusion: compared with the traditional valve group service life test, the device only needs the power source 30 to provide the initial operation pressure of the device, the power consumption of single normal overflow and the power consumption of friction during the reciprocating motion of the stepped plug body 20, the power consumption is only about 3% -5% of the power consumption of the conventional test, and the device is particularly related to the design, so that the energy consumption of the stepped plug body 20 in the whole stroke to overcome the high back pressure to do work in the traditional liquid drainage process is greatly saved, and the energy-saving effect of the high-power high back pressure reciprocating pump is more obvious.
Generally, the characterization parameter of the service life of the check valve group is time, and actually, the time for reliable operation of the valve group can also be equivalently converted into the operation time of the step plug body 20 in the normal state, namely the accumulation of the reciprocating times of the step plug body 20; therefore, the service life of the measuring valve group can be equivalently converted into the accumulated operation times of the step plug body 20 under the normal operation condition of the reciprocating pump. After the accumulated running times of the stepped plug body 20 before the valve bank is damaged is measured, the service life of the valve bank can be obtained by conversion according to the rated rotating speed of the pump.
The number of reciprocations of the step plug body 20 can be recorded and accumulated by the stroke frequency sensor 93, and the signal is very critical and error-free. The invention adopts a homologous and heterologous double comparison method to carry out self-calibration and error correction: two homologous frequency of stroke signal sensors are arranged at the initial position of the end of the stepped plug body 20, and the reciprocating frequency of the stepped plug body 20 is measured and recorded as the effective frequency of stroke of the test and is self-checked; and a rotating speed sensor 94 is also arranged at the position which is connected with the step plug body 20 and does not have speed reduction and low-speed rotation, the rotating speed sensor 94 can be converted into the stroke frequency, is different from the stroke frequency sensor 93, records the stroke frequency and compares the stroke frequency with the record of the stroke frequency sensor 93 so as to verify the stroke frequency and the stroke frequency with each other. The sensors, even including the temperature sensor 91 and the pressure sensor 92 in fig. 1, are in signal connection with the acquisition and control module 92.
The driving end adopts a variable frequency driving mode, the rotating speed is adjustable, and the reciprocating times of the stepped plug body 20 are changed along with the variable frequency driving mode. After the device stably operates, the pressures in the left cavity and the right cavity, namely the simulation pump cavity b and the high-pressure energy storage cavity d, can be balanced in a very short time along with the movement of the step plug body 20, the reciprocating frequency of the step plug body 20 cannot influence the pressure distribution of the left cavity and the right cavity, and the step plug body 20 does not need to overcome high back pressure to do work. Thus, the drive end has the potential for high speed operation from power wear and structural forces.
In order to ensure the accuracy of the valve group service life test, two sets of same valve groups can be subjected to a comparison test at the same time, so that the test transparency is increased, and the test contingency is reduced. .
So far, the advantages of the valve group service life testing device with the high-efficiency energy-saving function can be summarized as follows:
1) low cost
Compared with the traditional valve group service life test mode, the scheme adopts a multi-cavity pressure self-balancing type stepped plug body 20 matched with a valve group motion structural mode; the device can simulate the opening and closing state of the valve bank in actual working conditions completely, and the stepped plug body 20 does not need to overcome the high back pressure to do work in the whole process, so that the test power and the strength of the driving end are greatly reduced, the test cost is saved, the test period is shortened, and the energy-saving and load-reducing targets are realized for enterprises.
2) Short test period
The structure form used by the invention ensures that the opening and closing times of the valve group, namely the reciprocating frequency of the stepped plug body 20, has little relation with the driving power and the stress of the driving end, and can greatly improve the test rotating speed, the pump speed of the conventional common reciprocating pump is within the range of 80-300, the common test rotating speed can be increased to about 1500 synchronous rotating speeds of a 4-pole motor at the maximum through the invention, and the test can be shortened to one fifth or even more than the previous test. If the normal service life of one valve group is 6 months, the normal test can be completed in 6 months, and if the test is performed at a speed 5 times that of the valve group, the test can be performed only in 36 days, so that the test and testing period is greatly shortened, a large amount of time cost is saved, and the technical development period is shortened.
3) High efficiency
The valve group service life test boundary conditions are automatically controlled by a data control system; test records are automatically recorded and controlled; meanwhile, the test cost is low, and the test period is short, which is a concrete embodiment of high efficiency of the test system.
4) High accuracy
In the test system, key data such as pressure and reciprocating times are mutually verified by adopting multiple parameters, so that the boundary of the test is always in a design state, the test result is correct, the consistency of test conditions and the accuracy of test life data are fully ensured, and the test accuracy is improved.
The invention is suitable for testing in a laboratory, is convenient for professionals to participate in the whole process, and also ensures the specialty and the accuracy of the test. The structural design of the invention is convenient for simultaneously carrying out the double-valve-group test without difference, and simultaneously obtaining double sample data without difference, thereby being convenient for further discriminating the accuracy of the test result and improving the actual effect of the test accuracy.
Meanwhile, due to the fact that the cost is low, the implementation is easy, the pertinence and diversity tests can be carried out more conveniently and widely, the pertinence tests can be carried out according to a plurality of factors influencing the service life of the valve group, and the service life data of the valve group under the influence of different factors are more accurate.
5) Has super strong practicability, is easier to realize and is convenient to popularize
In conclusion, the novel service life testing device for the detection valve group is convenient for lower cost, higher efficiency, rapider and wider test development, is convenient for valve group production enterprises and whole pump production enterprises to equip the system, brings possibility for a large number of tests of service life tests of the valve group, brings possibility for scientific researches of service lives of various valve groups, and can rapidly and greatly improve the reliability of the reciprocating pump valve group, thereby prolonging the service life of the whole equipment.
Through practical tests, the energy-saving device can save energy by 90-95%, and can shorten the original test period to within 1/5, thereby having remarkable effect.
Of course, when the tested object is a plunger or a piston represented by the stepped plug body 20 shown in fig. 1-3, the high-pressure drain valve 50 as the tested object can be directly replaced by a conventional drain valve, so as to achieve the purpose of monitoring and testing the service life of the plunger or the piston represented by the stepped plug body 20; the test flow and the test mode are the same as those of the high-pressure drain valve 50. If desired, even the subject may be a plunger or piston represented by the stepped plug body 20 and the high pressure drain valve 50, i.e., both may be tested simultaneously. In addition, the tested object can also be a filler and a cylinder sleeve which form a friction pair with the stepped plug body 20, that is, both the valve group and the friction group which are matched with the stepped plug body 20 can be used as the tested object, so that the structure provided by the invention is used for matching tests, the experimental principle and the steps are the same as above, and the details are not repeated here.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
The techniques, shapes, and configurations not described in detail in the present invention are all known techniques.
Claims (10)
1. The utility model provides a reciprocating pump vulnerable part life test device, includes cylinder liner (10) and arranges ladder cock body (20) that are used for constituting piston or plunger in cylinder liner (10) cover intracavity which characterized in that:
the stepped plug body (20) comprises a small head plug (21), a working plug (22) and an energy storage plug (23), which are coaxially arranged from front to back along the axial direction in sequence and have gradually increased diameters; an additional plug rod (24) is coaxially arranged on the rear end face of the energy storage plug (23) so as to be connected with an external power source (30), and therefore the stepped plug body (20) is driven to perform linear reciprocating motion along the axial direction of a sleeve cavity of the cylinder sleeve (10);
the cylinder sleeve (10) is characterized in that a sleeve cavity is axially and sequentially divided into a pressure exchange transition cavity (a) which is used for forming sealing sliding fit with the outer wall of a small-head plug (21) so as to seal the front end of the sleeve cavity, a simulation pump cavity (b) used for realizing simulation pump conditions, a middle section matching cavity which is used for forming sealing sliding fit with the outer wall of a working plug (22), a rear section matching cavity which is used for forming sealing sliding fit with the outer wall of an energy storage plug (23) and a tail cavity which is used for forming sealing sliding fit with the outer wall of an additional plug rod (24) so as to seal the rear end of the sleeve cavity from front to back; the axial length of the rear-section matching cavity is greater than that of the energy storage plug (23), so that the rear-end matching cavity is divided into a front cavity (c) and a rear high-pressure energy storage cavity (d) by the energy storage plug (23);
the cavity (c) is provided with a normal pressure environment; a high-pressure energy storage liquid inlet valve (41) and a high-pressure energy storage liquid outlet valve (42) which are communicated with the high-pressure energy storage cavity (d) are arranged at the high-pressure energy storage cavity (d); a high-pressure liquid inlet valve (43) communicated with the simulation pump cavity (b) and a high-pressure liquid outlet valve (50) forming a tested piece are arranged at the simulation pump cavity (b), and an outlet of the high-pressure liquid inlet valve (43) is positioned at an inlet of the pressure exchange transition cavity (a); the high-pressure energy-storage liquid inlet valve (41) is communicated with the high-pressure liquid outlet valve (50) through a pump cavity discharge high-pressure pipe (61), and the high-pressure energy-storage liquid outlet valve (42) is communicated with the high-pressure liquid inlet valve (43) through a pump cavity suction high-pressure pipe (62);
the device also comprises a detection component for monitoring the working information of the stepped plug body (20), the cylinder sleeve (10) and the medium;
the tested object is one or more of a high-pressure drain valve (50), a stepped plug body (20) forming a plunger or a piston, a filler forming a friction pair with the stepped plug body (20), and a cylinder sleeve forming a friction pair with the stepped plug body (20).
2. The reciprocating pump wearing part life test device of claim 1, characterized in that: a low-pressure liquid inlet valve (44) communicated with the simulation pump cavity (b) is also arranged on the wall of the cylinder sleeve (10); the device also comprises a circulation auxiliary assembly (70) for supplying the medium and the cooling medium, wherein the inlet of the circulation auxiliary assembly (70) is communicated with the pump cavity discharge high-pressure pipe (61) and the pump cavity suction high-pressure pipe (62) respectively, and the outlet of the circulation auxiliary assembly (70) is communicated with the inlet end of the low-pressure liquid inlet valve (44).
3. The reciprocating pump wearing part life test device of claim 2, wherein: the circulation auxiliary assembly (70) comprises a liquid storage tank (71) used for storing media, the media are discharged from a high-pressure pipe (61) through a pump cavity and sucked into the high-pressure pipe (62) through the pump cavity and enter the liquid storage tank (71) through an overflow valve (80) and a liquid inlet pipeline respectively, and the media at the liquid outlet end of the liquid storage tank (71) enter a liquid outlet pipeline after being cooled through a first water-cooling heat exchanger (72) and finally enter a low-pressure liquid inlet valve (44) and a simulation pump cavity (b); temperature sensors (91) for monitoring the temperature of the medium when entering and flowing out are respectively arranged on the liquid inlet pipeline and the liquid outlet pipeline; the signal output end of the temperature sensor (91) is connected with the signal input end of the acquisition and control module (92).
4. The reciprocating pump wearing part life test device of claim 3, wherein: a liquid replenishing pipe is arranged on the liquid storage tank (71), and a liquid replenishing valve (73) is arranged on the liquid replenishing pipe.
5. The reciprocating pump wearing part life test device as claimed in claim 2, 3 or 4, wherein: the device further comprises a forced one-way valve (45), said forced one-way valve (45) being arranged within the pressure exchange transition chamber (a); when the small head plug (21) is scheduled to enter the pressure exchange transition cavity (a) and a sealing fit is formed between the small head plug and the pressure exchange transition cavity, the medium flows back to the pump cavity discharge high-pressure pipe (61) through the forced one-way valve (45); the sum of the liquid inlet flow of the low-pressure liquid inlet valve (44) and the liquid inlet flow of the pressure exchange transition cavity (a) is equal to the sum of the passing discharge capacities of the high-pressure liquid discharge valve (50) and the forced check valve (45).
6. The reciprocating pump wearing part life test device as claimed in claim 1, 2, 3 or 4, wherein: the detection assembly comprises a stroke frequency sensor (93) for monitoring the reciprocating times of the stepped plug body (20), a rotating speed sensor (94) for monitoring the rotating speed of the stepped plug body (20) and a pressure sensor (95) for monitoring the hydraulic pressure in the simulated pump cavity (b); the signal output ends of the stroke frequency sensor (93) and the pressure sensor (95) are connected to the signal input end of the acquisition and control module (92).
7. The reciprocating pump wearing part life test device as claimed in claim 1, 2, 3 or 4, wherein: the device also comprises a pressure boosting and stabilizing assembly (100), wherein the liquid outlet end of the pressure boosting and stabilizing assembly (100) is communicated with the pump cavity discharge high-pressure pipe (61) and the pump cavity suction high-pressure pipe (62) through a group of overflow valves (80); the pump chamber discharge high-pressure pipe (61) and the pump chamber suction high-pressure pipe (62) are both provided with an energy accumulator (110).
8. The reciprocating pump wearing part life test device as claimed in claim 1, 2, 3 or 4, wherein: an overflow valve (80) is arranged between the outlet of the high-pressure liquid discharge valve (50) and the inlet of the liquid storage tank (71); an overflow valve (80) is arranged between the outlet of the high-pressure energy-storage drain valve and the inlet of the liquid storage tank (71).
9. The reciprocating pump wearing part life test device as claimed in claim 1, 2, 3 or 4, wherein: a second water-cooled heat exchanger (62a) is arranged on the pump chamber suction high-pressure pipe (62).
10. The reciprocating pump wearing part life test device as claimed in claim 1, 2, 3 or 4, wherein: the power source (30) is a rotary reciprocating conversion mechanism driven by a variable frequency motor, and the tail end of the rotary reciprocating conversion mechanism is fixedly connected and matched with the rear end of the additional plug rod (24).
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