3000马力电驱动齿轮传动绞车设计研究
摘要
绞车是钻机的核心部件。为开发国内大型石油钻机市场，本文完成了9000m钻机配套的3000马力钻井绞车的设计研究。
3000马力电驱动齿轮传动绞车课题为国家十五期间重大装备国产化项目“ZJ90DB钻机”的子课题，绞车为全新设计，绞车的设计思想突破了当前国内现有绞车结构模式，结构独特、新颖。绞车设计采用了交流变频、液控盘刹、伊顿气控多盘刹车等最新国际先进技术，其特点是：绞车只设两档，换档采用高、低速离合器换档方式，动力从滚筒一侧输入，各主要单元模块采用联轴器连接，传动选用齿轮变速形式等。
3000马力电驱动齿轮传动绞车设计要点如下：
(1)介绍了现有绞车类型、结构和性能特点，阐述了绞车今后的发展趋势和开发设计3000马力大型绞车的目的、意义及国内外石油钻井绞车的研究现状。
(2)阐述了绞车的功能、原理，在充分分析确定了绞车主要组成元件形式的情况下，建立了4种绞车方案，通过方案对比和工艺性、可靠性、经济性、运输安装维修性、标准化、通用性、技术性等综合分析，择优选择出绞车设计传动方案，并对此方案的可行性进行了分析。
(3)确定了绞车基本参数，同时对绞车主要组成系统如电动机、绞车滚筒、变速传动箱、主刹车、辅助刹车、离合器等进行了详细的参数设计和配套选型。
(4)建立了绞车转速与扭矩、大钩速度与钩载、快绳拉力之间的关系及绞车提升性能曲线，同时介绍了绞车交流变频、液压盘刹、气动辅助刹车、高、低速离合器等控制系统。
(5)系统的设计了绞车总体、变速箱总成、滚筒轴总成等图形结构，介绍了绞车及主要部件的结构特点，详细绘制了滚筒轴等关键零件结构尺
寸图形。
(6)绞车强度设计以滚筒轴、变速箱输出端低速级齿轮等典型零件
为设计重点，先后从模型简化、受力分析、应力计算、静强度、疲劳强度
和可靠性设计等多方面着手，进行了全面系统的设计，同时对其它重要零
件如变速箱三根轴、输入齿轮、主要轴承、关键联接键、滚筒体等也进行
了强度设计。
(7)在设计的基础上，总结了3000马力电驱动齿轮传动绞车的性能
特点，并对本文设计的绞车未来进行了前景展望。
Drawworks is a core component of a drilling rig. With the purpose of exploring domestic large size drilling rig market, in this article some design research attempt is made for 3000HP drawworks, which shall be used to match 9000m drilling rig.
The subject matter, 3000HP electrical powered gear transmission drawworks, is one of the sub-item of "ZJ 90DB DRILLING RIG", which is one of the important "have equipment domestically made" item during our national "the 10th 5-year plan". This drawworks has a completely novel design (no similar design has been found) , which made a great breakthrough against the present drawworks structure mode in China. In this design, many latest international technical development such as variable - frequency AC power, hydraulic disc brake, Eaton pneumatic multi-disc brake are adopted. It features that there are only two shifts designed for this drawworks, shifting is realized by means of high/low speed clutches, power is inputted from the drum stele, the main modules are joined together by couplings, power transmission is by means of gear speed regulation.
Key point of 3000HP electrical powered gear transmission drawworks design are stated as following:
1 It is presented here about the current drawworks' type, structure and performance characteristic, stated its future development tendency and the purpose, significance to develop this 300QHP drawworks. Drilling drawworks research development circumstance home and abroad at present is also introduced here.
2 It is elaborated here on drawworks function and working principles. Detailed analysis is made to set drawworks main components, based upon which four kinds of drawworks design are established. After making collation and comparison between these designs, and making comprehensive analysis on their technique performance, reliability, economy, transportation, installation, maintenance, standardization, universalism, the optimum drawworks transmission design is selected. Feasibility analysis of the selected design is also made herein with.
3 Set the drawworks basic parameters. Meanwhile elaborated parameters design for drawworks configuration is also made herein for all the constitution system such as motor, drawworks drum, transmission box, main/auxiliary brakes and clutch as well.
4 Work out the hoisting performance curve and performance curve on the relations between drawworks speed and torque, hook speed and hook load, fast line pull. Control system of AC variable frequency, hydraulic disc, pneumatic auxiliary brake as well as high/low speed clutch are also stated
5 Systematically make the design the structure of drawworks assy, gear reducer box assy, and drum shaft as well. State the structural features of drawworks and its main components. Work out in detail the structural dimension drawings of all the crucial parts such as drum shaft and so on.
6 Focused upon typical parts such as drum shaft, gear box output lower speed gear etc, carrying out from varies ramifications such as model simplification, force analysis, stress calculation, static strength, fatigue strength and design reliability as well, all - sided comprehensive design has been made. Meanwhile strength design is also made for others important parts such as the three shafts of gearbox, input gear, main bearings, important joint key as well as drum body.
7 Based on the aforesaid design work, generalize the performance characteristics of this 3000HP electrical powered drawworks, envisage prospective in the future for drawworks stated herein with.
3000马力电驱动齿轮传动绞车课题为国家十五期间重大装备国产化项目“ZJ90DB钻机”的子课题，绞车为全新设计，绞车的设计思想突破了当前国内现有绞车结构模式，结构独特、新颖。绞车设计采用了交流变频、液控盘刹、伊顿气控多盘刹车等最新国际先进技术，其特点是：绞车只设两档，换档采用高、低速离合器换档方式，动力从滚筒一侧输入，各主要单元模块采用联轴器连接，传动选用齿轮变速形式等。
3000马力电驱动齿轮传动绞车设计要点如下：
(1)介绍了现有绞车类型、结构和性能特点，阐述了绞车今后的发展趋势和开发设计3000马力大型绞车的目的、意义及国内外石油钻井绞车的研究现状。
(2)阐述了绞车的功能、原理，在充分分析确定了绞车主要组成元件形式的情况下，建立了4种绞车方案，通过方案对比和工艺性、可靠性、经济性、运输安装维修性、标准化、通用性、技术性等综合分析，择优选择出绞车设计传动方案，并对此方案的可行性进行了分析。
(3)确定了绞车基本参数，同时对绞车主要组成系统如电动机、绞车滚筒、变速传动箱、主刹车、辅助刹车、离合器等进行了详细的参数设计和配套选型。
(4)建立了绞车转速与扭矩、大钩速度与钩载、快绳拉力之间的关系及绞车提升性能曲线，同时介绍了绞车交流变频、液压盘刹、气动辅助刹车、高、低速离合器等控制系统。
(5)系统的设计了绞车总体、变速箱总成、滚筒轴总成等图形结构，介绍了绞车及主要部件的结构特点，详细绘制了滚筒轴等关键零件结构尺
寸图形。
(6)绞车强度设计以滚筒轴、变速箱输出端低速级齿轮等典型零件
为设计重点，先后从模型简化、受力分析、应力计算、静强度、疲劳强度
和可靠性设计等多方面着手，进行了全面系统的设计，同时对其它重要零
件如变速箱三根轴、输入齿轮、主要轴承、关键联接键、滚筒体等也进行
了强度设计。
(7)在设计的基础上，总结了3000马力电驱动齿轮传动绞车的性能
特点，并对本文设计的绞车未来进行了前景展望。
Drawworks is a core component of a drilling rig. With the purpose of exploring domestic large size drilling rig market, in this article some design research attempt is made for 3000HP drawworks, which shall be used to match 9000m drilling rig.
The subject matter, 3000HP electrical powered gear transmission drawworks, is one of the sub-item of "ZJ 90DB DRILLING RIG", which is one of the important "have equipment domestically made" item during our national "the 10th 5-year plan". This drawworks has a completely novel design (no similar design has been found) , which made a great breakthrough against the present drawworks structure mode in China. In this design, many latest international technical development such as variable - frequency AC power, hydraulic disc brake, Eaton pneumatic multi-disc brake are adopted. It features that there are only two shifts designed for this drawworks, shifting is realized by means of high/low speed clutches, power is inputted from the drum stele, the main modules are joined together by couplings, power transmission is by means of gear speed regulation.
Key point of 3000HP electrical powered gear transmission drawworks design are stated as following:
1 It is presented here about the current drawworks' type, structure and performance characteristic, stated its future development tendency and the purpose, significance to develop this 300QHP drawworks. Drilling drawworks research development circumstance home and abroad at present is also introduced here.
2 It is elaborated here on drawworks function and working principles. Detailed analysis is made to set drawworks main components, based upon which four kinds of drawworks design are established. After making collation and comparison between these designs, and making comprehensive analysis on their technique performance, reliability, economy, transportation, installation, maintenance, standardization, universalism, the optimum drawworks transmission design is selected. Feasibility analysis of the selected design is also made herein with.
3 Set the drawworks basic parameters. Meanwhile elaborated parameters design for drawworks configuration is also made herein for all the constitution system such as motor, drawworks drum, transmission box, main/auxiliary brakes and clutch as well.
4 Work out the hoisting performance curve and performance curve on the relations between drawworks speed and torque, hook speed and hook load, fast line pull. Control system of AC variable frequency, hydraulic disc, pneumatic auxiliary brake as well as high/low speed clutch are also stated
5 Systematically make the design the structure of drawworks assy, gear reducer box assy, and drum shaft as well. State the structural features of drawworks and its main components. Work out in detail the structural dimension drawings of all the crucial parts such as drum shaft and so on.
6 Focused upon typical parts such as drum shaft, gear box output lower speed gear etc, carrying out from varies ramifications such as model simplification, force analysis, stress calculation, static strength, fatigue strength and design reliability as well, all - sided comprehensive design has been made. Meanwhile strength design is also made for others important parts such as the three shafts of gearbox, input gear, main bearings, important joint key as well as drum body.
7 Based on the aforesaid design work, generalize the performance characteristics of this 3000HP electrical powered drawworks, envisage prospective in the future for drawworks stated herein with.
引文
1．华东石油学院矿机教研室．石油钻采机械[上册]．北京．石油工业出版社．1980
2．陈如恒．沈家骏编著．钻井机械的设计计算．北京．石油工业出版社．1995
3．杨敏嘉．常玉连编著．石油钻采设备系统设计．北京．石油工业出版社．2000
4．中国石油天然气行业标准SY／T5609-1999．石油钻机形式与基本参数．国家石油和化学工业局．1999
5．汪寒．屠由义．盘式刹车系统设计初探．石油机械第15卷第2期．1987
6．马小亮．大功率交—交变频调速及矢量控制技术．机械工业出版社．1999—2版
7．樊启蕴．李维明等．用盘式刹车取代带刹车的分析与建议．石油机械第22卷第8期．1994
8．张连山．刘永红．国外顶驱AC变频驱动的应用与发展．石油机械第26卷第5期．1998
9．高向前．齐明侠等．2000米钻机液控盘式刹车的设计．石油机械第21卷第5期．1993
10．张嗣伟．樊启蕴．关于发展我国钻机盘式刹车技术的几点认识．石油机械第28卷第1期．2000
11．高向前摘译．世界第一台5000马力绞车．国外石油机械．第9卷第3期．1998
12．刘鸿文主编．材料力学(第三版)．高等教育出版社．1992
13．秋丽．新型液压驱动齿轮绞车．石油机械．第28卷第10期．2000
14．张连山．国外新型单轴齿轮绞车．石油机械．第28卷第8期．2000
15．机械设计手册联合编写组编．机械设计手册第二版(修订)．化学工业出版社．1982
16．徐灏主编．机械设计手册．第2、第3卷．机械工业出版社．1991
17．宝石钻机液压盘式刹车使用说明书．宝鸡石油机械厂．2000
18．径向气胎离合器选用规范．兰州石油化工机器厂
19．32L钻机设计计算书．宝鸡石油机械厂．1999
20．DFS系列风冷型电磁涡流刹车使用说明书．华北石油华源机械设备制造厂．2000
21．宝石ZJ40L、ZJ50D、ZJ60D、ZJ70D图纸．宝鸡石油机械厂．2001
22. Airflex clutches,brackes,rotorseals and quick release valves for oil and gas applications Eaton Lnvestments Co.,Ltd
23. Varco's Automated Hoisting System Introduction.VARCO.2002
24. GE Drilling Motors.GE Drilling Equipment.2002
25. 1982/1983 General catalog.IDECO.2002
26．宜文．世界第一台特大功率绞车问世．石油机械第26卷第2期．1998
27．张连山．石油钻机绞车的设计与计算．石油机械第25卷第9期．1997
28．郭公喜等．发展电驱动钻机势在必行．石油矿场机械第26卷第5期．1997
29．康涛．张军等．钻机电传动控制系统国产化现状与发展．电气传动自动化第22卷第6期．2000
30．舒远彬．国内石油钻机技术发展趋势探讨．石油矿场机械．第27卷第1期．1998
31．张连山编译．国外石油钻机技术发展趋势．国外石油机械．第7卷第2期．1996
32．濮良贵主编．机械零件(1982年修订本)．高等教育出版社．1982
33．美国石油学会API．油田设备标准译文汇编(上册)．机械电子工业部兰州石油机械研究所．1989
34．卢玉明编．机械零件的可靠性设计．高等教育出版社．1980
35．赵来军等．变频调速技术在智能化抽油机系统中的应用．石油机械．第26卷第2期．1998
2．陈如恒．沈家骏编著．钻井机械的设计计算．北京．石油工业出版社．1995
3．杨敏嘉．常玉连编著．石油钻采设备系统设计．北京．石油工业出版社．2000
4．中国石油天然气行业标准SY／T5609-1999．石油钻机形式与基本参数．国家石油和化学工业局．1999
5．汪寒．屠由义．盘式刹车系统设计初探．石油机械第15卷第2期．1987
6．马小亮．大功率交—交变频调速及矢量控制技术．机械工业出版社．1999—2版
7．樊启蕴．李维明等．用盘式刹车取代带刹车的分析与建议．石油机械第22卷第8期．1994
8．张连山．刘永红．国外顶驱AC变频驱动的应用与发展．石油机械第26卷第5期．1998
9．高向前．齐明侠等．2000米钻机液控盘式刹车的设计．石油机械第21卷第5期．1993
10．张嗣伟．樊启蕴．关于发展我国钻机盘式刹车技术的几点认识．石油机械第28卷第1期．2000
11．高向前摘译．世界第一台5000马力绞车．国外石油机械．第9卷第3期．1998
12．刘鸿文主编．材料力学(第三版)．高等教育出版社．1992
13．秋丽．新型液压驱动齿轮绞车．石油机械．第28卷第10期．2000
14．张连山．国外新型单轴齿轮绞车．石油机械．第28卷第8期．2000
15．机械设计手册联合编写组编．机械设计手册第二版(修订)．化学工业出版社．1982
16．徐灏主编．机械设计手册．第2、第3卷．机械工业出版社．1991
17．宝石钻机液压盘式刹车使用说明书．宝鸡石油机械厂．2000
18．径向气胎离合器选用规范．兰州石油化工机器厂
19．32L钻机设计计算书．宝鸡石油机械厂．1999
20．DFS系列风冷型电磁涡流刹车使用说明书．华北石油华源机械设备制造厂．2000
21．宝石ZJ40L、ZJ50D、ZJ60D、ZJ70D图纸．宝鸡石油机械厂．2001
22. Airflex clutches,brackes,rotorseals and quick release valves for oil and gas applications Eaton Lnvestments Co.,Ltd
23. Varco's Automated Hoisting System Introduction.VARCO.2002
24. GE Drilling Motors.GE Drilling Equipment.2002
25. 1982/1983 General catalog.IDECO.2002
26．宜文．世界第一台特大功率绞车问世．石油机械第26卷第2期．1998
27．张连山．石油钻机绞车的设计与计算．石油机械第25卷第9期．1997
28．郭公喜等．发展电驱动钻机势在必行．石油矿场机械第26卷第5期．1997
29．康涛．张军等．钻机电传动控制系统国产化现状与发展．电气传动自动化第22卷第6期．2000
30．舒远彬．国内石油钻机技术发展趋势探讨．石油矿场机械．第27卷第1期．1998
31．张连山编译．国外石油钻机技术发展趋势．国外石油机械．第7卷第2期．1996
32．濮良贵主编．机械零件(1982年修订本)．高等教育出版社．1982
33．美国石油学会API．油田设备标准译文汇编(上册)．机械电子工业部兰州石油机械研究所．1989
34．卢玉明编．机械零件的可靠性设计．高等教育出版社．1980
35．赵来军等．变频调速技术在智能化抽油机系统中的应用．石油机械．第26卷第2期．1998