射孔弹药型罩旋压设备的设计
摘要
射孔技术是石油开采工程中的关键技术之一。射孔弹在石油工业中有着广泛和大量应用,其性能优劣对石油产能影响极大,然而射孔弹的质量及可靠性除与其正确的设计、所用材料质量、生产工艺及生产过程中工艺参数的控制密切相关外,还有一个重要的影响因素——药型罩。药型罩是射孔弹的“刀刃”、是影响石油生产的关键因素之一。目前,由于多数药型罩生产厂家都是采用老式油压机,生产自动化程度很低,液压系统的整体精度靠手动调整压力继电器和手动溢流阀的匹配关系保证,调整困难,受器件、压力显示精度和人为因素的影响,很难保证同一压制压力下,调整后和未调整前压制结果的一致性。虽然很多厂家从改变药型罩粉末配方等方面做出了许多研究,但是很少从药型罩生产设备入手来提高药型罩生产效率和提高药型罩生产过程中的自动化程度。
针对现行药型罩生产厂家的生产设备,本文对提高药型罩自动化生产程度的旋压设备进行了结构设计,其主要工作包括:
(1)根据金属粉末的流动性,设计了以刮板法为基本原理、以1s内快速稳定、称量精度为0.02g的高精度电子称作为称量工具的称量系统。
(2)结合现有的金属旋压成形技术和粉末成形技术,设计了会属粉末旋压成形的旋压系统,在原有模具基础上加以改进,设计一套适合旋转压制的主轴系统,并进行了强度校核。
(3)为避免药型罩在检测过程中容易划伤、提高药型罩壁厚差检测精度,设计基于激光位移传感器的非接触自动检测系统,激光传感器的检测精度达到2μm,超过了手工检测的0.04mm的要求。
(4)为提高设备生产的自动化程度,设计了进行自动上料和下料的机械手。
(5)设计了保证设备的正常运行的液压和控制系统。
本论文结合厂家提供的药型罩生产工艺,设计了一套完整的金属粉末药型罩旋压设备,提高了药型罩生产效率和压制压力的控制精度。
The perforating is one of the key technologies in petroleum engineering. Perforating charge is extensively applied in petroleum engineering. It's quality directly affects petroleum productivity. However, it is vital important to guarantee perforating charge quality and to enhance the credibility. The quality and credibility of perforating charge not only relate with the right design、the material quantity、producing process and controlling process parameters of perforating charge, but also have close relation with another important factor, its the liner. Liner is the knife edge of the perforating charge. It is one of the most important key parties. There are lots of manufacturer produce the liner by the old press machine with low level automation, the Precision of hydraulic system guaranteed through manual operating the pressure relay and relief valve. It's difficulty to make sure the result consistent with adjusting. Although they do lots of research in improve the metal power, but they never do research to improve the efficiency and the level automation.
According to the equipment of the manufacturer, this paper researches mainly includes the following aspects:
(1) According to the fluidness of metal power, designing the scraper blade, and using the electronic balance (soon responded in 1s、Measuring Accuracy at 0.02g) as the tool for the weighing system.
(2) According to the metal rotary pressured technology and the Powder molding technology, design the metal power rotary pressed system. Improving the old mold and designing a shaft system for rotary press, and Strength check is finished.
(3) Because the old measure method will scratch the outside of the liner, the non-contact laser measurement system is designed, which improved the precision.
(4) The Manipulator for translation the material and the product is designed for high level automation.
(5) Hydraulic system and the control system are designed.
针对现行药型罩生产厂家的生产设备,本文对提高药型罩自动化生产程度的旋压设备进行了结构设计,其主要工作包括:
(1)根据金属粉末的流动性,设计了以刮板法为基本原理、以1s内快速稳定、称量精度为0.02g的高精度电子称作为称量工具的称量系统。
(2)结合现有的金属旋压成形技术和粉末成形技术,设计了会属粉末旋压成形的旋压系统,在原有模具基础上加以改进,设计一套适合旋转压制的主轴系统,并进行了强度校核。
(3)为避免药型罩在检测过程中容易划伤、提高药型罩壁厚差检测精度,设计基于激光位移传感器的非接触自动检测系统,激光传感器的检测精度达到2μm,超过了手工检测的0.04mm的要求。
(4)为提高设备生产的自动化程度,设计了进行自动上料和下料的机械手。
(5)设计了保证设备的正常运行的液压和控制系统。
本论文结合厂家提供的药型罩生产工艺,设计了一套完整的金属粉末药型罩旋压设备,提高了药型罩生产效率和压制压力的控制精度。
The perforating is one of the key technologies in petroleum engineering. Perforating charge is extensively applied in petroleum engineering. It's quality directly affects petroleum productivity. However, it is vital important to guarantee perforating charge quality and to enhance the credibility. The quality and credibility of perforating charge not only relate with the right design、the material quantity、producing process and controlling process parameters of perforating charge, but also have close relation with another important factor, its the liner. Liner is the knife edge of the perforating charge. It is one of the most important key parties. There are lots of manufacturer produce the liner by the old press machine with low level automation, the Precision of hydraulic system guaranteed through manual operating the pressure relay and relief valve. It's difficulty to make sure the result consistent with adjusting. Although they do lots of research in improve the metal power, but they never do research to improve the efficiency and the level automation.
According to the equipment of the manufacturer, this paper researches mainly includes the following aspects:
(1) According to the fluidness of metal power, designing the scraper blade, and using the electronic balance (soon responded in 1s、Measuring Accuracy at 0.02g) as the tool for the weighing system.
(2) According to the metal rotary pressured technology and the Powder molding technology, design the metal power rotary pressed system. Improving the old mold and designing a shaft system for rotary press, and Strength check is finished.
(3) Because the old measure method will scratch the outside of the liner, the non-contact laser measurement system is designed, which improved the precision.
(4) The Manipulator for translation the material and the product is designed for high level automation.
(5) Hydraulic system and the control system are designed.
引文
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[2]倪德忠.油气井射孔层位的深度定位方法.海洋石油,2004,(2):6-9.
[3]Hatz J.F.,Haney B.L.,Ager S.A..High-speed down hole memory recorder and software used to design and confirm perforating propellant behavior and formation fracturing.1999SPE Annual Technical Conference and Exhibition,Houston,Texas,1999(11):3-6.
[4]惠宁利,王秀芝.石油工业用爆破技术.北京:石油工业出版社,1994.
[5]W.T.贝尔,R.A.苏库普.射孔.北京:石油工业出版社,1999.
[6]大庆射孔弹厂内部资料,2000.
[7]王海东,孙新波.国内外射孔技术发展综述.爆破器材.2006,35(3):33-36.
[8]中林等.国外金属旋压发展概况.第一届旋乐技术交流文集,1999.
[9]Weimann K,et al.18th Int Symp on Ballistics.International Ballistics Committee,San Antonio,2003.
[10]Wang SongKang,et al.High-Tech Ammunition.Ordnance Industry Press,Beijing,1997.
[11]《锻压技术手册》编委会.锻压技术手册.北京:国防工业出版社,1989.
[12]张顺福,孙存福.国产旋乐设备的发展和应用.金属成形工艺,2003(1):1-3,9.
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[16]洪奕.药型罩制造技术和新工艺.弹箭技术.1996,24-37.
[17]郑连清.火工品压药工艺方法的改进.火工品.1999.
[18]郭红军等.粉末药型罩的试验研究.测井技术,2005,29(5):71-73.
[19]李寿刚.液压传动.北京:北京理工大学出版社,1994.
[20]陈子皋,周凤香,廖振功.机械设计手册(第四卷)气乐传动.北京:机械工业出版社,2004.
[21]施吕彦.动态称重测力技术的现状利发展趋势.计量学报.2001,22(3):200-205.
[22]张海清,李宝支,罗先利.定量下料问题的动态称量解决方案.计量学报.1998,19(3):221-224.
[23]徐科军.称重传感器自适应动态补偿方法.仪表技术与传感器.1997(6):6-8.
[24]汪俊等.金属粉末零件压制过程有限元模拟的研究.中国机械工程.1997,8(4):40-43.
[25]DoraiveIu S M,et al.A New Yield Function for Compressible P/M Materials.Inter.J Mech,Sci.1984,26(9/10):527-535.
[26]LeeDN,et al.Plastic Yield Behavim- of Porous Metals.Powder Metallurgy.1992,35(4):275-279.
[27]HwangBB,et al.Deformation Characterization of Powdered Metals inCompaction.Inter.J.Mech,Tools Manufacture.1990,30(2):309-323.
[28]Hewitt R L,WallaceW,MalherbeM C.Plastic deform in metal powder compaction.Powder metallurgy,1974,17(33) 6-7.
[29]黄培云.粉末冶金原理.北京:冶金工业出版社,1997.
[30]康爱英.润滑剂对粉末制品模压成形的影响分析.邵阳学院学报,2004,1(2):30-31.
[31]Barber J et al.Dynamic magnetic compaction to high density using pulsed magnetic forces.Metal Powder Report,1997,52(5):54.
[32]吴成义,张丽英.粉体成形力学原理.北京:冶金工业出版社,2003.
[33]王盘鑫.粉末冶金学.北京:冶金工业出版社,1996.
[34]任学平.粉末金属屈服准则和流动应力的研究:(博士学位论文).哈尔滨:哈尔滨工业大学,1999.
[35]Tran D V,et al.Numerical Modillion of powder Compaction Processes:Displacement Based Finite Element Method.Powder Metallurgy.1993,36(4):257-263
[36]胡良忱.聚能射孔弹药型罩的质量控制及提高聚能弹性能的途径.国外测廾情报资料选编,1993,2(2):10-12.
[37]史慧生:核技术在药型罩密度检测中的应用,核技术.1998.8.
[38]于海蓉:特种弹药弹体尺寸自动监测系统测量方法和软件设计研究:(硕士学位论文).长沙:国防科技大学,2003.
[39]马明健等.数据采集与处理技术.西安交通大学出版社,1999.
[40]Saeed Moaveni.有限元分析-ANSYS理论与应用.欧阳宇,王菘等译.北京:电子工业出版社,2003.
[41]Q.M.Li,H.Meng,Pressure-impulse diagram for blast loads based on dimensional analysis and single-degree-of-freedom model,Journal of Engineering Mechanics 2002,128(1):87-92.
[42]M.Y.H.Bangash,Impact and Explosion-Analysis and Design,Blackwell Scientific Publication,Oxford,1993.
[43]嘉木工作室.ANSYS5.7有限元实例分析教程.北京:机械工业出版社,2002.
[44]曾攀.有限元分析及应用.北京:清华大学出版社,2004.
[45]邵将,李世国.Pro/E与ANSYS的连接方法利应用.机械设计,2004(9):58-60.
[46]蓝宇,张连杰.大型有限元分析软件ANSYS.应用科技,2004,27(6):13-15.
[47]俞继印.直动式压力-流量复合阀的研究:(硕士学位论文).杭州:浙江工业大学,2006.
[48]裴翔,郑家锦,李胜等.P/Q复合阀调压静特性分析.浙江工业大学学报,2001(3):14-19.
[49]邵安岑.电液比例压力流量复合控制阀的特性研究:(硕士学位论文).杭州:浙江大学,2002.
[50]刘安治.PQ阀在冶金液压系统中的应用.江苏冶金,2003,5(2):17-19.
[51]GP高级应用手册.2003.
[52]西门子S7-200PLC编程手册.2001.
[2]倪德忠.油气井射孔层位的深度定位方法.海洋石油,2004,(2):6-9.
[3]Hatz J.F.,Haney B.L.,Ager S.A..High-speed down hole memory recorder and software used to design and confirm perforating propellant behavior and formation fracturing.1999SPE Annual Technical Conference and Exhibition,Houston,Texas,1999(11):3-6.
[4]惠宁利,王秀芝.石油工业用爆破技术.北京:石油工业出版社,1994.
[5]W.T.贝尔,R.A.苏库普.射孔.北京:石油工业出版社,1999.
[6]大庆射孔弹厂内部资料,2000.
[7]王海东,孙新波.国内外射孔技术发展综述.爆破器材.2006,35(3):33-36.
[8]中林等.国外金属旋压发展概况.第一届旋乐技术交流文集,1999.
[9]Weimann K,et al.18th Int Symp on Ballistics.International Ballistics Committee,San Antonio,2003.
[10]Wang SongKang,et al.High-Tech Ammunition.Ordnance Industry Press,Beijing,1997.
[11]《锻压技术手册》编委会.锻压技术手册.北京:国防工业出版社,1989.
[12]张顺福,孙存福.国产旋乐设备的发展和应用.金属成形工艺,2003(1):1-3,9.
[13]王盘鑫.粉末冶金学.北京:冶金工业出版社,1997.
[14]黄培云.粉末冶金原理.北京:冶金工业出版社,1981.
[15]王宝生.国外药型罩材料技术研究.兵器工业情报研究所,1998.
[16]洪奕.药型罩制造技术和新工艺.弹箭技术.1996,24-37.
[17]郑连清.火工品压药工艺方法的改进.火工品.1999.
[18]郭红军等.粉末药型罩的试验研究.测井技术,2005,29(5):71-73.
[19]李寿刚.液压传动.北京:北京理工大学出版社,1994.
[20]陈子皋,周凤香,廖振功.机械设计手册(第四卷)气乐传动.北京:机械工业出版社,2004.
[21]施吕彦.动态称重测力技术的现状利发展趋势.计量学报.2001,22(3):200-205.
[22]张海清,李宝支,罗先利.定量下料问题的动态称量解决方案.计量学报.1998,19(3):221-224.
[23]徐科军.称重传感器自适应动态补偿方法.仪表技术与传感器.1997(6):6-8.
[24]汪俊等.金属粉末零件压制过程有限元模拟的研究.中国机械工程.1997,8(4):40-43.
[25]DoraiveIu S M,et al.A New Yield Function for Compressible P/M Materials.Inter.J Mech,Sci.1984,26(9/10):527-535.
[26]LeeDN,et al.Plastic Yield Behavim- of Porous Metals.Powder Metallurgy.1992,35(4):275-279.
[27]HwangBB,et al.Deformation Characterization of Powdered Metals inCompaction.Inter.J.Mech,Tools Manufacture.1990,30(2):309-323.
[28]Hewitt R L,WallaceW,MalherbeM C.Plastic deform in metal powder compaction.Powder metallurgy,1974,17(33) 6-7.
[29]黄培云.粉末冶金原理.北京:冶金工业出版社,1997.
[30]康爱英.润滑剂对粉末制品模压成形的影响分析.邵阳学院学报,2004,1(2):30-31.
[31]Barber J et al.Dynamic magnetic compaction to high density using pulsed magnetic forces.Metal Powder Report,1997,52(5):54.
[32]吴成义,张丽英.粉体成形力学原理.北京:冶金工业出版社,2003.
[33]王盘鑫.粉末冶金学.北京:冶金工业出版社,1996.
[34]任学平.粉末金属屈服准则和流动应力的研究:(博士学位论文).哈尔滨:哈尔滨工业大学,1999.
[35]Tran D V,et al.Numerical Modillion of powder Compaction Processes:Displacement Based Finite Element Method.Powder Metallurgy.1993,36(4):257-263
[36]胡良忱.聚能射孔弹药型罩的质量控制及提高聚能弹性能的途径.国外测廾情报资料选编,1993,2(2):10-12.
[37]史慧生:核技术在药型罩密度检测中的应用,核技术.1998.8.
[38]于海蓉:特种弹药弹体尺寸自动监测系统测量方法和软件设计研究:(硕士学位论文).长沙:国防科技大学,2003.
[39]马明健等.数据采集与处理技术.西安交通大学出版社,1999.
[40]Saeed Moaveni.有限元分析-ANSYS理论与应用.欧阳宇,王菘等译.北京:电子工业出版社,2003.
[41]Q.M.Li,H.Meng,Pressure-impulse diagram for blast loads based on dimensional analysis and single-degree-of-freedom model,Journal of Engineering Mechanics 2002,128(1):87-92.
[42]M.Y.H.Bangash,Impact and Explosion-Analysis and Design,Blackwell Scientific Publication,Oxford,1993.
[43]嘉木工作室.ANSYS5.7有限元实例分析教程.北京:机械工业出版社,2002.
[44]曾攀.有限元分析及应用.北京:清华大学出版社,2004.
[45]邵将,李世国.Pro/E与ANSYS的连接方法利应用.机械设计,2004(9):58-60.
[46]蓝宇,张连杰.大型有限元分析软件ANSYS.应用科技,2004,27(6):13-15.
[47]俞继印.直动式压力-流量复合阀的研究:(硕士学位论文).杭州:浙江工业大学,2006.
[48]裴翔,郑家锦,李胜等.P/Q复合阀调压静特性分析.浙江工业大学学报,2001(3):14-19.
[49]邵安岑.电液比例压力流量复合控制阀的特性研究:(硕士学位论文).杭州:浙江大学,2002.
[50]刘安治.PQ阀在冶金液压系统中的应用.江苏冶金,2003,5(2):17-19.
[51]GP高级应用手册.2003.
[52]西门子S7-200PLC编程手册.2001.