油田防喷器一步法注射覆胶成型硫化设备的设计研究与三维动态模拟
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摘要
油田防喷器因其功能全面,能适用井口的多种工况迅速封井等优点在油田生产中得到广泛应用。然而其工作环境充满了泥浆、沙粒、碎石,条件十分恶劣,因此对其物理机械性能要求较高。但是传统的覆胶成型方法及配套设备存在着诸多不足,一是,制品的质量不高,稳定性差;二是,生产效率低,劳动强度高,提高了其生产成本。影响了防喷器的使用寿命和工作可靠性。
本文通过对橡胶注射成型装置的工作原理和设备的研究,在一步法注射原理基础上,设计了一种全新的防喷器注射覆胶成型硫化设备。对此,本课题着重做了如下工作:
1、首次将一步法注射成型技术应用在油田防喷器连续注射覆胶成型设计中,解决了国内外长期来未解决的防喷器注射覆胶成型的容量问题和可控注射成型压力问题,为油田防喷器实现连续注射覆胶成型提供关键技术。
2、首次设计了油田防喷器注射覆胶成型硫化机,这在硬件技术上保证了防喷器注射覆胶成型的可行性,同时实现提高制品质量,提高制品寿命,提高生产效率,降低能耗,降低运行成本和实现机械化、自动化等一系列优点。
3、首次设计采用电动锁环技术与电磁吸合技术相结合的新技术,成功地解决了机内注射——硫化和移模注射——硫化的技术问题,使本设计具有灵活机动的双功能效果,其根据生产需要自主选择操作方式,有效地提高生产效率,方便操作和节省运行成本等。
4、设计中运用了先进的数字——传感技术。在机模压合力、注射轴向力和机头压力等关键参数均采用了数字——传感技术,实现了数字化操作,使设备运行安全可靠、制品质量稳定、操作方便简单以及易于实现自动化。
5、本次设计采用CAD技术对重要零部件进行建模,并转换为CAE模型,通过有限元法对主要受力部件进行分析,同时对分析结果再分析,并针对分析结果中所暴露出来的原设计方案中的不足进行改进和优化,从而提高了设计方案的可靠性。
6、运用三维造型软件SolidWorks对整机所有零部件进行三维造型,同时利用三维模拟软件3dsmax对注射硫化装置进行三维动态模拟仿真,证明设计是符合安装、拆卸、尺寸配合的。
Because the function of the oil field ejection controller is comprehensive and can be suitable for many operating modes of the well head to seal rapidly, it is used widely in the oil field production. But its working conditions is very bad to fill the mud, the sand, the crushed stone, the core part-rubber core needs high physical mechanical property .The traditional duplicate rubber formation method and the supplementary equipment have many insufficiencies: firstly, the product quality is not high, the stability is bad; Secondly, the production efficiency is low, the labor intensity is high, its production cost enhances. These shortcomings have affected the ring-like ejection controller's service life and the operational reliability.
This article researches the rubber injection molding installment's principle and equipment, based on one-stage process injection principle, has designed a brand-new kind of dual purpose ring-like ejection controller’s rubber core injection curing formation equipment. The topic has been recreating the following works:
1. It is the first time to use one-step process injection molding technology in the formation design of the oil field ejection controller which is duplicated with rubber continuously. It has solved the capacity question of the ejected formation of ejection controller and the controllable ejected formation presure question which have puzzled the domestic and foreign research institution for so long time. It provides the key technology for realizing formation design of the oil field ejection controller which is duplicated with rubber continuously.
2. It is the first time to design ejected duplicated rubber formation curing unit for the oil field ejection controller. It can guarantee the feasibility of the ejected formation of ejection controller on the hardware technology. Meanwhile, it also can improve the product quality, enhance the product life, raise the production efficiency, reduce the energy consumption, reduce the run cost and realize the mechanization、the automation and so on.
3. It is the first time to use the electrically operated circlet technology and the electromagnetism attracts gathers technology simultaneously.It has solved the technical question of injected the curing within the barrel and the moved mold injection-curing successfully which enables the design to have the nimble mobile double function effect. The operated ways which can be changed according to the production could raise the production efficiency obviously, facilitated operate and save the run cost and so on.
4. It has used the advanced digital sensing technology in the design for the key parameter of the mold pressing with joint forces, the injection axial force and the head pressure. It has realized the digital operation which can cause the equipment movement safe, the product quality to be stable, the operation simple and easy as well as easy to be automated.
5. It has modelled the important parts using the CAD technology and transformed to the CAE model in the design. It has analyzed the main stress part and analyzed the results using the finite element method .It has improved and optimized the original design plan aimed at insufficiencies which has been exposed to enhance the design proposal reliability.
6. It carries on the three dimensional kinetic simulator simulations to the injection installment using three dimensional simulation software 3dsmax and utilizes three dimensional blast effect to indicate the connection relations of the various spare parts which can prove the design conformed to the installment, the demolition, the size coordination.
本文通过对橡胶注射成型装置的工作原理和设备的研究,在一步法注射原理基础上,设计了一种全新的防喷器注射覆胶成型硫化设备。对此,本课题着重做了如下工作:
1、首次将一步法注射成型技术应用在油田防喷器连续注射覆胶成型设计中,解决了国内外长期来未解决的防喷器注射覆胶成型的容量问题和可控注射成型压力问题,为油田防喷器实现连续注射覆胶成型提供关键技术。
2、首次设计了油田防喷器注射覆胶成型硫化机,这在硬件技术上保证了防喷器注射覆胶成型的可行性,同时实现提高制品质量,提高制品寿命,提高生产效率,降低能耗,降低运行成本和实现机械化、自动化等一系列优点。
3、首次设计采用电动锁环技术与电磁吸合技术相结合的新技术,成功地解决了机内注射——硫化和移模注射——硫化的技术问题,使本设计具有灵活机动的双功能效果,其根据生产需要自主选择操作方式,有效地提高生产效率,方便操作和节省运行成本等。
4、设计中运用了先进的数字——传感技术。在机模压合力、注射轴向力和机头压力等关键参数均采用了数字——传感技术,实现了数字化操作,使设备运行安全可靠、制品质量稳定、操作方便简单以及易于实现自动化。
5、本次设计采用CAD技术对重要零部件进行建模,并转换为CAE模型,通过有限元法对主要受力部件进行分析,同时对分析结果再分析,并针对分析结果中所暴露出来的原设计方案中的不足进行改进和优化,从而提高了设计方案的可靠性。
6、运用三维造型软件SolidWorks对整机所有零部件进行三维造型,同时利用三维模拟软件3dsmax对注射硫化装置进行三维动态模拟仿真,证明设计是符合安装、拆卸、尺寸配合的。
Because the function of the oil field ejection controller is comprehensive and can be suitable for many operating modes of the well head to seal rapidly, it is used widely in the oil field production. But its working conditions is very bad to fill the mud, the sand, the crushed stone, the core part-rubber core needs high physical mechanical property .The traditional duplicate rubber formation method and the supplementary equipment have many insufficiencies: firstly, the product quality is not high, the stability is bad; Secondly, the production efficiency is low, the labor intensity is high, its production cost enhances. These shortcomings have affected the ring-like ejection controller's service life and the operational reliability.
This article researches the rubber injection molding installment's principle and equipment, based on one-stage process injection principle, has designed a brand-new kind of dual purpose ring-like ejection controller’s rubber core injection curing formation equipment. The topic has been recreating the following works:
1. It is the first time to use one-step process injection molding technology in the formation design of the oil field ejection controller which is duplicated with rubber continuously. It has solved the capacity question of the ejected formation of ejection controller and the controllable ejected formation presure question which have puzzled the domestic and foreign research institution for so long time. It provides the key technology for realizing formation design of the oil field ejection controller which is duplicated with rubber continuously.
2. It is the first time to design ejected duplicated rubber formation curing unit for the oil field ejection controller. It can guarantee the feasibility of the ejected formation of ejection controller on the hardware technology. Meanwhile, it also can improve the product quality, enhance the product life, raise the production efficiency, reduce the energy consumption, reduce the run cost and realize the mechanization、the automation and so on.
3. It is the first time to use the electrically operated circlet technology and the electromagnetism attracts gathers technology simultaneously.It has solved the technical question of injected the curing within the barrel and the moved mold injection-curing successfully which enables the design to have the nimble mobile double function effect. The operated ways which can be changed according to the production could raise the production efficiency obviously, facilitated operate and save the run cost and so on.
4. It has used the advanced digital sensing technology in the design for the key parameter of the mold pressing with joint forces, the injection axial force and the head pressure. It has realized the digital operation which can cause the equipment movement safe, the product quality to be stable, the operation simple and easy as well as easy to be automated.
5. It has modelled the important parts using the CAD technology and transformed to the CAE model in the design. It has analyzed the main stress part and analyzed the results using the finite element method .It has improved and optimized the original design plan aimed at insufficiencies which has been exposed to enhance the design proposal reliability.
6. It carries on the three dimensional kinetic simulator simulations to the injection installment using three dimensional simulation software 3dsmax and utilizes three dimensional blast effect to indicate the connection relations of the various spare parts which can prove the design conformed to the installment, the demolition, the size coordination.
引文
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