铁钻工夹紧缸同步技术与钻具自动找心方法的研究

【作者】 刘伟；

【导师】 朱兴龙；

【作者基本信息】 扬州大学 ， 机械电子工程， 2016， 硕士

【摘要】 铁钻工作为现代化石油生产中重要的自动化辅助设备,在钻井平台上能够安全、高效的完成钻具的上、卸扣和紧、冲扣等工作,为了提高铁钻工自动化程度和工作效率。在广泛的阅读铁钻工研究现状的基础上,本文针对夹紧缸同步技术和钻具自动找心方法等关键问题,对铁钻工夹紧缸进行了重新设计,并对其组成的液压系统进行了改进,对自动找心方法展开了深入对比研究。本文首先根据铁钻工样机试验中存在的问题,分析了铁钻工样机采用的同步方法和找心方法的缺点,提出了一种新的同步技术方案与自动找心方案,该方案具有同步精度高,找心准确,能大幅度提高铁钻工自动化程度。根据铁钻工夹紧缸的同步精度要求,本文设计了电动同步液压助力夹紧缸,即夹紧钳双缸采用电机推动滚珠丝杠副实现电动同步,夹紧时采用液压夹紧,可以满足大夹紧力的要求。并对原样机的液压回路进行了改进。根据铁钻工的实际工作情况,要求铁钻工夹紧钳中心和钻具中心重合,避免损坏钻具和夹紧钳圆形导轨。结合铁钻工钻具的找心要求,本文提出了一种基于光电传感器与光栅尺相结合,采用高速计数模块确定钻具中心的方法,该方法能够确定钻具中心位置和钻具直径,但不能保证夹紧钳左右夹爪到钻具中心的距离相等。鉴于此,本文提出了另一种基于超声波传感器确定钻具中心的方法,该方法采用分布在同一圆周上的三个超声波传感器来确定钻具中心,试验研究表明,该方法能够确定钻具中心,但不能确定钻具直径。结合上述两种方法,分析对比了各自的优缺点,提出了基于光电传感器、超声波传感器和光栅尺相结合的多传感器融合的自动寻找钻具中心的方法,实验表明该方法不仅能确定钻具中心位置,还能确定钻具直径,同时保证了夹紧钳左右夹爪到钻具中心的距离相等。根据铁钻工同步技术和自动找心方法的控制要求,设计了基于PLC的铁钻工夹紧缸同步控制与钻具自动找心检测的控制系统,铁钻工同步控制和找心检测系统的设计过程主要包括PLC选型、I/O地址分配、外部接线和控制程序编制。最后,设计了铁钻工同步控制与自动找心检测的人机界面。针对铁钻工夹紧缸液压与控制系统和自动找心检测控制系统,进行了相关的实验。实验分为四部分：1、完成电动同步液压助力夹紧缸同步精度实验,并对同步精度是否满足要求进行评价；2、对基于光电传感器和光栅尺确定钻具中心的方法进行了实验,分析了直径测量实验误差的原因,提出了补偿方法；3、对基于超声波传感器确定钻具中心的方法进行了实验,在实验前,首先对每个超声波传感器通过实验进行参数标定,确定了每个超声波传感器的参数,为控制与检测程序的编写提供了依据；4、结合上述两种方法,对基于光电传感器、超声波传感器和光栅尺相结合的多传感器融合的自动寻找钻具中心的方法进行了实验,实验结果表明,该方法能够满足铁钻工自动找心的精度要求。更多还原

【Abstract】 Iron roughneck is well known as an importantly automated auxiliary equipment in modem oil production, which can efficiently accomplish the making-up and breaking-out processes of drilling tools. In order to improve the automatic degree and the efficiency of the work and on the basis of reading the present situation of iron roughneck’s development, this paper aiming at some key problems such as the synchronization technology of hydraulic cylinder and the methods of automatically detecting the drill pipe center, redesigned the clamping cylinders of iron roughneck and improved it’s hydraulic system. And a further study of automatic centering has been to do.According to the operation process of the iron roughneck prototype, this paper analyzed the shortcomings of synchronization method and centering method using in the prototype. And a new synchronization scheme and schemes of automatically detecting the drill pipe center have been proposed, which have the advantages of high synchronization precision and high efficiency and greatly improving the iron roughneck automatic degree.According to the synchronization accuracy requirement of iron roughneck’s, the paper designed a new grip cylinder of electrical synchronization. The double cylinders of clamp pincers realized the electric synchronization by using stepping motor drive nut set of ball screw and clamped by hydraulic drive that meets large clamping force. And hydraulic circuit of the original prototype was improved.According to the actual working status of iron roughneck, it’s required that the center of clamping pliers and the center of the drill tool should be coincident, in order to avoid damaging the drill tool and the circular guide in clamping pliers. Combining the centering requirement of system of iron roughneck, the paper proposed a method of determining the center of the drill pipe by using high speed counter module based on photoelectric sensor and grating ruler. The method can determine the center and diameter of drill pipe, but can’t guarantee that the distance between the left clamping jaw of clamping cylinder and the center of the drill pipe is equal to the distance between the right clamping jaw of clamping cylinder and the center of the drill pipe. Then the paper proposed a method of determining the center of the drill pipe based on ultrasonic sensor, which used three ultrasonic sensors distributed on the same circumference. Experimental research shows that the method can determine the center of the drill pipe, but can’t determine the diameterof drill pipe. By analyzing the advantages and disadvantages of the two methods and synthesizing the two methods, the paper proposed a multi-sensor fusion method of determining the center of the drill pipe based on photoelectric sensor, ultrasonic sensor and grating ruler. The Experiment shows that the method can determine the position of the drill pipe center, determine the diameter of drill piper and ensure that the distance between the left clamping jaw of clamping cylinder and the center of the drill pipe is equal to the about equal to the distance between the right clamping jaw of clamping cylinder and the center of the drill pipe.According to the control requirements of the synchronization technology and automatic centering methods, the synchronization control system of iron roughneck’s grip cylinder and the detection control system of automatic centering has been designed which is based on the programmable logic controller (PLC). The design process of control system contains choosing the PLC, distributing the I/O ports, designing the external wiring diagram and preparing the control program. Last, the human-computer interface of the synchronization control system and automatic centering detection control system of iron roughneck has been designed.According to the hydraulic and control system of iron roughneck’s grip cylinder and the detection control system of automatic centering, some related experiments have been carried out. The experiment was divided into four parts:1) completed the experiment of clamping cylinder synchronization precision and evaluated the synchronization accuracy.2) proceed with the method of determining the center of the drill pipe based on the photoelectric sensor and the grating ruler, analyzed the reason of the error of the diameter measurement experiment and proposed the compensation method.3) proceed with the method of determining the center of the drill pipe based on ultrasonic sensors, calibrated ultrasonic sensor by experiments before the experiment, which provided the basis of programming.4) synthesizing the two methods, conducted the experiment of multi-sensor fusion method of determining the center of the drill pipe based on photoelectric sensor, ultrasonic sensor and grating ruler, the results of which indicated that the designed methods of the method can satisfy the requirements of precision requirement of automatic centering.更多还原