Design and energy saving analysis of non-round gear transmission of beam pumping unit
[Objective]Amid the background of carbon peak and carbon neutrality strategy,it is particularly critical to study the oil-production technology with low energy consumption,high efficiency and green environmental protection characteristics.As a type of oil production equipment with simple structure,high stability and strong environmental adaptability,the beam pumping unit has been widely used in the oil field exploitation.However,a shortage of low system efficiency and high energy consumption remains.In view of the energy-saving technical problem of beam pumping unit,this paper presents a beam pumping unit energy-saving design method based on non-circular gear transmission.[Methods]In the original state equipment,the output power of the motor needs to be selected according to the peak load,which cannot adapt to the fluctuation of the load,thus resulting in low matching degree between the motor and the load,also resulting in large energy consumption.However,for the new non-circular gear structure,the crank angle speed can vary appropriately according to the load due to the variability of the gearbox speed and acceleration.Based on the generated tooth shape data,the gear drawing is obtained,and the non-circular gear is manufactured by cutting the slow moving wire.[Results]Simulation results show that the peak load of the motor is reduced from 317.3 N·m to 238.3 N·m,decreasing by 24.9％,and that the requirment of changing 37 kW motor to 30 kW motor is met.At the optimal crank angular speed,the energy consumption of 37 kW original state structure motor is 52 493 J;the energy consumption of 37 kW non-circular structure motor is 50 044 J;the energy consumption of 30 kW non-circular motor is 46 722 J.Under the same power of 37 kW motor,the energy saving rate is 4.7％.After 30 kW motor is used,the energy saving rate is 11.0％.After non-circular gear transmission is used,the energy saving effect of beam pumping unit appears remarkable.The designed active pitch curve formula is used to obtain the change curve of curvature and angle.The curvature of the gear pitch curve does not change much and looks reasonable.Therefore,the gear will not produce large impact and acceleration in the engagement process,thus demonstrating the feasibility of the node curve design.Test results show that,by comparing the total energy consumption,the average energy saving rate is 4.8％under the same power of 37 kW motor;after we use the 30 kW motor,the average energy saving rate is 10.9％.Because the gear reducer moves at 6 r/min,the impact of the dynamic engagement loss is basically negligible,and experimental results are basically consistent with the theoretical results.These results confirm the correctness of the theoretical design method.[Conclusions]Because the cylindrical gear driven beam pumping unit has been used in a large range,it is unsuitable to change the original structure.Herein we propose the method of the non-circular gear pitch curve design to attain the energy saving effect of the beam pumping unit.Hopefully,our proposal secures a strong practical engineering value.Although our study has made some achievements in the energy saving research of non-circular gear driven beam pumping unit,some shortcomings in numerous aspects remain.Two major issues are recommended below for further research.1)Many models of beam pumping unit exist with complex and changeable working conditions.In this paper,we only demonstrate that a certain type of beam pumping unit under specific working conditions exert a satisfactory energy-saving effect.Therefore,when models and working conditions of the beam pumping unit change,it is necessary to design different non-circular gear joint curves and verify the energy saving effect of the non-circular gear driven beam pumping unit.2)In the test verification in this paper,we do not use one to one prototype under actual condition,but instead adopt the prototype according to a certain proportion.Furthermore,in the test process,we do not consider the simulation of the curve angle speed and the influence on the suspension load under the actual condition.Consequently,although test results secure certain reliability,the actual condition is not completely restored,and the test must be further improved.
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