Method for manufacturing stator of screw pit-face engine

FIELD: mining industry.

SUBSTANCE: method includes physical-chemical treatment of metallic body parts, made in form of two half-cylinders, placement of puncheon within them, preparation of fresh rubber mixture, heating press-form up to 150±2°C, with following vulcanization of rubber mixture, detaching press-form, removing puncheon and controlling manufacture. Three compounds of rubber mixture are prepared, with following calendaring thereof on shafts and preparing fresh rubber strip of each compound, 0.5-0.6 mm thick, which prior to placement of puncheon in half-cylinders is wound in halving fashion onto the latter. Of rubber strip of compound, providing for durability, inner layer of rubber winding is made, of compound strip, providing for auto-compensation of wear - middle layer, and of strip, providing for hardness of connection between resin and half-cylinders - outer layer. Each layer of rubber winding is made of thickness, determined from relation k·hw, where h - thickness of each winding layer, mm; k - coefficient, determined empirically, equal to 30-0.35 for inner layer, 0.50-0.60 for middle layer, 0.10-0.15 for outer layer; hw - total thickness of rubber mixture winding, mm. glue covering is applied to each layer and rolled under pressure. After heating of press-form, the latter is placed into one of half-cylinders. Puncheon with rubber winding is deployed and connected to second half-cylinder. After vulcanization and removal of puncheon, rubber-metallic portion of stator is fixed in body pipe.

EFFECT: higher durability and simplified maintenance.

4 cl, 2 dwg, 5 ex

 

The invention relates to the drilling technique, in particular, to methods for producing stators screw downhole motors (PDM).

Analysis of the existing state of the art showed the following:

a well - known method of manufacturing a stator PDM, including physico-chemical treatment of body parts (armature), the placement of the punch (core) inside the cooking raw rubber mixture, heating the mold and subsequent vulcanization of the raw rubber compound, disassembly of the mold, remove plug (core) and production control (see Guzman, M.L., Balenko J.F. ñ and others, Downhole screw motors for drilling, Moscow, Nedra, 1981, p.129-132). The stator PDM is made of injection-molding method.

The disadvantage of this method is the short life and low maintainability made of the stator. Using this technology it is possible to manufacture only a single layer of rubber stator element that does not provide autocompensation wear rubber stator element and decreases the magnitude of the tension in the pair of the rotor-stator during operation. In such stators often occurs separation of the rubber element from the Cabinet of the pipe. In addition, it is impossible to replace the rubber element of the stator with multiple use of Cabinet pipe of the engine;

as the prototype is known a method of manufacturing a stator PDM, including chemical processing of body parts (armature), the placement of the punch within the last (the Assembly of the mold), the preparation of raw rubber mixture, heating the mold and subsequent vulcanization of the raw rubber compound, disassembly of the mold, removal of the punch and control of manufacturing (see Balenko J.F. ñ, Balenko FD, Gnoevykh A.N. Screw downhole motors, Moscow, Nedra, 1999, s-338). The stator PDM is made of injection-molding method.

The disadvantage of this method is the short life and low maintainability made of the stator. The manufacture of the stator molding method allows the rubber element of the stator only a single layer that cannot provide autocorrelation wear rubber stator element and decreases the magnitude of the tension in the pair of the rotor-stator during operation, and this, in turn, leads to poor engine performance and reduce resource of his work. In the stators manufactured using this technology, not reliable fastening of the rubber element of the stator to Cabinet pipe. In addition, it is impossible to replace the rubber element of the stator with multiple use of Cabinet pipe of the engine.

The technical result that can be obtained by carrying out the present invention, comprises the I in the following:

- increases the durability of the stator by providing self-compensation of the wear of the rubber element of the stator, leading to the preservation and restoration of tightness in the pair of the rotor-stator during operation, and prevent separation of the rubber element of the stator from the Cabinet pipe;

- improved maintainability due to the possibility of replacement of the rubber element of the stator and reusable Cabinet pipe PDM.

The technical result is achieved by using a known method of manufacturing PDM, including physico-chemical treatment of metal body parts, placement punch inside them, cooking raw rubber mixture, heating the mold to 150±2°With subsequent vulcanization of the raw rubber compound, disassembly of the mold, removal of the punch and control of manufacturing. By the present method is conducted physico-chemical treatment of metal body parts, made in the form of two semi-cylinders. This serves three of the composition of the raw rubber mixture, with subsequent calandrinia it on rolls and getting rubber bands each composition in a thickness of 0.5-0.6 mm Before placing a punch in metal semicylinders raw rubber band each lap wound on the latter. Moreover, from the raw rubber tape composition, ensuring of sostonol, make the inner layer of the winding of the tape composition, providing autocompensation wear, make the middle layer, and from a tape composition, ensuring the bonding strength between rubber and metal semi-cylinders, made the outer layer. Each layer of rubber wound is made in the thickness determined from the relationship

h=k·hn,

where h is the thickness of each layer of the winding, mm;

k is a coefficient determined empirically, 0.30 and 0.35 for the inner layer, 0.50 to 0.60 for the middle layer of 0.10 to 0.15 for the outer layer;

hn- the total thickness of the wound raw rubber mixture, mm.

With each layer applied adhesive floor and rolled under a pressure of 0.1-0.2 MPa. After heating the mold to 150±2°it put one of the metal parts of the coupling, then place the punch with rubber wrapped and connected with the second metal half. After vulcanization and removal of the rubber plug part of the stator is fixed in the Cabinet pipe.

The inner layer rubber windings are made of rubber tape having the following composition, parts by weight:

Elastomers 100,0

Dispersant 0,5-1,0

The vulcanization activator of 5.0-10.0

Antioxidants 1,5-3,5

Softeners 5,0-15,0

Fillers 50,0-70,0

Vulcanizing agents of 2.5-3.5.

The middle layer of rubber UAI the Cai is made from rubber bands, having the following composition, parts by weight:

Elastomers 100,0

Dispersant 0,5-1,0

The vulcanization activator of 5.0-10.0

Antioxidants 1,0-3,0

Softeners 5,0-10,0

Fillers 50,0-60,0

Modifiers 1,0-5,0

Vulcanizing agents of 2.5-3.5.

The outer layer of rubber windings are made of rubber tape having the following composition, parts by weight:

Elastomers 100,0

Dispersant 0,3-0,5

The vulcanization activators 5,0-15,0

Antioxidants 1,5-3,0

Softeners 6,0-12,0

Fillers 50,0-70,0

Modifiers 3,0-10,0.

Figure 1 shows a graph of the self-compensation of the wear of the stator PDM; figure 2 is a cross section of the stator PDM.

The health condition of the working bodies of PDM is saving during operation Diametric interference fit in a pair of friction, the rotor-stator and the pressure difference in the chambers of the high and low pressures. The value of diametrically tightness δ in the working bodies of PDM is 0.2-0.6 mm, depending on the size of PDM, and is calculated based on (see Guzman, M.L., Balenko J.F. ñ and others, Downhole screw motors for drilling, Moscow, Nedra, 1981, s-123)

δ=(0,005÷0,007)Dto,

where Dtodual diameter of the working bodies of the PDM.

Minimum thickness δpthe rubber element of the stator is determined by dependencies

δp=(0,04÷0,07)D

where D is the diameter of the jet is, mm;

Contour diameter related to the diameter of the engine by the following ratio:

Dto=D-2(δmp),

where δmthe wall thickness of the metal frame of the stator, mm;

in this case the manufacture of the stator value δmshould be δm=(0,07÷0,1)D, and is calculated by the formula

δm

CT
m
p
m
,

where δ

CT
m
the wall thickness of Cabinet of pipe, mm;

δ

p
m
- the thickness of the metal half, mm.

The wear of the working bodies of the PDM during operation leads to reduced diametral preload to zero and the emergence of the gap, causing a sharp decline in energy, power, kinematic parameters, violates the stability and efficiency of its operation.

A method of manufacturing a stator PDM injection molding method comprises the manufacture of rubber e is ementa stator from the same rubber composition, that provides a certain level of technical and technological properties of the vulcanizate. The durability of the working bodies PDM, produced by this technology, on average 80-100 hours. The most wearing part in the working bodies of PDM is a rubber element of the stator. To save and restore the tension in the working bodies due to the self-compensation of wear during operation, the authors propose to produce rubber element of the stator of the three layers, each of which performs a specific function. First - contact inner layer provides wear resistance, durability, low degree of swelling in the working agents. The second middle layer provides not only progesterone and ostorozhno.sploshnye properties, but managed and regulated the degree of swelling during operation, which may vary from 10 to 100%. The third outer layer provides a high strength rubber and metal. The total thickness of the wound raw rubber compound hndepends on the size of the engine and is calculated by the formula

hn=(0,04÷0,07)D+2e,

where e is the eccentricity of the engine,

and the thickness of each layer of winding is determined by the formula proposed by the inventors.

The sum of the coefficients k, determining the thickness of the winding of raw rubber mixture for each layer of the stator, to which Gina to be the unit because it is associated with the finite size of the stator, to ensure its performance and durability. The deviation in the direction of increasing when k>1 leads to difficulties starting the engine, and the deviation in the direction of decreasing when k<1 drop of power, energy and kinematic parameters. The claimed range of coefficients for each layer of the winding caused by the following factors. Based on the conditions that the contact of the inner layer is in direct interaction with the rotor and subjected to intense wear, the minimum thickness should be 3-4 times higher than the value Diametric interference fit. On the basis of analysis of experimental data, the optimal value of the coefficient k for that layer winding of 0.30 and 0.35. The middle layer of the stator winding is not subject to wear during operation, and restores and stabilizes the tension in the working bodies due to swelling under the influence of the penetrating ability of a working agent. The degree and rate of swelling of the middle layer are governed by the rubber composition, temperature and type of work agent. The amount of swelling depends mainly on the thickness of the middle layer, which should be 2-2 .5 times greater than the thickness of the inner layer. The best option for stabilization of tightness in the working bodies is the fact that the rate of wear of the working bodies shall Rav is taken of the speed of the swelling of the middle layer. This condition corresponds to the value of the coefficient k equal to 0.50 to 0.60. To ensure the bond strength between rubber-to-metal coefficient k for the outer layer of the winding should be of 0.10 to 0.15, because he is not involved in the process of self-compensation of wear.

Kinematics changes of tension in the working bodies of PDM, its restoration during operation, the implementation of self-compensation of wear graphically shown in figure 1, with the assumption - uniform wear of the working bodies during operation. Conventionally, the graph presented in figure 1, can be divided into three zones: I - zone wear of the working bodies PDM; II - area of self-compensation of wear in the working bodies of the PDM due to the stabilization of tightness, swelling of the middle layer, under the influence penetrated the working agent; III - zone of conditional gap, where the exploitation of PDM impractical.

Lines 1, 2 describe, respectively, the change in tightness and wear in the working bodies of the PDM in the process of operation of the single-layer rubber element of the stator. After 100 hours of operation (average life of the engine) at the point “C” to decrease preload to zero, which leads to a fall in energy, power, kinematic parameters of the engine and its operation becomes impractical.

Point “b” point, 100% of wear corresponding to the zero tension in the working bodies of the single-layer rubber is the first element of the stator. Point “ba” the point of wear of the inner layer of three-layer rubber element of the stator when the self-compensation of wear.

In the case of operation of the stator with a three-layer rubber element at point “a” due to the permeability of the working agent through the partially worn inner layer of the stator is the swelling of the middle layer. Line 3 defines the degree of swelling of the middle layer during operation, which leads to stabilization of tightness in the working bodies - line 4. Because the process of wear of the working bodies occurs with the same rate, the appearance of a gap in the working bodies does not occur at the point “C”and point “Cand”. This ensures that the mechanism of self-compensation of the wear of the working bodies of the PDM.

For a better understanding of the technology of manufacturing the stator with a three-layer rubber element, figure 2 presents its cross-section, where: 1 - corpus pipe; 2 - the case of the stator in the form of two semi-cylinders; 3 - outer layer, providing the bonding strength between rubber and metal semi-cylinders; 4 - middle layer, providing autocompensation wear; 5 - inner layer, providing wear resistance.

Run the metal housing of the stator in the form of two semi-cylinders enables the manufacture of the rubber element of the stator of a three-layer that the impossible is you can perform the injection molding method according to the current technology.

In the Assembly of multilayer rubber parts (RTP), it is important that tires were no air bubbles, microdefects, which after vulcanization, can cause destruction of the product. When the thickness of the rubber bands 0.5-0.6 mm is ensured by its solidity and lack of air bubbles.

Under dynamic loading in multi-RTD there is such a defect as a bundle interface. To exclude the specified defect rubber band wound lap (not less than 10 mm), and each layer is applied, the adhesive coating. Compacting is effected for the purpose of solidity of the product during Assembly and removal of air between the layers. Experience shows that the optimal pressure of prokatchikov of 0.1-0.2 MPa.

Analysis of inventive step showed the following: the known methods of manufacturing stator PDM, in which the rubber element of the stator is made of double-layer and with the possibility of changing the stator (see A.S. No. 936654 from 20.08.80, CL E 21 In 4/02, chipboard, 2; A.S. No. 2018620 from 20.03.92, CL E 21 In 4/02, publ. in ABOUT No. 16. 1994, 4); a method of manufacturing the stator of the downhole motor in which the motor housing and the stator is made of the node wear compensation in the form of a system of rigid and elastic rings (see A.S. No. 1808951 from 30.04.91, CL, E 21 In 4/02, publ. in ABOUT No. 14, 1993, article 3); the known methods of manufacturing the stator of the downhole motor is El, in which the stator is provided with reinforcing elements (see A.S. No. 1385686 from 14.07.86, CL E 21 In 4/02, publ. in ABOUT No. 24, 1993, article 1; A.S. No. 1594258 from 11.05.87, CL E 21 In 4/02, publ. in ABOUT No. 35,1990,, 3).

Based on the above, we have not identified technical solutions, based on the signs consistent with the distinctive features of the proposed technical solution, namely the manufacture of rubber stator element PDM sandwich, with the possibility of providing self-compensation of wear, leading to the preservation and restoration of tightness in the working bodies as they wear. Thus, the technical solution is not obvious from the prior art, i.e. meets the condition of inventive step.

In more detail the essence of the proposed method is illustrated by the following example.

Example. Make the stator of the downhole motor brand D2-106.

Dimensions PDM D2-106:

The diameter of 106 mm

Length 2000 mm

Operating 6/7.

The inner diameter of the metal housing 90 mm

Contour diameter 80 mm

The shape factor of the tooth of 2.0.

The coefficient of netsentralnoe 1,2.

The eccentricity of the engagement of 4.4 mm

The total thickness of the wound raw rubber mixture of 12.8 mm

Conduct physical-chemical treatment of metal body parts, made of split pipe in the form of two semi-cylinders, with which the wall thickness is not more than 1.0-1.5 mm, in accordance with the applicable technical regulations. The semi-cylinders subjected to electrochemical treatment, namely degrease the bath electrolyte at a temperature of 30-80°during 8-19 min at current strength 900±200 a and a voltage of the 6th Century, Washed with hot water at a temperature of 60±3°C for 3+1min and dried in a heating Cabinet at a temperature of 100-150°C for 10-12 minutes After degreasing the inner surface of the semi-cylinders grovestreet when the pressure of compressed air of 0.5-0.7 MPa, and then for 60 min on it are layers of glue from calculation of 150 ml/DM2to avoid drips, flows and neprodazhnyh places. Further, the semi-cylinders are dried in a drying chamber at a temperature of 50-70°C for 60 minutes

Prepare three composition of the raw rubber mixture. Mixing the rubber composition of each formulation is carried out in two stages in a rubber mixer high pressure rvsd frequency-250-140. The first stage involves mixing at a temperature of 140±5°With a rotor speed of 40 rpm, the Second stage involves mixing at a temperature of 113±2°With a rotor speed of 30 rpm After cooling and curing for 24 hours to conduct enhanced physico-mechanical tests.

Spend calendering of rubber compounds. Make rubber band thickness 0.5-0.6 mm from each composition of crude cramps the new mixture, on a three-roll calender 3-500-1250 when the temperature of the rolls 60-75°C, the speed of the calendering 5-15 m/min, followed by sealing in the sealing material treated with a release composition (to prevent clumping) and seasoning of at least 8 hours.

The Assembly machine TFR-1 fix the plug with the screw cutting. On unrolling device placed calandrino rubber band for each layer of the stator.

Example 1:

Make the inner rubber layer winding. The punch wound lap crude rubber band is included, providing durability, thickness:

h=k·hn=0,3·12,8=3,84 mm

Make the middle layer of rubber wound. The inner layer of the wound lap crude rubber band is included, wear compensating, thickness:

h=0,6·12,8=7,68 mm

Make the outer layer of rubber wound. On the middle layer wound lap crude rubber band, ensuring the bonding strength between rubber and metal semi-cylinders, of a thickness of:

h=0,1·12,8=1,28 mm

or (example 2):

the inner layer rubber winding perform thickness: h=0,32·12,8=4,10 mm

the middle layer of rubber winding perform thickness: h=0,53·12,8=6,78 mm

the outer layer of rubber winding perform thickness: h=0,1·12,8=1,92 mm

or (example 3):

the inner layer of rubber is first winding perform thickness: h=0,35· 12,8=4,48 mm

the middle layer of rubber winding perform thickness: h=0,50·12,8=6,40 mm

the outer layer of rubber winding perform thickness: h=0,15·12,8=1,92 mm

or (example 4):

the inner layer rubber winding perform thickness: h=0,30·12,8=3,84 mm

the middle layer of rubber winding perform thickness: h=0,58·12,8=7,42 mm

the outer layer of rubber winding perform thickness: h=0,12·12,8=1,54 mm

For exceptions bundle interface on each adhesive layer is applied to the floor and rolled under a pressure of 0.1-0.2 MPa.

One of the semi-cylinders are placed in the lower mold, preheated to a temperature of 153±2°C. Stack assembled plug with a three-layer rubber ribbon and cover the second half. Perform the pre-pressing under a pressure of 20 MPa for 10 seconds on the vulcanizing press, after which relieve pressure and pressed again. The vulcanization is performed under a pressure of 25-30 MPa for 45 minutes.

After vulcanization of the rubber stator together with the punch is cooled in a bath with running water to a temperature of 30°C. Then vivencial punch on a horizontal press, and the stator is sent to the rack-drive and put the seasoning within 48 hours, for shrinkage and dimensional stability. The parameters of the rubber stator element: diameter of the protrusions of the teeth, continuity kr is the accumulation of rubber to metal, the curvature of the inner channel of the stator surface and the hardness of the rubber element is subjected to control in accordance with the requirements of normative-technical documentation. Existing marking on the surface of the semi-cylinders, the complement value of the diameter of the protrusions of the teeth of the stator. The inner channel of the stator protect caps, plugs from ingestion of foreign objects and substances that can damage the rubber element of the stator. On the stator, corresponding to the regulatory requirements and design documentation, make passports and sent to the Assembly area of the working bodies of the PDM.

Thus, the claimed technical solution meets the criteria of patentability, namely the condition of novelty, inventive step and industrial applicability.

1. A method of manufacturing a stator of the downhole motor, including physico-chemical treatment of metal body parts, placement punch inside them, cooking raw rubber mixture, heating the mold until (150±2)°With subsequent vulcanization of the raw rubber compound, disassembly of the mold, remove the plug and control the manufacture, characterized in that conduct physico-chemical treatment of metal body parts in the form of two semi-cylinders, while preparing three composition of the raw rubber is howling mixture with subsequent calandrinia it on rolls and raw rubber bands each composition thickness 0.5-0.6 mm, which before placing a punch in metal semicylinders lap wound on the latter, and from the raw rubber tape composition, ensuring durability, made of the inner layer rubber windings of the tape composition, providing autocompensation wear, make the middle layer, and from a tape composition, ensuring the bonding strength between rubber and metal semi-cylinders, made the outer layer, each layer of rubber wound is made in the thickness determined from the relationship

h= k·hn,

where h is the thickness of each layer of the winding, mm;

k is a coefficient determined empirically, 0.30 and 0.35 for the inner layer, 0.50 to 0.60 for the middle layer of 0.10 to 0.15 for the outer layer;

hn- the total thickness of the wound raw rubber mixture, mm,

with each layer applied adhesive floor and rolled under a pressure of 0.1-0.2 MPa, and after heating the mold to (150±2)°placed in the last one of the metal parts of the coupling, then place the punch with rubber wrapped and connected with the second metal half, and after vulcanization and removal of the punch is fixed rubber part of the stator in the Cabinet pipe.

2. The method according to claim 1, characterized in that the inner layer rubber winding manufacturing the pour of the rubber belt, having the following composition, parts by weight:

Elastomers 100,0

Dispersant 0,5-1,0

The vulcanization activator of 5.0-10.0

Antioxidants 1,5-3,5

Softeners 5,0-15,0

Fillers 50,0-70,0

Vulcanizing agents of 2.5-3.5

3. The method according to claim 1, characterized in that the middle layer of rubber windings are made of rubber tape having the following composition, parts by weight:

Elastomers 100,0

Dispersant 0,5-1,0

The vulcanization activator of 5.0-10.0

Antioxidants 1,0-3,0

Softeners 5,0-10,0

Fillers 50,0-60,0

Modifiers 1,0-5,0

Vulcanizing agents of 2.5-3.5

4. The method according to claim 1, characterized in that the outer layer of rubber windings are made of rubber tape having the following composition, wt. including:

Elastomers 100,0

Dispersant 0,3-0,5

The vulcanization activators 5,0-15,0

Antioxidants 1,5-3,0

Softeners 6,0-12,0

Fillers 50,0-70,0

Modifiers 3,0-10,0.



 

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2 cl, 10 dwg

FIELD: well drilling equipment, particularly bearings adapted to work in abrasive medium.

SUBSTANCE: radial bearing has body and shaft, as well as thrust collars secured in the body and spring-loaded holders arranged between the shaft and the body. Inserts with conical outer surfaces are located between the holders and the shaft so that inserts cooperate with the shaft and with inner surfaces of the holders. Radial bearing is made as two oppositely arranged blocks and as compression spring inserted in-between. Each block has stop member secured in the body and made as slotted bush. Inserts are arranged in the bush and may perform displacement in radial direction. Thrust collars have conical surfaces cooperating with outer surfaces of the inserts. Angles α at apexes of the cones defined by interacted conical surfaces of bearing support inserts, thrust collars and holders are correlated with friction coefficient μ of interacted surfaces as tg(α/2)≈μ. Insert surfaces cooperating with shaft surface may have coating of elastomeric or hard-alloy material. In accordance with the second embodiment surfaces of inserts, thrust collars and holders interacting one with another may have flat contact zones, which are inclined at (α/2) angle to longitudinal shaft axis.

EFFECT: increased operational reliability of radial bearing.

6 cl, 3 dwg

FIELD: oil and gas well drilling equipment with the use of hydraulic downhole motors.

SUBSTANCE: support-and-centering member is made as metal hub with blades connected to spindle connector. Spindle connector has support cone formed on outer surface thereof and adapted to provide rigid connection with metal hub from inner surface thereof. Support cone of the connector is formed from side of conical thread connecting spindle body with connector. Spindle connector has splines to connect thereof with metal hub. Metal hub is pressed with pressing cone, retaining washer and nut from another side thereof. Metal hub may be installed concentrically or eccentrically to spindle connector axis or outer surface thereof may be differently shaped and arranged eccentrically, concentrically or obliquely with respect to spindle connector axis.

EFFECT: reduced costs of spindle usage.

5 dwg

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