Research On The Load-Testing System Of Speed Reducer For The Pumped Machine

Pumped machine is the driving devices of the pumping systems with stem on the ground of oilfield, the number of which occupies more than a half of the total number of equipments. Speed reducer is the key part of pumping machine. Its quanity concerns the whole production. Both SY/T 5044-2003 and API SPEC 11E stipulate no load test and step stress test of the speed reducer and make sure the necessity of analysis on speed reducer system. At present, a set of standard or load test equipment has not been developed in our country to testify the speed reducer's performance index. Hence, it is of great significance to research on a set of load test system which can ensure speed reducer's good performance by dynamical dececting its property parameters in real time.Combine with present status of oil production of our country, advanced load, sensor measurement and data processing technology are used to complete the research of pumping unit gear reducer Load Test System. The whole testing system is consisted of loading sub-system, sensor measurement sub-system and data process sub-system. The system measures speed reducer's input and output torque, power supply, oil temperature in the tank, gear mesh's temperature and vibration noisy in real time, and then these data are transmitted to data process system by wireless net. After processing in data process system, we can get each parameter's dynamic curve which can be used as proofs of speed reducer's property. Based on the expansion of the component of loading test system, loading sub-system, sensor measurement sub-system, data processing subsystem and the simulation experiments are respectively studied.At first, total solution for loading test system is studied. Through the analysis of the function, composition and technical requirements, the key technology, experiment environment and environment target of the system are determined. Based on the composition of the system, researches on each sub-system are done:Load system. On the basis of analysising and researching DJZ electric feedback loading technique, load test-bed with large torque and low power consumption is built, and the advanced non-linear finite element method would be employed to analysis the internal stress and dangerous deformation of the axis under the circumstance of reducer of overload.The modular designing method is adapt for sensing detection sub-system, according to the design principle of small size, high reliability, easy installation, easy extension, the sensor is properly chosen, ATmega8 is the core processor of every data-collected module, connecting with central processor in the main control room by wireless networks in order to construct test subsystem with real-time, dynamic measurement. C++ Builder programmed software is used for data process sub-system, the drawing of the operating parameters curve is realized, saved and printed, all of these has perfect human-machine interaction.Finally, appropriate signal is chosen for every sensor's actual output of the system, data acquisition and processing subsystem are carried on simulation experiments, and acquisition accuracy and reliability of the system are inspected and analyzed.