连续油管牵引器微型电磁阀研制及性能实验

Development and Performance Experiment of a Micro Solenoid Valve for Coiled Tubing Tractor

  • 摘要: 常规电磁阀径向尺寸过大(>30 mm)严重制约连续油管牵引器小型化发展,为解决该瓶颈问题,研制了适用于井下狭小空间的高集成度微型电磁阀。基于电磁阀结构原理,建立了微型电磁阀的力学与运动学模型;采用有限元仿真方法,定量分析了动铁芯半径与线圈外径对轴向电磁力的影响规律,并确定了最优微型化结构参数。加工了微型电磁阀实物样机,搭建了包含连续油管牵引器的实验系统,进行换向动作与压力响应测试。仿真结果表明:在线圈安匝数一定时,减小动铁芯半径或增大线圈外径均可提升轴向电磁力;最终确定动铁芯半径为3.0 mm、线圈外半径为8.5 mm(最大直径17.0 mm,高度18.2 mm)为最优参数组合,在此结构下轴向电磁力全程大于动作阻力。实验验证显示,微型电磁阀在3.75 MPa压力下换向动作顺畅,阀芯开启响应时间约52 ms,工作状态稳定可靠。设计的微型电磁阀在保持驱动力的前提下将最大径向尺寸压缩至17.0 mm,显著提升了连续油管牵引器的集成度。研究成果可为井下工具微型化液控系统的开发提供理论依据与实验支撑。

     

    Abstract: To address the bottleneck issue that the excessive radial size (>30 mm) of conventional solenoid valves severely restricts the miniaturization of coiled tubing tractors, a highly integrated micro solenoid valve suitable for confined downhole spaces is investigated. Based on the structural principles of solenoid valves, mechanical and kinematic models of the micro solenoid valve were established. The influence of the moving core radius and coil outer diameter on the axial electromagnetic force was quantitatively analyzed using the finite element simulation method, and the optimal miniaturized structural parameters were determined. A prototype of the micro solenoid valve was fabricated, and an experimental system integrated with the coiled tubing tractor was constructed to evaluate the directional switching performance and pressure response. The simulation results show that, under a constant number of ampere-turns, either decreasing the moving core radius or increasing the coil outer diameter effectively enhances the axial electromagnetic force. The optimal parameters were determined as a moving core radius of 3 mm and a coil outer radius of 8.5 mm (resulting in a maximum diameter of 17 mm and a height of 18.23 mm). Under this configuration, the axial electromagnetic force consistently exceeds the motion resistance throughout the stroke. Experimental validation confirms that the micro solenoid valve operates smoothly at a pressure of 3.75 MPa, with a spool opening response time of approximately 52 ms, demonstrating stable and reliable performance. The designed micro solenoid valve achieves a maximum radial size of only 17 mm without compromising driving force, significantly enhancing the integration density of the coiled tubing tractor. The findings provide a theoretical basis and experimental support for the development of miniaturized hydraulic control systems in downhole tools.

     

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