Design and Testing of Electric Whipstock with Gear Transmission for Coiled Tubing Drilling
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摘要:
定向器是连续管钻井中实现定向作业的必备工具，其中电动定向器能够连续准确地调整工具面角，具有很大的技术优势，但受限于井下狭小径向空间和定向作业大扭矩要求，其中关键部件齿轮减速器是设计的难点。设计了一种基于大扭矩电机和多级行星齿轮减速器相配合的电动定向器，对其行星减速齿轮进行了优化，以弯曲疲劳强度安全系数、接触疲劳强度安全系数和输出扭矩3个关键参数的乘积为优化依据，得到了在要求空间下的最优齿数比，并对其进行了有限元强度校核和实际承载能力室内试验。研究结果表明，电动定向器两级行星齿轮减速器的实际承载能力超过800 N·m的设计目标，瞬时可达1 260 N·m，满足现场连续管钻井定向作业要求。研究结果为今后电动定向器设计和加工组装提供了参考。
Abstract:Whipstock is essential for directional drilling with coiled tubing, and the electric whipstock offers great technical advantages with its ability to make continuous and accurate tool face angle adjustments. However, due to narrow downhole radial space and high torque requirements for directional drilling, the design of the key structure in the electric whipstock, namely the gear reducer, becomes a difficult point of development. Therefore, a kind of electric whipstock based on a high-torque motor and multi-stage planetary gear reducer was designed, and the planetary gear reducer was optimized. The product of three key parameters, i.e, bending fatigue strength safety factor, contact fatigue strength safety factor, and output torque, was used as the basis for optimization so that the optimal gear ratio was obtained under the required space, and the finite-element strength calibration and the actual load carrying capacity of the gear reducer tests were carried out. The results show that the actual load bearing capacity of the designed two-stage planetary gear reducer of the electric whipstock exceeds the design target of 800 N·m, and the instantaneous capacity can reach 1 260 N·m, which meets the requirements of directional drilling operation of the coiled tubing drilling in the field. The research results can provide a reference for the design and processing assembly of future electric whipstock.
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Keywords:
- coiled tubing drilling /
- electric whipstock /
- planetary gear reducer /
- gear ratio
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图 2 模式转换机构工作过程
1.输出级行星架；2.上花键副；3.锥形摩擦副；4.锁紧滑套；5.模式转换机构外壳；6.下花键副；7.输出轴
Figure 2. Process of mode shifting mechanism
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图 3 连续管钻井电动定向器结构示意
1.减速电机；2.中间级行星减速器；3.空心轴；4.输出级行星减速器；5.模式转换机构；6.输出轴
Figure 3. Structure of electric whipstock for coiled tubing drilling
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图 4 中间级减速器在不同配齿数量下弯曲疲劳强度与接触疲劳强度的安全系数
Figure 4. Safety factor for bending and contact fatigue strength of intermediate stage reducers under different tooth numbers
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图 5 输出级减速器在不同配齿数量下优化指标的分布
Figure 5. Optimization indicator distribution of output stage reducers under different tooth numbers
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图 7 无安装误差时不同转角下应力的分布
Figure 7. Stress distribution at different rotating angles without installation error
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图 8 有安装误差时不同转角下应力的分布
Figure 8. Stress distribution at different rotating angles with installation error
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图 11 不同啮合状态下轮齿接触应力的分布
Figure 11. Contact stress distribution of gear teeth under different meshing states
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图 12 试验装置工作原理
1.试验机机架；2.加载装置；3.联轴器；4.太阳轮输入轴；5.减速器外壳；6.摩擦块；7.紧定螺钉；8.承载套筒；9.行星架输出轴；10.联轴器；11.扭矩传感器；12.行星架输入轴；13.太阳轮输出轴
Figure 12. Working principle of experimental device
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图 13 行星减速器输入扭矩随时间变化的曲线
Figure 13. Variation of input torque of planetary reducer with time
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