Emulsion pump station system for super high fully mechanized working face

In order to meet the emulsion demand of 8.8 m super high fully mechanized working face, and solve the problems of the existing emulsion pump station system, such as low flow rate of single pump station, insufficient reliability of transmission system, short life of suction and discharge valve and slow system response, the emulsion pump station system for super high fully mechanized working face is designed. The flow rate of a single emulsion pump station reaches 1,200 L/min and the rated working pressure reaches 37.5 MPa.The key technologies of pump station system design such as slider and connecting rod spherical articulated kinematic pair, four-point support crankshaft design, super flow suction and discharge valves, pump station equalization control and real-time rapid system response are discussed.In the existing emulsion pump structure, the slider is connected to the connecting rod in the form of a cylindrical pin, which cannot adjust the center automatically, cannot eliminate the influence of lateral forces, and make the slider easily worn. In order to solve the above problems, a new form of spherical articulation is proposed, in which the connecting rod can swing to a certain extent in the horizontal direction, eliminating the influence of lateral forces in the traditional form.The unique multiple point lubrication channel design makes a stable lubricating oil film to be formed between the ball head and the hinge seat, and makes the service life longer. Four cylindrical roller bearings are used to support the crankshaft, which has strong stability and reduces the deflection of the crankshaft effectively. The stress on the crankshaft is more balanced, which solves the problem of sudden stress changes in the journal fillet. The performance of the suction and discharge liquid valve has been improved in terms of the structure, material and process, and the life of the suction and discharge liquid valve has been increased. The pump station adopts a pump station equalization control strategy to ensure that the running time of each pump is basically the same and the life of the pumps is balanced.The pump station system adopts real-time rapid response technology, which improves the response speed of the system and responds to the equipment's demand for flow and pressure in real time, ensuring the timeliness and accuracy of the action. The practical application results show that the system has reasonable structure, reliable performance and easy maintenance, which meets the requirements of the fluid supply system in the 8.8 m super high fully mechanized working face and improves the high production efficiency and safe production of coal mines.