抽油泵柱塞的仿生耐磨和减阻原理及关键技术研究

Pumpjack is a major equipment for mechanical oil recovery in China. It is also one of the most energy-consuming and frequently-worn-out equipments in oilfields. Moreover, the late-stage recovery of underground oil usually leads to deterioration of pumpjack’s working condition, which in turn causes faster worn-out of pump plunger and pump barrel. Current research of pumpjack has not found an ideal solution to make the working pair of plunger and barrel less resistant and more endurable. Bionics, which is the application of biological methods found in nature to the study and design of engineering systems, has opened a new direction for pumpjack research. The bionic non-smooth surface theory, which has been verified and successfully applied to brakes, drills, and cement rollers, can probably help pumpjack’s anti-wear and anti-friction research to find creative solutions. In this project, we propose to use bionic approach to solve pumpjack’s problems of fast worn-out and common failures. We choose rock lizard, Laudakin stoliczkana, from Xinjiang, as the model animal, since we are inspired by the semi-hexagonal shape of its scale on the back. In order to reveal the mechanism and principles for the friction-reducing and wear-resistant effect of hexagonal non-smooth surface structure, we will build mathematical, mechanical and hydrodynamic models and use theoretical calculation and computer simulation to do geometric, mechanical and hydrodynamic analyses. Meantime, we will also investigate the effect of the hexagonal non-smooth surface structure on pumpjack’s sealing performance. Then we are going to synthesize findings from the above efforts to establish the fundamental theory about the effects of non-smooth surface structure on the friction-reducing, wear-resistant and sealing performance for kinematic pairs. Furthermore, we will test our designed bionic pumpjacks on a testing platform for abrasion and friction, and in a facility simulating underground working conditions of pumpjack, under the premise that current sealing performance of pumpjacks should be maintained and improved. We intend to find a comprehensive solution for three key scientific questions that will incur when applying the bionic non-smooth theory to the surface of pump plunger, i.e. maintaining sealing, reducing friction, and enduring longer wearing, and subsequently establish corresponding theoretical foundations and key technologies to expand the application of the bionic non-smooth surface theory.

抽油泵是我国油田机采的主要方式，也是油田高耗能和易磨损的主要装备，而油田开发后期的高含水量和高含砂量工况加剧了抽油泵柱塞和泵筒间的磨损。目前的抽油泵研究尚未理想地解决柱塞和泵筒摩擦副的减阻和耐磨问题，而仿生非光滑表面理论为其减阻和耐磨研究开辟了新的方向。本研究拟针对抽油泵工作时的磨损问题和失效的主要形式，借鉴自然界中新疆岩蜥体表鳞片的近六边形结构，建立相关的数学模型、力学模型和流体力学模型，并通过理论推导和计算机模拟等手段开展几何学分析、力学分析和流体力学分析，揭示六边形非光滑结构的减阻和耐磨机理与规律，同时探索六边形非光滑结构在近抽油泵工况下对抽油泵密封性的影响，从而确立运动副非光滑表面形貌对其耐磨、减阻、密封三个功能影响的基础研究理论，并通过摩擦磨损实验台和模拟井下实验装置实验验证和优化相关参数。在保证和提高现有抽油泵密封性的前提下，应用仿生非光滑理论解决抽油泵柱塞表面减阻和耐磨问题，形成六边形非光滑表面结构的密封、减阻和耐磨的基础理论和关键技术，拓展仿生非光滑理论的应用。

有杆抽油泵（简称“抽油泵”）是我国油田高耗能和易磨损的主要装备之一，目前的抽油泵研究尚未理想地解决柱塞和泵筒摩擦副的减阻和耐磨问题。本项目针对抽油泵工作时柱塞磨损的主要问题，选取东方沙蚺和红尾蚺作为仿生研究的生物模本，设计仿生六边形织构表面，利用仿真模拟研究仿生六边形织构在抽油泵柱塞耐磨、减阻、密封方面的作用，并搭建多个加工和检测装置，开展试验验证和相关参数优化，基于仿生非光滑理论解决抽油泵柱塞表面的耐磨、减阻、密封三个关键问题，形成相应关键技术，拓展仿生非光滑理论的应用。.生物模板研究结果表明，形状近似于六边形的红尾蚺与东方沙蚺体表鳞片从外至内存在硬度梯度，且单一鳞片的前端和后部也存在硬度变化，蛇体表具有软硬相间的特性，而鳞片表面形貌特征与材料力学特性对摩擦学性能具有耦合作用。耦合机制的提出，合理地解释了蛇体表鳞片具有良好耐磨减阻性能的自然现象。.基于生物模板特征，利用聚亚胺开发出仿生软硬相间材料，证实了软硬相间的复合材料具有协同效应，可以表现出比单一材料更为优异的机械性能与摩擦性能。利用激光淬火技术制备的仿生六边形织构样件，从外至内存在硬度梯度变化，且在干摩擦条件下比传统淬火技术加工的光滑表面样件具有更为优异的摩擦学性能。这些结果佐证了生物模板研究中提出的协同效应和耦合机制，发展了仿生耦合理论。.本项目将仿真模拟分析与实际试验相结合，证明了在混合摩擦与全润滑摩擦状态下仿生六边形织构样件具有比光滑表面样件更低的摩擦系数、更小的磨损量和更优的密封性能，丰富和发展了非光滑理论，开发了新型密封技术。.此外，本项目设计开发的多种新型设备和装置可满足摩擦磨损和密封性试验的需求，而仿生抽油泵柱塞的实际应用则推动了新技术的推广和普及，促进了科研成果的转化和利用。.综上，本项目已完成了项目计划书的研究内容及目标，本研究推动了仿生科学与工程知识体系的构建和完善，促进了新理论与新技术的发展与应用。