Let plasticization and molding continue

Equal wall thick screw pumps are widely used in the oil field as a high-efficiency machining equipment. However, in its manufacturing process, how to uniformly inject a rubber with a thickness of 6 mm into the inside of a pump tube having a diameter of 10 cm and a length of more than 7 meters is a very thorny problem. The team of associate professor Zong Dianrui of Qingdao University of Technology finally solved this industry problem in 5 years. Using the low-temperature continuous extrusion process developed by them and LCE108 type pump pump rubber stator molding device, extrusion plasticizing, injection molding and vulcanization molding can be performed continuously on the same equipment. The equal wall thickness stator screw pump manufactured by this technology has already entered the stage of industrialization.

According to reports, the equal wall thickness stator screw pump makes up for the shortcomings of the conventional screw pump stator technology, and the rubber bushings with uneven thickness of the wearing parts are designed as uniform rubber bushings with a thicker wall thickness, which can extend the period of the pump inspection of the screw pump and improve it. Downhole pump efficiency. However, rubber has poor fluidity and good elasticity. It is very difficult to press the rubber into a thin tube having a diameter of 10 cm and a length of more than 7 meters. On the one hand, you give it much pressure, it can produce much reaction; on the other hand, once the temperature is reduced, the rubber flow will be more difficult, and will not flow completely due to half-ripening. Foreign companies use a complex and large rubber injection machine to complete this process, but the whole machine costs as much as 15 million yuan. Domestic enterprises rely on the soil method and press the rubber into the pump tube again and again. The efficiency is low and the product quality is not guaranteed.

The research team led by Associate Professor Zong Dianrui put forward new ideas. They considered using ordinary rubber extruders to push directly into the mandrel through the die.

Extruder is a screw extrusion device that can extrude hoses, films, wire and cable and other products, but only a few simple products can be made on the injection of rubber. Extruder generally lower pressure, use it to achieve uniform injection? All people are skeptical about this.

However, Zong Dianrui believes that the extruder also has its own advantages. For example, the extruded rubber is fresh, the viscosity does not change, and the temperature can be adjusted freely. The fluidity of the rubber compound can be monitored and adjusted in real time. But can low-temperature, low-pressure rubber really fill the entire pipeline as researchers hope? This is still a knowledge number.

In order to this idea, TsingTai University has specially set up a scientific research team that integrates excellent talents such as mechanical design, mechanical manufacturing, electrical control, automation, computer and rubber technology, and has made several attempts, which took 5 years and was finally optimized. In the case of process, assembly and formulation, the specially designed extrusion lock vulcanizing device can perform pressurized injection rubber lining, and the rubber material is “satisfactory” filled with the entire pump body tube cavity at low temperature and low pressure.

This low-temperature continuous extrusion process has a good innovation, the production cost is greatly reduced, and when used in the production of large-scale engineering rubber products, it has better performance than an ordinary rubber injection machine. It overcomes the intermittent production restrictions of ordinary injection molding machines and vulcanizing cans, and enables extrusion plasticization, injection molding, and vulcanization molding to be performed continuously on the same equipment, thus creating the “intermittent production of large-scale polymer injection products”. "Continuous production" of the new mode of production. The successful development of this process and device has provided a new method for large-scale rubber injection products in China and around the world. In November of last year, the result passed technical appraisal. At present, the same-wall thick stator screw pump produced by this equipment and process has been applied in Changlong Rubber & Plastic Machinery Co., Ltd., Dongying Xianhe Oil Production Plant, Shengli Oilfield Bohai Drilling Company, etc. and has been well received by the industry.

According to statistics, each major oilfield in China needs about 3,000 single-screw deep well pump each year in 2011. The service life of the rubber inner liner of each screw pump is about 180 hours. A well pumped by a screw pump needs about 50 times a year to replace the rubber material in the stator. The number of stator injections is about 125,000 times, and it is obtained according to each injection. With a net profit of 2,500 yuan, each year, plastic injection can achieve economic benefits of more than 300 million yuan.

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