Resonance Tracing and Suppression for Drive Systems of Distributed Full Hydraulic Fracturing Trucks

doi:10.3969/j.issn.1004-132X.2026.03.024

Abstract

Abstract:

The low intrinsic frequency and low constant damping ratio of the pump-controlled motor hydraulic systems resulted in system resonance. To solve the problem in hydraulic systems of 318E distributed fully hydraulic fracturing trucks， a resonance origin-tracing and suppression study was conducted through experiments and classical control theory. Firstly， experiments were carried out on the fracturing trucks， and through the frequency characterization， it was initially determined that the resonance originated from proximity of fracturing pump excitation frequency and hydraulic system intrinsic frequency. Further， a mathematical model of the pump-motor systems was established to determine the intrinsic frequency of hydraulic systems. A theoretical model of the fracturing pumps was established to clarify that under specific flow，the frequency of fracturing pump operating torque fluctuation was similar to the intrinsic frequency of hydraulic systems， leading to system resonance. The system resonant was then avoided by introducing an accumulator to reduce the inherent frequency to an uncommon flow. The experimental results show that compared with the original system without the accumulator， the peak pressure resonance of the hydraulic systems is reduced by 60%， and the life and reliability of the hydraulic systems are greatly improved.

Key words: full hydraulic fracturing truck, pump-controlled motor hydraulic system, resonance traceability, resonance suppression, accumulator

摘要：

针对泵控马达液压系统因固有频率低、阻尼比低且较恒定导致的系统振动问题，以某公司的318E分布式全液压压裂车为研究对象，采用实验与经典控制理论相结合的方式进行振动溯源及抑制。对压裂车进行实验，通过频域特征分析，初步确定振动源于压裂泵激励频率与液压系统固有频率相近。进一步建立泵马达系统数学模型，确定液压系统固有频率。建立压裂泵理论模型，明确特定流量下压裂泵工作转矩波动频率与液压系统固有频率相近导致系统振动。通过引入蓄能器，降低液压系统固有频率至压裂车不常用流量以避开振动。现场测试结果表明，相较于未增加蓄能器的原系统，液压系统压力振动峰值降低了60％以上，液压系统的寿命及可靠性显著提高。

关键词: 全液压压裂车, 泵控马达液压系统, 振动溯源, 谐振抑制, 蓄能器

CLC Number:

TH137.1

CHEN Wenting, ZHANG Zhen, WANG Wenlong, AI Chao, HE Yifei, ZHONG Yuhang. Resonance Tracing and Suppression for Drive Systems of Distributed Full Hydraulic Fracturing Trucks[J]. China Mechanical Engineering, 2026, 37(3): 743-751.

陈文婷, 张震, 王文龙, 艾超, 何一非, 钟宇航. 分布式全液压压裂车驱动系统振动溯源及抑制[J]. 中国机械工程, 2026, 37(3): 743-751.

Figures/Tables 21

Fig.1 318E full hydraulic fracturing truck

Fig.2 Simplified hydraulic schematic diagram of 318E full hydraulic fracturing truck

Fig.3 Schematic diagram of test principle

Tab.1 Hardware for hydraulic system test of fracturing truck

测试所用硬件	用途
研华PCI-1716数据采集板卡	采集测试信号
测试工控机	安装采集板卡及采集系统
压力传感器	采集液压系统各点压力值
流量传感器	采集主泵出口及马达出口流量
+24 V/0 V 电源	传感器供电

Fig.4 Site testing and interface of on-board control system

Tab.2 Test conditions and excitation information table

序号	压裂泵			发动机频率/Hz	液压泵频率/Hz	液压马达频率/Hz
序号	流量/ （L·min^-1）	压力/MPa	频率/Hz	发动机频率/Hz	液压泵频率/Hz	液压马达频率/Hz
1	194.5	95.8	2.0	87.5	320.8	36.2
2	514.8	4.6	5.1	87.5	320.8	92.1
3	514.8	30.2	5.1	87.5	320.8	92.1
4	514.8	60.8	5.1	87.5	320.8	92.1
5	514.8	96.4	5.1	87.5	320.8	92.1
6	789.4	96.0	7.8	87.5	320.8	141.9
7	1098.2	95.7	11.1	87.5	320.8	200.8

Fig.5 Pressure spectrum diagram of high-pressure pipeline under 95 MPa pressure

Fig.6 Pressure spectrum diagram of high-pressure pipeline under 500 L/min flow

Tab.3 Measured values of the hydraulic system parameters of fracturing trucks

变量	数值
马达排量 $D m$ /（m³·rad^-1）	3.82 $×$ 10^-4
总流量增益 $K q p$ /（m³·s^-1）	65.33
等效转动惯量 $J t$ /（kg·m²）	1.47
等效黏性阻尼系数 $B m$ /（N·m·s·rad^-1）	0.001
高压腔容积 $V 0$ /m³	0.096
等效油液体积弹性模量 $β e$ /Pa	1.4 $×$ 10⁹
总泄漏系数 $C t$ /（m³·Pa^-1·s^-1）	8 $×$ 10^-10
等效总负载刚度系数 $G$ /（N·m·rad^-1）	0

Tab.3 Measured values of the hydraulic system parameters of fracturing trucks

变量	数值
马达排量 $D m$ /（m³·rad^-1）	3.82 $×$ 10^-4
总流量增益 $K q p$ /（m³·s^-1）	65.33
等效转动惯量 $J t$ /（kg·m²）	1.47
等效黏性阻尼系数 $B m$ /（N·m·s·rad^-1）	0.001
高压腔容积 $V 0$ /m³	0.096
等效油液体积弹性模量 $β e$ /Pa	1.4 $×$ 10⁹
总泄漏系数 $C t$ /（m³·Pa^-1·s^-1）	8 $×$ 10^-10
等效总负载刚度系数 $G$ /（N·m·rad^-1）	0

Fig.7 Bode diagram of high-pressure pipeline pressure versus variable pump opening and external load torque

Fig.8 Three-dimensional structure diagram of the interior of a fracturing pump

Fig.9 Schematic diagram of the movement of the crank slider mechanism

Fig.10 Force analysis of the crank slider mechanism

Tab.4 Key parameters of fracturing pumps

变量	数值
曲轴偏心质量 $m 1$ /kg	168.7
连杆质量 $m 2$ /kg	115.80
柱塞滑块质量 $m 3$ /kg	107.68
曲轴转动惯量 $J 1$ /（kg·m²）	77.9
曲轴偏心距 $r$ /m	0.1016
连杆转动惯量 $J 2$ /（kg·m²）	6.78
连杆长度 $l$ /m	0.6426
柱塞面积 $A 1$ /m²	8.008 $×$ 10^-3
BS₂长度a/m	0.2552
S₂C长度b/m	0.3874
AS₁长度c/m	0.0623

Tab.4 Key parameters of fracturing pumps

变量	数值
曲轴偏心质量 $m 1$ /kg	168.7
连杆质量 $m 2$ /kg	115.80
柱塞滑块质量 $m 3$ /kg	107.68
曲轴转动惯量 $J 1$ /（kg·m²）	77.9
曲轴偏心距 $r$ /m	0.1016
连杆转动惯量 $J 2$ /（kg·m²）	6.78
连杆长度 $l$ /m	0.6426
柱塞面积 $A 1$ /m²	8.008 $×$ 10^-3
BS₂长度a/m	0.2552
S₂C长度b/m	0.3874
AS₁长度c/m	0.0623

Fig.11 Spindle torque of the fracturing pump at 500 L/min and 95 MPa

Tab.5 The corresponding excitation frequencies to different flow of fracturing pumps

压裂泵流量/ （L·min^-1）	压裂泵激励频率/Hz
100	1.0
200	2.0
300	3.0
400	4.0
500	5.0
600	6.1
700	7.1
800	8.1
900	9.1
1000	10.1

Tab.6 Increase the key parameters of the accumulator system

参数	数值
蓄能器平均工作压力 $p A 0$ /MPa	26
剩余可压缩体积 $V A 0$ / m³	0.03

Tab.6 Increase the key parameters of the accumulator system

参数	数值
蓄能器平均工作压力 $p A 0$ /MPa	26
剩余可压缩体积 $V A 0$ / m³	0.03

Fig.12 Bode diagram of pressure versus variable pump opening and load moment with additional accumulator

Fig.13 Test and installation of energy storage site

Fig.14 Time domain diagram of high pressure of hydraulic system

Fig.15 Pressure vibration under different working conditions with accumulator

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