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<p>The continuous-wave pulser is a key tool for high-rate mud-signal transmission, and the structural parameters of its rotor–stator throttling unit directly affect the pressure-wave amplitude and hydraulic-torque characteristics. A three-dimensional CFD model incorporating the valve-port throttling zone and the radial-gap flow channel was established using the SST k–w turbulence model, forming a research route of “steady-state structural optimization–transient characteristic verification”. The steady-state simulations show that the rotation termination angle exerts a significant nonlinear influence on the throttling pressure drop, with the effective strong-throttling interval located at 26–30°. Blade thickness has little effect on the pressure drop but strongly affects the hydraulic-torque response. Considering the pressure-drop plateau and torque response, the optimal structural parameters are a blade thickness of 6.5 mm and a rotation termination angle of 28°. Transient simulations indicate that the sensitivity of pressure-wave amplitude to the investigated factors, from strong to weak, is as follows: flow rate and rotor–stator gap; density and operating frequency; and viscosity. These results provide a theoretical basis for structural design and for matching field operating parameters of continuous-wave pulsers.</p>

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Structural Optimization and Unsteady Hydraulic Characteristics of a Rotor–Stator Valve in a Continuous-Wave Pulser

  • 期刊论文

  • 发表日期：

    2026年3月1日

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  • Peng Wang,
  • Hui Zhang,
  • Weimin Mao,
  • Xia Xie,
  • Yuting Zhou,
  • Yifeng Fan

摘要

The continuous-wave pulser is a key tool for high-rate mud-signal transmission, and the structural parameters of its rotor–stator throttling unit directly affect the pressure-wave amplitude and hydraulic-torque characteristics. A three-dimensional CFD model incorporating the valve-port throttling zone and the radial-gap flow channel was established using the SST k–w turbulence model, forming a research route of “steady-state structural optimization–transient characteristic verification”. The steady-state simulations show that the rotation termination angle exerts a significant nonlinear influence on the throttling pressure drop, with the effective strong-throttling interval located at 26–30°. Blade thickness has little effect on the pressure drop but strongly affects the hydraulic-torque response. Considering the pressure-drop plateau and torque response, the optimal structural parameters are a blade thickness of 6.5 mm and a rotation termination angle of 28°. Transient simulations indicate that the sensitivity of pressure-wave amplitude to the investigated factors, from strong to weak, is as follows: flow rate and rotor–stator gap; density and operating frequency; and viscosity. These results provide a theoretical basis for structural design and for matching field operating parameters of continuous-wave pulsers.