Independent Auger Hopper Power for Hydraulic Fracturing Blenders
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Solution Overview
Problem
In hydraulic fracturing systems, aligning the hopper of the blender unit with the proppant feed is challenging due to the need for sequential steps involving power connection and physical positioning, leading to potential misalignment and increased downtime when trying to reposition the equipment after power is connected.
Innovation Solution
An independent power supply, such as a 12-volt DC battery, powers the auger and hopper assembly, allowing it to move between stowed and deployed positions without relying on the main power source, enabling alignment with the proppant feed before connecting the main power, and the battery is rechargeable by the main power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hopper is lowered into position only after power is connected to the blender unit, then the power connection requirement is satisfied, but the alignment precision between the hopper and proppant feed deteriorates because it becomes too late to reposition the trailer
Solution Approach 1:
The system divides the power supply function into two independent parts: a battery-powered subsystem for the hopper assembly and a main power subsystem for the blender unit. This segmentation allows the hopper to be positioned independently of the main power connection status, resolving the contradiction between power reliability and alignment precision.
Solution Approach 2:
The battery enables preliminary positioning of the hopper assembly before the main power connection is established. The hopper can be aligned with the proppant feed using battery power, and then the main power connection can be made without requiring repositioning, thus achieving both power reliability and alignment precision.
2Ease of operation
If the trailer must be positioned relative to the conveyor while the hopper is in the elevated position, then the power connection sequence is maintained, but the positioning accuracy deteriorates because alignment cannot be properly assessed from the elevated position
Solution Approach 1:
The battery enables the hopper to be lowered into the deployed position as a preliminary action before final trailer positioning and main power connection. This allows the operator to assess and adjust the alignment between the hopper and proppant feed from the correct operational position, ensuring positioning accuracy while maintaining ease of operation.
Solution Approach 2:
The system allows dynamic repositioning of the hopper assembly in the deployed position using battery power, enabling fine-tuning of the alignment between the hopper and proppant feed after the trailer has been positioned, thus achieving both ease of operation and positioning accuracy.
3Device complexity
If the hopper cannot be lowered until power is connected, then the system maintains a simple power dependency structure, but the setup time increases due to the sequential nature of the three required steps
Solution Approach 1:
The power supply structure is segmented into independent battery-powered and main-powered subsystems. This allows parallel execution of hopper positioning (using battery) and main power connection, reducing the sequential dependency and setup time while maintaining manageable system complexity.
Solution Approach 2:
The battery enables preliminary lowering and positioning of the hopper assembly before the main power connection is made. This preliminary action eliminates the need to wait for main power connection before positioning, thus reducing setup time while keeping the overall power supply structure relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for precise alignment and positioning of the hopper with the proppant feed independently of the main power connection, reducing setup time and avoiding costly repositioning errors, thus enhancing operational efficiency and safety.
Implementation Method 1
The hydraulic cylinder, when activated by one or more actuators for example, can move the auger and hopper assembly between a stowed position and a deployed position
Implementation Method 2
A second power supply, such as a battery, can power the auger and hopper assembly. The second power supply can operate independently of the first power supply
Implementation Method 3
The hopper can receive proppant through an upper opening and transport the proppant out of the hopper using one or more augers
Data Source
AI summary
Embodiments relate to a hydraulic fracturing system that includes a blender unit. The system includes an auger and hopper assembly to receive proppant from a proppant source and feed the proppant to the blender unit for mixing with a fluid. A first power source is used to power the blender unit in order to mix the proppant with the fluid and prepare a fracturing slurry. A second power source independently powers the auger and hopper assembly in order to align the hopper of the auger and hopper assembly with a proppant feed from the proppant source. Thus, the auger and hopper assembly can be stowed or deployed without use of the first power source, which is the main power supply to the blender unit.