Circular Force Generator Drill Cuttings Separator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional circular separators in the petroleum industry face limitations in motion profile range, material discharge, and adjustment complexity, leading to inefficiencies and difficulties in managing vibration profiles, especially in tall frame/screen stacks and on drill rigs, where space and weight are significant concerns.
Innovation Solution
The implementation of circular force generators (CFGs) that create complex, controllable motions by strategically phasing combinations of circular forces, allowing for increased degrees-of-freedom of motion and adjustable force and phase settings, enabling more effective material separation and reducing the weight and space requirements of separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional unbalanced weights are mounted far below the frame/screen stack, then the separator structure is simplified, but the motion profile range is limited and straight-thru material discharge is prevented
Solution Approach 1:
The patent transitions from traditional linear/vibratory motion to circular motion by positioning unbalanced weights on the motor shaft. This dimensional change in motion trajectory enables straight-thru material discharge and expands the motion profile range while maintaining structural simplicity.
Solution Approach 2:
The patent employs adjustable unbalanced weights that can be repositioned radially on the motor shaft, allowing dynamic adjustment of the motion profile. This enables the separator to adapt to different material separation requirements while maintaining a compact structure.
2Adaptability or versatility
If unbalanced weights are positioned on the motor shaft, then straight-thru material discharge is enabled and motion profile range is increased, but device complexity increases
Solution Approach 1:
The motor shaft serves multiple functions: it drives the screen vibration and simultaneously positions the unbalanced weights to create circular motion. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity despite enhanced adaptability.
3Adaptability or versatility
If manual force adjustments and angle adjustments of weights are required, then motion profile control is achieved, but operator safety risks increase and adjustment complexity increases
Solution Approach 1:
The patent replaces manual mechanical adjustment with electronic control of the unbalanced weights' position and phase. This substitution eliminates the need for operators to physically access hazardous areas, significantly improving safety while maintaining precise motion profile control.
4Ease of manufacture
If guards must be removed and operators must reach into small spaces to adjust weights, then weight adjustment is possible, but ease of operation deteriorates and safety risks increase
Solution Approach 1:
The patent replaces manual mechanical adjustment with electronic control interfaces that allow operators to adjust weight position and phase from a safe distance. This substitution maintains the capability for precise weight adjustment while dramatically improving ease of operation by eliminating the need to remove guards or reach into confined spaces.
5Device complexity
If unbalanced weights are positioned well below the center of mass, then separator structure is simplified, but generating desired motion shapes on upper screens becomes impractical
Solution Approach 1:
The patent positions unbalanced weights on the motor shaft to generate circular motion, which creates motion profiles that effectively reach all screens including upper screens. This dimensional change in motion generation enables desired motion shapes on upper screens while maintaining structural simplicity.
6Reliability
If significant mass and space are required for shale shaker installation on drill rig, then separator structural integrity is ensured, but space requirements and weight increase
Solution Approach 1:
The patent adopts circular motion generated by unbalanced weights on the motor shaft, which creates more efficient material separation with reduced mass requirements. This dimensional change in motion pattern allows the separator to maintain structural integrity while occupying less space and weighing less, suitable for drill rig installation.
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 enhances the performance, throughput, and fidelity of material separation, allows for controlled retention and direction of solids, and facilitates screen cleaning and oversize material discharge, while maintaining consistent motion despite material loading and enabling efficient screening modes.
Implementation Method 1
circular force generators (CFGs) that create complex, controllable motions by strategically phasing combinations of circular forces
Data Source
AI summary
Apparatus and vibratory separators having a base, a separator housing movably connected with the base, the separator housing including a top having an inlet chute, a bottom having a liquid discharge chute, a cylindrical sidewall defining an axial centerline and having a discharge spout, and at least one screen mounted within the separator housing. A vacuum system proximate the at least one screen may also be incorporated. The apparatus further includes at least one circular force generator (CFG) disposed on the separator housing, and at least one sensor positioned on the apparatus for measuring an operating function associated with and enabled by the vibration profile, and a controller in electronic communication with the sensor and with the at least one CFG. The difference between the measured operating function and the prescribed operating function is reduced. The apparatus may also include at least one CFG having a plurality of imbalanced masses which rotate in a plane parallel the axial centerline. The CFG may be disposed in an annular ring arrangement on the top, on the bottom, or CFGs disposed on both the top and the bottom.