Diamond-Coated Thrust Bearings in Horizontal Pumps
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Solution Overview
Problem
Conventional horizontal surface pump assemblies face challenges with thrust bearing durability due to high rotational speeds and loads, heat generation, and contamination issues, leading to frequent maintenance and replacement needs.
Innovation Solution
The implementation of a thrust-bearing system with diamond-coated pads in the intake section of the pump, allowing the thrust bearings to operate directly in the pumped fluid flow, eliminating the need for a standalone thrust chamber and reducing maintenance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If roller element bearings are used to handle pump thrust, then the pump can operate at high rotational speeds, but the bearings wear out quickly and generate excessive heat
Solution Approach 1:
The patent replaces roller element bearings with a hydrodynamic thrust bearing system that uses fluid dynamics instead of rolling contact. The thrust bearing includes a rotating disk with a smooth surface that rotates within a stationary housing containing lubricating oil, creating a hydrodynamic film that supports the shaft thrust without mechanical contact, thereby eliminating wear and heat generation from rolling elements.
2Force
If conventional hydrodynamic bearings are used, then the pump can handle high axial loads, but the bearing surface area is insufficient and contamination of motor oil occurs
Solution Approach 1:
The patent segments the bearing system into distinct components: a rotating disk with thrust-bearing surfaces, a stationary housing containing the lubricating oil, and separate sealing elements. This segmentation allows the thrust bearing to handle axial loads while the housing contains the lubricating oil, preventing contamination from pump fluid. The system also separates the lubrication function from the thrust support function, allowing independent optimization of each.
3Reliability
If a standalone thrust chamber with clean motor oil is used, then the thrust bearings can operate reliably, but regular maintenance and oil changes are required
Solution Approach 1:
The patent implements a self-lubricating thrust bearing system where the lubricating oil is contained within the thrust bearing assembly itself. The rotating disk continuously circulates the oil through the bearing surfaces, providing automatic lubrication without external intervention. The sealed design prevents contamination, allowing the system to operate for extended periods without maintenance, and the oil can be replaced by simply removing the thrust bearing assembly from the pump intake.
4Force
If bronze pads are used in hydrodynamic bearings, then the bearings can carry load, but the load capacity is limited to about 500 pounds per square inch
Solution Approach 1:
The patent uses a composite material system for the thrust bearing surfaces: the rotating disk is made of a hard material such as tungsten carbide or stainless steel, while the stationary housing contains soft metal pads made of bronze or other bearing materials. This composite approach allows the hard rotating surface to maintain precision and the soft stationary pads to conform and distribute load, achieving load capacities far exceeding 500 psi while maintaining reasonable surface area.
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 pump's ability to handle high axial loads, reduces maintenance needs, and extends the lifespan of the bearings by utilizing the pumped fluid as a hydrodynamic film for cooling and lubrication, while maintaining the integrity of the diamond coating.
Implementation Method 1
utilizing the pumped fluid as a hydrodynamic film for cooling and lubrication
Implementation Method 2
diamond-coated pads in the intake section of the pump, allowing the thrust bearings to operate directly in the pumped fluid flow
Data Source
AI summary
An apparatus and system for a thrust-absorbing horizontal surface pump assembly is described. A thrust-absorbing horizontal surface pump system includes an intake chamber including a stationary thrust bearing paired with a rotatable thrust runner to form a thrust bearing set, wherein a first face of the stationary thrust bearing positioned towards the rotatable thrust runner is at least partially diamond-coated, and wherein a second face of the rotatable thrust runner positioned towards the stationary thrust bearing is at least partially diamond-coated, a fluid entrance that receives a fluid into the intake chamber, and a pump inlet that receives the fluid into the multi-stage centrifugal pump, wherein the thrust bearing set is arranged around the intake shaft such that during operation of the electric motor the thrust bearing is in a pathway of the fluid as the fluid flows between the fluid entrance and the pump inlet.