Direct Drive Motor Crank System for Beam Pumping Unit
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Solution Overview
Problem
Conventional beam pumping units for extracting underground objects face issues with short lifespan and high maintenance costs due to the use of gear speed reducers and belts, and inability to adjust torque and speed according to varying load conditions.
Innovation Solution
The implementation of a direct drive motor system with a control system that provides variable voltage and frequency control signals to adjust the speed and torque of a rotating motor, eliminating the need for belts and gear speed reducers, and enabling position sensor-less control for flexible torque delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If gear speed reducers and belts are used to convert rotary motion to reciprocating motion, then sufficient torque is produced to drive the load, but the lifespan is short and maintenance costs are high
Solution Approach 1:
The patent removes the gear speed reducer and belt from the drivetrain, extracting the problematic intermediate components that caused short lifespan and high maintenance. The motor directly drives the crankshaft without these intermediary mechanical elements, eliminating their wear and failure modes while maintaining sufficient torque delivery to the pump.
Solution Approach 2:
The patent merges the motor and drivetrain into a more integrated configuration where the motor directly couples to the crankshaft through a simplified transmission system. This consolidation eliminates the separate gear reducer and belt components, reducing the number of moving parts that require maintenance while preserving the necessary torque transmission capability.
2Force
If gear speed reducers and belts are used to convert rotary motion to reciprocating motion, then sufficient torque is produced to drive the load, but maintenance effort is high
Solution Approach 1:
The patent extracts and removes the gear speed reducer and belt from the system, eliminating the components that require frequent maintenance and repair. This direct-drive configuration reduces maintenance effort by eliminating the complex mechanical transmission elements that are prone to wear, misalignment, and failure.
Solution Approach 2:
The patent replaces the mechanical gear reducer and belt system with a more simplified direct mechanical coupling. This substitution eliminates the need for complex mechanical transmission components that require maintenance, while still achieving the necessary torque conversion through the motor's direct coupling to the crankshaft mechanism.
3Stability of the object's composition
If AC electric motor receives fixed frequency and fixed voltage control signals, then the motor operates stably, but the torque cannot be adjusted according to load variations
Solution Approach 1:
The patent implements a variable frequency drive (VFD) system that dynamically adjusts the motor's operating parameters. The controller varies the frequency and voltage of the control signals based on real-time feedback from sensors monitoring load conditions, oil level, and pump performance. This enables the motor to adapt its torque output to match varying load requirements while maintaining stable operation through closed-loop control.
Solution Approach 2:
The patent incorporates a feedback control system where sensors monitor operating parameters such as load conditions, oil level, and pump performance. This feedback information is fed to the controller, which adjusts the motor's control signals in real-time to optimize torque delivery. The feedback mechanism enables the system to respond to changing conditions and maintain optimal performance across varying operating scenarios.
4Force
If linear motor is used to drive the load, then direct linear force is produced, but the cost is high and commercial value is reduced
Solution Approach 1:
Instead of using a linear motor that directly produces linear force (which is expensive), the patent inverts the approach by using a conventional rotary motor to produce rotational torque, which is then converted to linear reciprocating motion through the crankshaft and connecting rod mechanism. This inverted approach achieves the necessary linear force delivery at a fraction of the cost of a linear motor while maintaining the essential pumping function.
Solution Approach 2:
The patent replaces the expensive linear motor system with a more economical rotary motor coupled to a mechanical conversion mechanism. The rotary motor produces rotational motion that is converted to linear reciprocating motion through traditional mechanical components (crankshaft, connecting rod, crosshead). This substitution achieves the same functional outcome as a linear motor but at a significantly lower cost, improving the commercial viability of the system.
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 extends the lifespan of the system, reduces maintenance costs, and allows for adjustable torque and speed to optimize oil extraction, increasing efficiency and the amount of extracted liquid or gas.
Implementation Method 1
a rotating motor and one or more cranks (304) coupled to an output shaft of the rotating motor. The method includes receiving, at a control system, one or more input signals; and providing, based on the input signals, one or more control signals to the rotating motor to enable the rotating motor to directly drive the one or more cranks
Data Source
AI summary
Systems and methods are disclosed for extracting underground objects using a beam pumping unit including a rotating motor and one or more cranks coupled to a walking beam enabling the extraction. According to certain embodiments, the method includes receiving, at a control system, one or more input signals; and providing, based on the input signals, one or more control signals to the rotating motor to enable the rotating motor to directly drive the one or more cranks for extracting the underground objects. The method also includes varying, based on the one or more control signals, a rotating speed of the rotating motor based on one or more conditions of the underground objects; and enabling the extraction in a reciprocated manner based on the varying rotating speed of the rotating motor.