Downhole Pump Diffuser Locking for Stable Coupling Under Rotational Force
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Solution Overview
Problem
Submersible pumps face operational inefficiencies and potential failure due to internal and external forces causing loosening and failure of couplings and orientations between components, particularly in high heat environments or high gas applications where lubrication is inadequate.
Innovation Solution
Incorporation of locking features such as coupling pins and mechanical stops to secure diffusers relative to each other and to an anchoring component, using nonthreaded pins and protrusions for simplified assembly and disassembly, and interference fits to maintain diffuser position during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional couplings are used between diffusers, then assembly is simple, but rotational forces cause loosening and failure during operation
Solution Approach 1:
The coupling features (protrusions and recesses) are pre-formed on the diffusers during manufacturing, enabling automatic alignment and secure coupling when diffusers are assembled. This preliminary preparation ensures that the coupling structure is inherently resistant to rotational forces without requiring additional complex fastening mechanisms during operation.
Solution Approach 2:
The coupling features act as intermediary elements between adjacent diffusers, providing a mechanical interface that transfers and distributes rotational forces across multiple diffusers. The protrusion-recess interaction creates a distributed force path that prevents localized stress concentration and coupling failure.
2Stability of the object's composition
If diffusers are secured with locking features, then relative movement is minimized, but assembly and disassembly become more complex
Solution Approach 1:
The locking features (protrusions and recesses) are integrated into the diffuser structure during manufacturing, eliminating the need for separate locking components. This preliminary integration maintains manufacturing simplicity while providing stable diffuser positioning through the inherent geometry of the coupling features.
Solution Approach 2:
The coupling and locking functions are merged into a single integrated feature set. The same protrusions and recesses that couple adjacent diffusers together also provide the locking action that prevents relative movement, eliminating the need for separate coupling and locking mechanisms.
3Force
If multiple coupling features are added to transfer rotational forces, then force distribution improves, but device complexity increases
Solution Approach 1:
The coupling system is segmented into multiple discrete protrusions and recesses distributed around the diffuser circumference. This segmentation allows rotational forces to be distributed across multiple contact points, reducing the load on any single coupling feature while maintaining a relatively simple overall structure.
Solution Approach 2:
The coupling features serve multiple functions simultaneously: they couple adjacent diffusers together, transfer rotational forces between diffusers, provide locking action to prevent relative movement, and distribute mechanical loads. This multi-functionality reduces the need for separate components for each function.
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
Enhances pump efficiency and reduces failure risk by minimizing relative movement of diffusers, even in high heat and high gas environments, ensuring stable operation and prolonged lifespan.
Implementation Method 1
coupling pins configured to at least partially transfer a rotational force applied to one or more of the stationary diffusers to the remaining stationary diffusers
Implementation Method 2
interference fits to maintain diffuser position during operation
Data Source
AI summary
Downhole centrifugal pumps and related components and methods may include diffusers housing impellers where the diffusers have radial sidewalls defining a radially outer portion of each of the diffusers. Coupling members may extend between and engage with the diffusers.