Detachable Electric Fracturing Pump Drive With Thermal Control
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Solution Overview
Problem
Existing electric drive pump systems for hydraulic fracturing face inefficiencies due to heavy mechanical components, high maintenance costs, and temperature regulation issues, leading to reduced hydraulic horsepower and potential premature failure.
Innovation Solution
An electric drive pump system with a plurality of individual motors configured around a gearbox for linear motion conversion, a detachable transmission assembly, a temperature regulation system capable of both heating and cooling, and a control module for monitoring and regulating motor performance and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel-powered pumps are used to pump fracture fluid at high pressure, then sufficient pumping pressure and rate are achieved, but the pumps become very heavy requiring heavy duty trailers for transport
Solution Approach 1:
The patent replaces the diesel engine (mechanical system) with an electric motor (electrical system). The electric motor drives the pump through a gearbox, eliminating the need for a diesel engine while maintaining the required pumping pressure. This substitution reduces weight and eliminates the need for heavy duty trailers.
2Power
If diesel-powered pumps are used, then high pressure pumping is achieved, but maintenance costs increase due to expensive diesel engine maintenance
Solution Approach 1:
The diesel engine is replaced with an electric motor and gearbox system. Electric motors have fewer moving parts and require less maintenance compared to diesel engines, reducing maintenance costs and improving ease of repair while maintaining the required pumping pressure.
3Use of energy by moving object
If existing mechanical units are integrated into an electric system, then electric power is provided, but efficiency and performance are limited due to design conflicts
Solution Approach 1:
The patent uses a variable frequency drive (VFD) to dynamically control the speed of the electric motor based on the actual pumping requirements. This allows the system to operate at optimal efficiency across varying load conditions, rather than running at fixed speed, thereby improving overall productivity and energy efficiency.
Solution Approach 2:
The electric motor and gearbox assembly is designed as a universal power unit that can be coupled with different pump types and configurations. This multi-functional design eliminates design conflicts by creating a standardized electric drive system that adapts to various pumping applications, improving efficiency and performance.
4Temperature
If air-cooling solutions are used for electric motors, then cooling is provided, but temperature regulation is insufficient leading to motors running hotter and less efficiently
Solution Approach 1:
The patent transitions from air-cooling to liquid-cooling (hydraulic cooling system) for the electric motor. Liquid cooling provides superior heat transfer efficiency, maintaining lower motor temperatures even under high load conditions. This temperature regulation preserves motor efficiency and maintains optimal hydraulic horsepower output.
5Use of energy by moving object
If existing mechanical components are repurposed for electric applications, then electric drive is achieved, but effective horsepower decreases due to hydraulic and mechanical resistance
Solution Approach 1:
The patent optimizes the gearbox ratio and motor speed parameters to match the specific requirements of the pump application. By changing these parameters rather than using off-the-shelf components, the system minimizes hydraulic and mechanical resistance, maximizing effective horsepower delivery to the pump.
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
The system enhances efficiency, reduces maintenance, minimizes hydrocarbon emissions, and allows for precise power control, resulting in improved hydraulic horsepower and extended equipment lifespan while reducing noise and environmental impact.
Implementation Method 1
The temperature regulation system can be configured to provide both a heating effect and a cooling effect
Implementation Method 2
The temperature regulation system can be configured to provide both a heating effect and a cooling effect
Implementation Method 3
The motors are arranged around a gearbox which is used to convert the rotary motion of the electric motors into linear motion
Data Source
AI summary
An electric drive pump system includes a power end and a detachable transmission assembly. The transmission assembly is mounted to the power end and is configured to provide rotational power to the power end through a plurality of electric motors. The plurality of electric motors use a gearbox to drive an output spline that engages the power end. A control module is used to regulate the performance characteristics of the plurality of electric motors. A temperature regulation assembly is configured to regulate the temperature of the transmission assembly and the power end.