Auto-Engageable Coupling to Block Reverse Torque in ESP Motors
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Solution Overview
Problem
Conventional ESP motors can generate dangerous back-EMF forces when acting as generators due to fluid flow through the pump, posing a risk to personnel safety.
Innovation Solution
An auto-engageable coupling that allows torque transfer from the motor to the pump in the intended direction while preventing torque transfer in the reverse direction, featuring drive and reaction plates with asymmetrical teeth and a braking mechanism to resist unintended rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the motor is directly coupled to the pump, then torque transfer from motor to pump is efficient, but the motor is vulnerable to unintended reverse rotation from the pump
Solution Approach 1:
The coupling employs asymmetrical teeth geometry where the drive plate teeth and reaction plate teeth are shaped to engage only in one rotational direction. The asymmetrical design allows torque transmission when the motor rotates the pump, but prevents torque transmission when the pump attempts to rotate the motor in reverse, thus resolving the contradiction between efficient torque transfer and protection from unintended rotation.
2Reliability
If a mechanical coupling is used to prevent reverse torque, then motor protection is improved, but device complexity increases
Solution Approach 1:
The coupling mechanism is designed to automatically engage and disengage based on the direction of rotational force applied. The asymmetrical teeth geometry causes the coupling to self-lock in the forward direction and self-release in the reverse direction without requiring external control systems, sensors, or complex actuation mechanisms, thus providing motor protection while maintaining relatively simple device architecture.
3Ease of operation
If the coupling allows free rotation in both directions, then ease of operation is improved, but back-EMF generation becomes possible
Solution Approach 1:
The asymmetrical tooth design inherently restricts rotational freedom to only the intended direction while maintaining ease of operation in that direction. The coupling allows smooth engagement during normal motor-driven rotation but automatically prevents reverse rotation that would generate back-EMF, thus resolving the contradiction between operational ease and prevention of harmful electrical generation.
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
Prevents the generation of back-EMF forces by isolating the motor from unintended torque, ensuring safety and reducing electrical hazards in ESP systems.
Implementation Method 1
The auto-engageable coupling permits the transfer of torque from the motor to the pump
Implementation Method 2
a braking mechanism that is configured to resist the rotation of the output shaft in an unintended direction
Implementation Method 3
the motor can act as a generator. If fluid is caused to flow through the pump, this may cause the pump to rotate, which will in turn cause the motor to rotate and generate an AC voltage
Data Source
AI summary
An auto-engageable coupling is disclosed for use in a pumping system that includes an electric motor and a pump driven by the electric motor. The auto-engageable coupling permits the transfer of torque from the motor to the pump, but prevents the pump from applying torque to the motor. In some embodiments, the auto-engageable coupling includes a drive plate connected to a motor shaft and a reaction plate connected to an output shaft. The drive plate and reaction plate are only coupled together to transmit torque from the motor to the pump when the motor is activated and rotating in a first, intended direction. When the motor is not activated and the pump is forced to rotate in a first direction, the drive plate and the reaction plate are disengaged to prevent the delivery of torque from the pump to the motor.