ESP Shaft Coupling Shell With Integrated Axial Load Handling
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Solution Overview
Problem
Conventional electric submersible pump (ESP) assemblies require additional thrust bearings to support up thrust, which increases costs and occupies limited space within ESP components.
Innovation Solution
The implementation of axial coupling mechanisms within the coupling shell of ESP assemblies, such as using balls and bolts or removable lugs, to axially couple drive shafts without the need for additional thrust bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional coupling shells are used to couple drive shafts, then rotational coupling is achieved, but axial coupling capability is lost requiring additional thrust bearings
Solution Approach 1:
The patent combines rotational coupling (via splines) and axial coupling (via ball-and-socket or lug mechanisms) into a single integrated coupling shell structure. This merging eliminates the need for separate thrust bearings while providing both rotational and axial constraint capabilities in one component.
Solution Approach 2:
The coupling shell is designed to perform multiple functions simultaneously: it provides rotational coupling through internal splines, axial coupling through ball-and-socket or lug mechanisms, and structural support for the drive shafts. This multi-functionality replaces what would traditionally require multiple specialized components including thrust bearings.
2Force
If additional thrust bearings are installed to support up thrust, then axial load capacity is improved, but cost and space occupation increase
Solution Approach 1:
The coupling shell merges the functions of rotational coupling and axial load support into a single structure. The ball-and-socket or lug mechanisms integrated into the coupling shell provide axial load capacity without requiring separate thrust bearing assemblies, thereby reducing space occupation.
Solution Approach 2:
The patent extracts the axial coupling function from the traditional thrust bearing component and integrates it directly into the coupling shell structure. This eliminates the need for separate thrust bearings and reduces the overall space required for axial load support.
3Power
If traditional coupling methods are used, then rotational power transmission is achieved, but axial coupling requires separate thrust bearings increasing cost
Solution Approach 1:
The coupling shell combines rotational power transmission (via splines) and axial coupling (via ball-and-socket or lug mechanisms) into a single manufactured component. This integration reduces the total part count and assembly complexity, leading to lower manufacturing costs compared to traditional methods requiring separate thrust bearings.
Solution Approach 2:
The coupling shell is designed as a universal component that handles both rotational power transmission and axial coupling forces. This multi-functionality eliminates the need for additional specialized components, reducing overall manufacturing cost and simplifying the supply chain.
Data Source
AI summary
An electric submersible pump (ESP) assembly. The ESP assembly comprises a first ESP component having a first drive shaft defining a plurality of male splines and defining at least one cut-out area; a second ESP component having a second drive shaft defining a plurality of male splines; a coupling shell defining a first plurality of female splines configured to mate with the male splines of the first drive shaft, a second plurality of female splines configured to mate with the male splines of the second drive shafts, and at least one shouldered aperture configured to align with the cut-out area of the first drive shaft; and at least one removable lug having a pin that is configured to extend through the shouldered aperture in the coupling shell to engage with the at least one cut-out area of the first drive shaft.