ESP Shaft Coupling With Integrated Axial Thrust Handling
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Solution Overview
Problem
Conventional ESP assembly coupling shells provide only rotational coupling, leading to the need for additional thrust bearings to handle axial loads, which increases costs and occupies limited space.
Innovation Solution
The implementation of axial coupling mechanisms within the coupling shell, such as ball-and-race systems, removable lugs, and locking lugs, to axially couple drive shafts while maintaining rotational coupling, thereby eliminating the need for additional thrust bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional coupling shells providing only rotational coupling are used, then the structure is simple, but additional thrust bearings are required which increases cost and occupies space
Solution Approach 1:
The patent merges the rotational coupling function and axial load handling function into a single integrated coupling shell. The coupling shell incorporates both male and female splines for rotational power transmission and integrated thrust bearing surfaces for axial load support, eliminating the need for separate thrust bearing components while maintaining both functions simultaneously.
Solution Approach 2:
The coupling shell is designed as a multi-functional component that simultaneously performs rotational coupling through spline engagement and axial load support through integrated thrust bearing surfaces. This universal component replaces what would traditionally require separate specialized components for each function.
2Force
If additional thrust bearings are added to handle axial loads, then axial load handling capability is improved, but the available space in the ESP assembly is reduced
Solution Approach 1:
The coupling shell combines rotational coupling and axial load support into one integrated structure, eliminating the need for separate thrust bearing components that would occupy additional space within the ESP assembly.
Solution Approach 2:
The multi-functional coupling shell provides both rotational power transmission and axial load support within a single component footprint, maximizing space utilization in the constrained ESP assembly environment.
3Force
If additional thrust bearings are added to handle axial loads, then axial load handling capability is improved, but the overall cost of the ESP assembly increases
Solution Approach 1:
The integration of thrust bearing surfaces directly into the coupling shell eliminates the need for separate thrust bearing components, reducing parts count, assembly steps, and overall manufacturing cost while maintaining full axial load handling capability.
Solution Approach 2:
The universal coupling shell that performs multiple functions reduces the total component count and bill of materials, leading to lower manufacturing costs compared to using separate specialized 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
This solution provides a low-cost, space-efficient axial coupling for ESP assemblies, enhancing their ability to handle both downhole and uphole thrusts without the need for additional thrust bearings.
Implementation Method 1
ball-and-race systems
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.