Remanufacturing Fluid End Block Segments

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Solution Overview

Problem

The fluid end block in high-pressure pump assemblies is prone to erosion, wear, and fatigue, leading to cracks and requiring the entire block's replacement, which is costly and inefficient for maintenance.

Innovation Solution

A method of remanufacturing the fluid end block by replacing damaged segments with identical or similar segments and coupling them using welding or stitch pins, with a seal between the segments to prevent leakage and ensure a pressure-tight joint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire fluid end block is replaced when damaged, then reliability is restored, but maintenance cost increases significantly

Engineering Contradiction:

Improvefluid end block operational integrityVSAvoidmaintenance cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The fluid end block is divided into multiple separable segments that can be independently removed and replaced. When damage occurs in one segment, only that specific segment needs to be replaced rather than the entire block, reducing material waste and maintenance costs while restoring reliability to the damaged portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Damaged segments are removed and discarded, while intact segments are retained and reused. The replacement segments are coupled to the existing intact segments using seals and coupling mechanisms, allowing recovery and continued use of the majority of the original fluid end block structure.

Inventive Principle:

Principle #34Discarding and recovering

2Ease of repair

If the fluid end block is segmented for easier repair, then ease of repair improves, but device complexity increases

Engineering Contradiction:

Improvesegment replacement simplicityVSAvoidfluid end block structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The fluid end block is divided into multiple separable segments with standardized coupling interfaces. Each segment can be independently removed and replaced through simple coupling mechanisms (such as stitch pins or welding), enabling easy repair of damaged segments without requiring complex disassembly or specialized equipment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling mechanisms and seal interfaces are designed to be universal across different segments, allowing the same coupling method to be used regardless of which segment is being replaced. This standardization simplifies the repair process while the modular design manages structural complexity through repetition of standardized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10563494B2Method of remanufacturing fluid end block

Publication Date: 2020.02.18 CATERPILLAR INC

AI summary

A method of remanufacturing a fluid end block having a plurality of segments adapted to receive working fluid includes removing at least one damaged segment from the plurality of segments of the fluid end block. The method also includes providing at least one replacement segment at a location of the at least one damaged segment. The method further includes providing a seal between a first surface of the at least one replacement segment and a first surface of at least one adjacent segment of the plurality of segments. The method includes coupling the at least one replacement segment with the at least one adjacent segment to form a remanufactured fluid end block.