Hydraulic Fracturing Transmission Gear Selection Controller
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Solution Overview
Problem
Current hydraulic fracturing systems lack an efficient and automated method for selecting the optimal transmission gear, relying on manual operation which can lead to suboptimal fuel efficiency and component durability, limiting the overall performance and reliability of the equipment.
Innovation Solution
A hydraulic fracturing system equipped with a controller and advisory system that uses fuel consumption data and component durability data to identify and display the optimal transmission gear, allowing for automated gear selection based on pump flow and pressure settings, thereby optimizing operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If manual gear selection is used, then the system is simpler to operate, but fuel efficiency and component durability are suboptimal
Solution Approach 1:
The system automatically selects optimal transmission gears using a controller that processes pump flow and pressure settings along with stored fuel consumption and component durability data, eliminating the need for manual gear selection by operators while optimizing fuel efficiency and component life
Solution Approach 2:
The controller continuously receives pump flow and pressure settings as input, processes this information against stored performance data, and automatically adjusts transmission gear selection to maintain optimal fuel efficiency and component durability under varying operating conditions
2Reliability
If automated gear selection system is implemented, then fuel efficiency and component durability are optimized, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives pump flow and pressure settings, stores and processes fuel consumption data and component durability data, automatically selects optimal transmission gears, and displays recommendations, consolidating these functions into a single multi-functional control system
Solution Approach 2:
Fuel consumption data and component durability data are pre-stored in the controller's memory before operation, allowing the system to quickly reference and process this information during runtime without requiring complex real-time calculations or external data sources
3Productivity
If optimal transmission gear is automatically identified, then overall system performance is improved, but the extent of automation increases
Solution Approach 1:
The automation system is divided into distinct functional modules: data storage for fuel consumption and component durability information, data processing through the controller, transmission gear selection logic, and display output, allowing the automation to be implemented in manageable segments rather than as a monolithic system
Data Source
AI summary
A hydraulic fracturing system includes an engine, transmission, and hydraulic fracturing pump. A driveshaft is coupled between the transmission and the hydraulic fracturing pump to transfer torque from the engine to the hydraulic fracturing pump. The hydraulic fracturing system also includes an advisory system including a display, a memory storing fuel consumption data and component durability data, and a controller. The controller is programmed to receive pump flow and pressure settings, identify an optimal transmission gear based on the pump flow and pressure settings, the fuel consumption data and the component durability data, and cause the optimal transmission gear to be displayed on the display.