Integrally Cast Fracturing Pump Spacer Frame
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Solution Overview
Problem
Conventional fracturing pump spacer frames, which are typically welded, suffer from defects such as internal stress, fatigue cracks, and reduced service life due to welding-induced structural changes and complex manufacturing processes.
Innovation Solution
An integrally formed fracturing pump spacer frame with an approximately U-shaped leg supporting both the hydraulic end connecting plate and the crosshead box connecting plate, enhancing support stiffness and allowing for bending deformation, while a varying diameter portion of the support sleeve increases flexural strength and facilitates casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding is used to form the spacer frame, then manufacturing speed is improved, but internal stress and fatigue cracks occur reducing service life
Solution Approach 1:
The patent merges multiple separate components (end plates, support sleeves, bottom support plate) into a single integrally formed spacer frame structure. This eliminates the welding process entirely, avoiding the internal stress and fatigue crack issues that arise from welding while maintaining manufacturing efficiency through integrated mold casting.
Solution Approach 2:
The patent replaces the welding mechanical process with a casting process. Instead of joining separate metal parts through welding, the entire spacer frame is formed as a single piece through integrated mold casting, thereby eliminating welding-induced defects while ensuring structural integrity.
2Device complexity
If welding is used to form the spacer frame, then assembly is simplified, but manufacturing precision deteriorates due to complex procedures
Solution Approach 1:
By combining all spacer frame components into a single integrally formed structure, the patent eliminates the need for complex welding procedures and multiple assembly steps. The integral structure ensures precise positioning of all components without requiring separate alignment and joining operations.
3Productivity
If welding is used to form the spacer frame, then production efficiency is improved, but structural strength deteriorates due to heat-affected zone
Solution Approach 1:
The patent substitutes the welding process with integrated mold casting to form the spacer frame. This casting process creates a homogeneous metal structure without heat-affected zones, maintaining consistent material properties and structural strength throughout the entire component while achieving production efficiency through direct casting.
4Ease of manufacture
If welding is used to form the spacer frame, then initial manufacturing cost is reduced, but maintenance cost increases due to crack detection and repair
Solution Approach 1:
By integrating all components into a single cast structure, the patent eliminates welding-related defects that would require costly inspection and repair. The integral structure has no weld joints that could develop cracks, significantly reducing long-term maintenance and inspection costs despite potentially higher initial casting complexity.
Data Source
AI summary
A fracturing pump spacer frame includes a hydraulic end connecting plate and a crosshead box connecting plate that are disposed spaced apart in parallel. The hydraulic end connecting plate and the crosshead box connecting plate are fastened by a support sleeve. The fracturing pump spacer frame further includes a leg. The hydraulic end connecting plate, the crosshead box connecting plate, the support sleeve, and the leg are integrally formed. The leg includes a first vertical supporting plate and a second vertical supporting plate that are vertically disposed and a first bottom supporting plate that is horizontally disposed. The first vertical supporting plate is located below the hydraulic end connecting plate. The second vertical supporting plate is located below the crosshead box connecting plate. Two sides of the first bottom supporting plate are respectively connected to lower ends of the first vertical supporting plate and the second vertical supporting plate. In the present disclosure, an integrally formed fracturing pump spacer frame is used, to avoid an impact of a welding defect on stiffness, strength, service life, and the like. An approximately U-shaped leg may support both a hydraulic end connecting plate and a crosshead box connecting plate, so that the number of support points is increased, a moment and a caused deformation are decreased, and service life is increased.