Impeller Clutch Control in Torque Converters for Load Rise Rates
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Solution Overview
Problem
Gaseous fuel engines are unsuitable for driving hydraulic fracturing pumps due to poor load acceptance and high load rise rates associated with gear shifts, making them unsuitable for hydraulic fracturing operations.
Innovation Solution
A torque converter system with an impeller clutch and lockup clutch is used to mechanically couple a gaseous fuel engine with a gear system, allowing for controlled engagement and disengagement to manage load changes, thereby improving load acceptance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a gaseous fuel engine is used to drive a hydraulic fracturing pump, then greenhouse gas emissions and fuel costs are reduced, but load acceptance and response to load changes deteriorate
Solution Approach 1:
A torque converter is introduced as an intermediary device between the gaseous fuel engine and the hydraulic fracturing pump. The torque converter includes an impeller coupled to the engine, a turbine coupled to the pump, and a stator positioned between them. This fluid coupling mechanism allows the engine to drive the pump while accommodating load variations, thereby maintaining reliability with reduced emissions.
Solution Approach 2:
The torque converter enables dynamic operation by allowing slip between the impeller and turbine. This slip capability allows the system to accommodate rapid load changes during hydraulic fracturing operations without requiring the engine to respond instantaneously, thus maintaining stable operation with gaseous fuel.
2Loss of energy
If a gaseous fuel engine is used to drive a hydraulic fracturing pump, then fuel costs are reduced, but response to load changes deteriorates
Solution Approach 1:
The torque converter acts as a mediator that decouples the direct mechanical connection between the engine and pump. This allows the pump to respond rapidly to load changes while the gaseous fuel engine operates more slowly and efficiently, reducing fuel costs while maintaining system responsiveness.
Solution Approach 2:
The torque converter's fluid coupling allows for dynamic speed adjustment. The impeller and turbine can rotate at different speeds, enabling the pump to maintain high response capability while the engine operates at optimal fuel-efficient speeds.
3Reliability
If direct mechanical coupling is used between engine and pump, then load acceptance is poor, but device complexity is reduced
Solution Approach 1:
The torque converter provides load acceptance benefits through its fluid coupling mechanism while adding only moderate complexity. The device includes an impeller, turbine, and stator, which together create a compact transmission system that improves reliability without excessive complexity.
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
The system enables gaseous fuel engines to handle high load rise rates in hydraulic fracturing applications, reducing greenhouse gas emissions and fuel costs compared to diesel engines.
Implementation Method 1
a torque converter configured to fluidly couple the gaseous fuel engine and the gear system
Data Source
AI summary
A hydraulic fracturing pump system may include a hydraulic fracturing pump, a gaseous fuel engine configured to drive the hydraulic fracturing pump, and a transmission system including a gear system mechanically coupled to the hydraulic fracturing pump and torque converter configured to fluidly couple the gaseous fuel engine and the gear system. The torque converter may include an impeller, a turbine fluidly coupled to the impeller and mechanically coupled to the gear system, a stator positioned between the impeller and the turbine, an impeller clutch configured to mechanically couple the impeller to the gaseous fuel engine, and a lockup clutch configured to mechanically couple the gaseous fuel engine and the gear system.