One-Piece Intake Manifold with Tapered Flow and Back-Flushing
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Solution Overview
Problem
Conventional intake manifolds used in hydraulic fracturing pumps are prone to leaks and poor flow patterns due to welded connections and lack a means for debris removal without disassembly, leading to inefficiencies and maintenance challenges.
Innovation Solution
A one-piece machined intake manifold with a tapered elongate hollow pipe section and angled side ports for inspection and cleaning, eliminating welds and allowing for back-flushing and reversible installation, along with fork-lift openings for easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welded manifold construction is used, then assembly is simplified, but leaks develop through welds and flow patterns deteriorate
Solution Approach 1:
The patent merges multiple separate manifold components into a single integral one-piece casting. This eliminates the welds between components that cause leaks, while maintaining the functional assembly of multiple ports and passages. The single-piece construction integrates the base plate, pipe sections, and fittings into one monolithic structure that is manufactured as a complete unit.
2Ease of manufacture
If conventional welded manifold construction is used, then manufacturing process is simplified, but flow patterns become poor
Solution Approach 1:
The integral one-piece casting combines all flow passages and structural elements into a unified design that allows optimization of flow paths. The tapered pipe sections and smoothly contoured passages are built-in during casting, eliminating flow disruptions caused by welds and sharp transitions between separate components.
3Stability of the object's composition
If conventional manifold design is used, then structure is complete, but debris removal requires complete manifold removal
Solution Approach 1:
The patent segments the debris removal function from the main manifold body by providing separate access ports and removable caps. These allow the interior passages to be flushed and cleaned while the manifold remains installed on the pump, eliminating the need to completely remove the manifold for maintenance.
4Productivity
If tapered pipe section is added for flow direction, then flow efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The tapered pipe sections are integrated directly into the one-piece casting design, combining the flow-directing function with the structural framework. The tapers are formed as part of the mold cavity during casting, so while the geometry is complex, the manufacturing process remains relatively simple compared to machining or assembling multiple components.
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 solution provides a leak-free, efficient flow path, prevents solid matter from settling, enables easy inspection and cleaning, and facilitates easy handling and installation, improving hydraulic fracturing pump performance and maintenance efficiency.
Implementation Method 1
The elongate hollow pipe section has tapered wall surfaces such that the elongate hollow pipe section progressively narrows and is reduced in size from adjacent the front end to the rear end for directing flow through the manifold body from the intake port through the discharge ports of the base plate
Data Source
AI summary
An intake manifold is provided having a base plate with discharge ports and an elongate pipe section extending along a face of the base plate. The pipe section has a front end with an intake port and progressively narrows at least adjacent a rear end. A first port in the rear end enables back-flushing of the manifold, and a second port in the rear end is angled relative to the base plate and enables insertion of a probe. Fork-lift openings extend between the base plate and the pipe section enabling the manifold to be lifted and positioned with a lift truck. Side ports extend through the pipe section and are angled relative to the base plate and adjacent one of the discharge ports to enable visual inspection of the discharge port. The side ports may include side ports located on both sides of the pipe section.