Integral Crosshead Box for Fracturing Pumps
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Solution Overview
Problem
The existing welded structure of crosshead boxes in fracturing pumps is prone to stress concentration, reduced strength and rigidity, and poor lubrication efficiency, leading to premature failure and increased maintenance costs.
Innovation Solution
An integral crosshead box is designed using an integral forming process, featuring a cast casing with in-line lubricating oil pathways and multi-functional structural holes, which enhances structural strength, rigidity, and lubrication efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a welded structure is used to combine crankcase and crosshead box, then manufacturing flexibility is improved, but structural strength and rigidity deteriorate due to stress concentration at welding seams
Solution Approach 1:
The patent merges the crankcase and crosshead box into a single integral casting, eliminating the welding seam between the two components. This integration removes the stress concentration points that would otherwise exist at the welding interface, while still allowing for flexible manufacturing through the casting process. The unified structure ensures homogeneous stress distribution and superior fatigue resistance.
2Ease of manufacture
If a welded structure is used for crosshead box, then assembly flexibility is improved, but reliability deteriorates due to weld cracking and deformation under high-pressure pulse loads
Solution Approach 1:
By combining the crankcase and crosshead box into one integral casting, the patent eliminates the welding process entirely. This removes the inherent risks of weld cracking, heat-affected zone embrittlement, and residual stresses that compromise reliability under the harsh high-pressure pulse loading conditions of fracturing pumps.
3Ease of manufacture
If a welded structure is used, then component modularity is improved, but lubrication efficiency deteriorates due to complex external oil pathways
Solution Approach 1:
The integral casting allows for the incorporation of lubrication oil pathways directly within the unified structure. These internal oil channels eliminate the need for complex external piping systems, reducing leakage points and improving lubrication reliability. The oil pathways are seamlessly integrated into the casting geometry, maintaining manufacturing simplicity while enhancing lubrication efficiency.
Data Source
AI summary
The present disclosure relates to a crosshead box, which is a substantially rectangular box body formed by an integral forming process and is provided with a front end surface, a rear end surface, an upper end surface, a lower end surface, and a side end surface, and the crosshead box is provided with: a plurality of crosshead cavities, each of the crosshead cavities extending in a longitudinal direction of the crosshead box and running through the box body, and the plurality of crosshead cavities being arranged in a transverse direction of the crosshead box. The crosshead box is further provided with a plurality of exhaust chambers, each of the exhaust chambers running through the crosshead box in the longitudinal direction of the crosshead box and being in communication with the corresponding crosshead cavity. The present disclosure further relates to a plunger pump provided with the crosshead box described above. In the crosshead box and the plunger pump according to the present disclosure, by integral forming, the service life is greatly improved, and the air pressure inside the box body during operation can be maintained always in balance, thereby improving the operating stability of the equipment and therefore further prolonging the service life.