Integral One-Piece Intake Manifold for Hydraulic Fracturing Pumps
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Solution Overview
Problem
Conventional intake manifolds used in hydraulic fracturing pumps are prone to leaks due to welds and threaded connections, and they do not effectively manage debris or provide uniform flow patterns, leading to issues like sand dropout and cavitation.
Innovation Solution
The development of one-piece machined intake manifolds made of ductile iron or stainless steel, featuring smooth tapered designs and angled side ports for visibility and back flushing, eliminating the need for welds and threads, ensuring even slurry flow and preventing particulate dropout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional intake manifolds are assembled from welded pipe fittings and machined base plates, then manufacturing flexibility and adaptability are improved, but reliability deteriorates due to leaks through welds and threaded connections
Solution Approach 1:
The patent merges multiple separate components (base plate, pipe fittings, threaded connections) into a single integral manifold body. This eliminates all welds and threaded connections that caused leaks, while maintaining the functional adaptability of the manifold through integrated port configurations and mounting features.
2Ease of manufacture
If conventional intake manifolds use standard pipe fittings and welds, then ease of manufacture is improved, but manufacturing precision deteriorates leading to poor flow patterns
Solution Approach 1:
By combining the entire manifold structure into one integral casting, the patent eliminates the need to assemble multiple precision-machined components. The flow paths are formed directly during casting with precise geometric control, ensuring uniform flow patterns without the tolerance accumulation inherent in multi-component assembly.
Solution Approach 2:
The patent employs controlled casting parameters and post-casting finishing processes to achieve the required surface finish and dimensional precision directly on the integral manifold body, replacing the need for precision machining of multiple separate components.
3Adaptability or versatility
If conventional intake manifolds are assembled from multiple components, then adaptability is improved, but device complexity increases making debris removal difficult
Solution Approach 1:
The integral manifold design consolidates the entire flow distribution system into a single accessible component. Debris removal is simplified through integrated access ports and cleanout features that can be reached from the exterior, eliminating the need to disassemble multiple connected components to access internal debris.
Solution Approach 2:
The manifold incorporates self-contained debris removal capabilities through integrated access ports and flushing connections that allow operators to clean the internal flow paths without external assistance or disassembly of the manifold structure.
Data Source
AI summary
An intake manifold provided as an integral one-piece manifold body. The manifold has a base plate with a series of spaced apart discharge ports and an elongate tapered pipe portion formed integrally with the base plate, having an inlet, and having inner tapered walls for directing flow through the manifold body from the inlet through the discharge ports of the base plate.