Integrated Load Cell and Inclinometer for Polished Rod Monitoring
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Solution Overview
Problem
Existing rod pumping systems face challenges in accurately measuring the load on polished rods due to complex and costly designs that require multiple load cells and external power supplies for inclinometers, leading to inaccurate measurements and difficult maintenance.
Innovation Solution
An integrated load cell and inclinometer system that combines load and position sensors within a single unit, powered by a solar battery, which can be easily installed between the rod clamp and clamping bar, eliminating the need for external power and multiple load cells, and wirelessly transmit data for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple load cells are used to measure upward and downward forces on the polished rod, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple load cells into a single integrated load cell assembly that measures both upward and downward forces on the polished rod. This unified structure eliminates the need for separate stacked load cells while maintaining measurement accuracy for total force acting on the rod.
Solution Approach 2:
The integrated load cell is designed to perform multiple functions: measuring both upward and downward forces, providing structural support, and serving as a mounting point for the inclinometer. This multi-functional design reduces the overall number of components needed in the system.
2Measurement precision
If load cells are stacked to encircle the polished rod, then total force measurement is improved, but installation and maintenance time increase
Solution Approach 1:
The patent merges multiple load cells into a single pre-assembled unit that can be installed in one operation rather than requiring sequential stacking of multiple individual load cells. This significantly reduces installation and maintenance time while maintaining the capability to measure total force.
3Use of energy by moving object
If external power supply is used for inclinometer, then power availability is improved, but reliability decreases due to wire damage and water leakage
Solution Approach 1:
The patent extracts the power supply function from external components and integrates it into the inclinometer housing itself. This eliminates exposed wires and external connections that are vulnerable to water and heat damage, significantly improving reliability in outdoor environments.
Solution Approach 2:
The inclinometer becomes self-powered through integrated battery and solar panel components housed within its own structure. This self-sufficient design eliminates dependence on external power sources and wiring, allowing the device to operate independently while resisting environmental damage.
4Measurement precision
If inclinometer is placed with precise positioning, then measurement accuracy is improved, but installation difficulty increases
Solution Approach 1:
The patent combines the inclinometer with the load cell into a single integrated assembly that is installed as one unit. This eliminates the need for separate precise positioning operations and makes installation easier while maintaining measurement accuracy through the integrated design.
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
This solution provides accurate and direct measurement of load and position data, reducing maintenance complexity and costs while enhancing the reliability of rod pumping systems by integrating sensors and power sources within a compact, weather-resistant unit.
Implementation Method 1
a solar battery configured to provide power to the integrated load cell and inclinometer, the solar battery including: a solar panel that is mounted externally on the outer shell of the integrated load cell and inclinometer
Implementation Method 2
a battery that is internal to the outer shell of the integrated load cell and inclinometer
Data Source
AI summary
An integrated load cell and inclinometer includes an outer shell including a u-shaped structure configured to receive a polished rod; a load sensor configured output a load signal based on a load experienced by the load sensor; a position sensor configured to output a position signal based on a position experienced by the position sensor; a load and position signal processor configured to receive and process the load signal from the load sensor and to output load signal data representative of the load experienced by the load sensor, and receive and process the position signal from the position sensor and to output position signal data representative of the inclination of the walking beam or the position of the polished rod; a solar battery configured to provide power to the integrated load cell and inclinometer; and a transmitter configured to transmit the load signal data and position signal data.