Linear Actuator Pumping With Coolant Circulation for Constant Flow
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Solution Overview
Problem
Conventional fracking pumps experience flow ripple due to variations in flow rate, leading to increased wear on valves and limited stroke distance, which results in high failure rates and maintenance challenges.
Innovation Solution
An electric linear-actuator pumping system with multiple units, each comprising two electric linear actuators and pumping chambers, utilizing a screw drive mechanism and one-way valves to maintain constant flow rate and reduce valve wear, while incorporating a coolant circulation system for motor cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reciprocating pumps with crankshaft and connecting rod mechanism are used to convert rotational motion into axial reciprocating motion, then flow rate can be generated, but flow ripple occurs causing pressure pulses that increase failure rates of components
Solution Approach 1:
The pump system is divided into multiple independent piston-cylinder assemblies (first piston assembly, second piston assembly, third piston assembly, fourth piston assembly) that operate with offset phases. Each assembly generates flow independently, and their combined output smooths out flow ripple through phase diversification, reducing pressure pulses and component failure rates.
Solution Approach 2:
The patent employs periodic offset phasing among multiple piston assemblies where each piston operates at a different phase angle. This periodic staggering of reciprocating motions ensures that when one piston is at dead center (minimum flow contribution), others are at peak flow, maintaining more constant total flow and reducing flow ripple.
2Productivity
If a large number of pistons with offset pulses are used to smooth out flow rate, then flow ripple is reduced, but the system becomes more complex and valve wear increases due to more strokes per unit time
Solution Approach 1:
Multiple piston assemblies share common components including a single crankshaft, common valve mechanisms, and integrated cooling systems. The pistons are mechanically coupled to the same crankshaft through connecting rods, allowing synchronized offset operation while sharing structural support and control systems, thereby reducing overall system complexity compared to fully independent assemblies.
Solution Approach 2:
The patent implements universal components that serve multiple functions: the crankshaft serves all pistons simultaneously, the cooling system cools multiple components (pistons, valves, motor), and the valve mechanisms are reused across different cylinders. This multi-functionality reduces the number of unique parts needed while maintaining smooth flow output.
3Productivity
If many strokes per unit time are required to achieve desired flow rate with limited stroke distance, then flow rate is maintained, but wear on valves increases due to frequent opening and closing
Solution Approach 1:
The patent employs offset phasing dynamics where pistons operate at different stages of their cycles simultaneously. This dynamic arrangement ensures that not all valves open and close at the same time, distributing wear across different time intervals and reducing peak stress on individual valves during high-frequency operation.
Solution Approach 2:
The cooling system is designed to preemptively cool valves and piston assemblies before they reach critical temperatures. The cooling passages are positioned to provide advance cooling to high-wear components, preventing thermal degradation that would accelerate wear during frequent valve operations.
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 achieves a constant flow rate with reduced valve wear and increased durability, allowing for maintenance with one unit offline and efficient heat dissipation through coolant circulation.
Implementation Method 1
The first housing has cooling fins and defines a first passageway proximate the cooling fins
Implementation Method 2
The first housing has cooling fins and defines a first passageway proximate the cooling fins
Implementation Method 3
The first one-way valve is configured to prevent flow from the first passageway to the first chamber... The second one-way valve is configured to prevent flow from the first chamber to the second passageway
Implementation Method 4
The first seal and second seals are located between the first housing and the shaft... The first sliding seal is axially fixed to the first housing. The second sliding seal is axially fixed to the shaft
Implementation Method 5
the motor drives the second section via a screw drive mechanism
Data Source
AI summary
A pumping system utilizes a linear actuator to move a shaft attached to two pistons within cylinders to pump a working fluid. A housing is designed with coolant passageways and one-way valves such that movement of the shaft also pumps coolant past cooling fins and over a motor. The shaft is formed of several sections joined by couplers which slide within a bore of the housing. The couplers have a non-round shape and the bore has a complimentary non-round cross section such that rotation of the shaft is prevented.