Master Controller for Automated Hydraulic Fracturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies due to the complexity of managing multiple trailers with disparate engines, transmissions, and pumps, leading to increased costs, fluid leaks, emissions, and equipment wear, as human operators struggle to optimize these systems effectively.
Innovation Solution
A master controller system that determines site and trailer configurations, receives desired operating conditions, and generates control signals using trailer models to optimize the operation of engines, transmissions, and pumps, reducing manual intervention and optimizing efficiency across multiple trailers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human operators manually control multiple trailers with disparate engines, transmissions, and pumps, then operational flexibility is maintained, but system efficiency decreases and equipment wear increases
Solution Approach 1:
The patent merges control of multiple disparate trailers into a unified automated control system. The system integrates control signals for multiple trailers with different engines, transmissions, and pumps, coordinating their operation to achieve optimal system efficiency while reducing the complexity of manual management.
Solution Approach 2:
The automated control system incorporates feedback mechanisms that monitor the operational status of multiple trailers and adjust control signals in real-time. This feedback loop enables the system to optimize efficiency dynamically while managing the complexity of coordinating disparate equipment through centralized intelligence.
2Object-generated harmful factors
If human operators manually monitor and control fracking equipment, then adaptability to changing conditions is maintained, but operational costs increase and emissions rise
Solution Approach 1:
The control system performs self-service by automatically monitoring equipment status and adjusting operational parameters without human intervention. This autonomous operation reduces emissions by optimizing fuel combustion and operational efficiency while eliminating the need for manual control, thereby reducing operational costs and harmful emissions simultaneously.
3Duration of action of stationary object
If traditional manual control methods are used, then equipment lifetime is reduced due to inefficiencies, but automation hardware complexity is avoided
Solution Approach 1:
The patent replaces manual mechanical control with an automated electronic control system that uses software algorithms to manage trailer operations. This substitution extends equipment lifetime by optimizing operational parameters and reducing wear through precise control, while the automation complexity is managed through integrated software that coordinates multiple trailers efficiently.
4Loss of substance
If multiple disparate trailers are operated manually, then operational flexibility is maintained, but fluid leaks increase due to inefficiencies
Solution Approach 1:
The automated control system uses feedback from sensors monitoring fluid pressure and flow to detect and respond to conditions that may cause leaks. By continuously adjusting operational parameters based on real-time feedback, the system prevents fluid leaks while maintaining high operational efficiency, eliminating the trade-off between leak prevention and productivity.
Data Source
AI summary
An automated hydraulic fracturing system and method for controlling various aspects of a fracking operation is disclosed. A master controller receives various operating parameters, such as desired operating conditions, information about a fracking site, information about trailers and/or other equipment at the fracking site, and/or sensor signals. The master controller may access one or more trailer model(s) that model various parameters of equipment (e.g., engines, transmissions, pumps, trailers, etc.) at the fracking site as a function of controlled operating conditions. The master controller uses the trailer models in conjunction with operating parameters to generate control signals that automatically control the various equipment at the fracking site to optimize various desired outcomes, such as reduced operating costs, reduced emissions, reduced idle time, increased efficiency, etc. The control signals are sent to controllers of the individual equipment to control the operations of those equipment and achieve an overall optimized fracking operation.