Modular Crankshaft Assembly for High-Pressure Pump Durability
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Solution Overview
Problem
Existing high-pressure pumps used in hydraulic fracturing operations face challenges due to extreme conditions, including high pressures, vibrations, and abrasives, which lead to increased maintenance costs and reduced efficiency.
Innovation Solution
The development of modular crankshafts with multi-piece construction, which are less expensive to manufacture than traditional single-piece crankshafts, and are designed to withstand the extreme conditions of hydraulic fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-piece crankshafts are used, then manufacturing precision and structural integrity are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The crankshaft is divided into multiple separate crank journal assemblies that can be manufactured independently and then assembled together. Each assembly includes a crank journal with connected rod journals and main bearing journals, allowing for simplified manufacturing processes while maintaining structural integrity through precise assembly and connection mechanisms.
2Ease of manufacture
If modular multi-piece crankshaft construction is used, then manufacturing cost is reduced, but device complexity increases
Solution Approach 1:
The crankshaft is segmented into modular crank journal assemblies that can be manufactured separately and assembled systematically. This segmentation reduces manufacturing complexity for each individual component while the standardized assembly process manages overall device complexity.
Solution Approach 2:
Multiple crank journal assemblies are merged together through connection mechanisms to form the complete crankshaft. The merging process uses standardized interfaces and alignment features to manage complexity while achieving the desired modular construction benefits.
3Strength
If single-piece crankshaft design is used, then structural integrity is improved, but ease of repair and maintenance worsen
Solution Approach 1:
The crankshaft is segmented into removable crank journal assemblies that can be independently accessed and replaced. This segmentation maintains structural integrity when assembled while dramatically improving ease of repair, as damaged assemblies can be quickly removed and replaced without disassembling the entire crankshaft structure.
4Ease of repair
If modular crankshaft design is used, then ease of repair is improved, but manufacturing precision requirements increase
Solution Approach 1:
The crankshaft is divided into modular assemblies with standardized connection interfaces that incorporate alignment features. These features guide precise positioning during assembly, ensuring manufacturing precision is achieved through design rather than relying solely on post-assembly adjustment.
Solution Approach 2:
Alignment features and positioning mechanisms are built into the crank journal assemblies during manufacturing. This preliminary action ensures that when assemblies are connected, the required precision is already established, reducing the need for complex post-assembly alignment procedures.
Data Source
AI summary
A modular crankshaft configured for use within a power end assembly. The modular crankshaft is configured to interconnect a drive shaft and a plurality of linear drive assemblies. The various embodiments of modular crankshafts disclosed herein are assembled by interconnecting a plurality of individual main bearing journals using a plurality of fasteners. One or more embodiments of modular crankshafts may also include individual connecting rod journals that are attached to individual main bearing journals using a plurality of fasteners.