Modular Crankshaft Assembly for Lower-Cost Pump Maintenance
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Solution Overview
Problem
Traditional high-pressure pumps used in hydraulic fracturing operations face challenges due to the high costs of manufacturing single-piece crankshafts, which are expensive to produce and maintain, especially under extreme conditions.
Innovation Solution
The development of modular crankshafts, composed of multiple attached pieces, reduces manufacturing costs by allowing for less expensive component production and assembly, enhancing durability and maintenance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If 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 modular segments including crankpins, journals, and connecting rods that can be manufactured separately and assembled together. This segmentation allows each component to be produced using cost-effective methods while maintaining the structural integrity of the complete crankshaft assembly through precision coupling interfaces.
2Strength
If single-piece crankshafts are used, then structural strength is improved, but ease of repair and maintenance cost worsen
Solution Approach 1:
The crankshaft is segmented into replaceable modules including crankpins, journals, and connecting rods. When wear or damage occurs, only the affected segment needs to be replaced rather than the entire crankshaft, significantly reducing maintenance costs and downtime while the modular design maintains overall structural strength through precision-engineered connection interfaces.
Solution Approach 2:
The modular crankshaft design allows damaged or worn segments to be discarded and replaced with new or reconditioned components. This enables selective replacement of only the necessary parts, recovering the value of intact segments and reducing overall maintenance expenses compared to replacing the entire single-piece crankshaft.
3Ease of manufacture
If modular crankshafts are used, then manufacturing cost is reduced, but device complexity increases
Solution Approach 1:
While segmentation into modules reduces manufacturing cost by allowing production of simpler individual components, the design minimizes assembly complexity through standardized coupling interfaces, alignment features, and pre-assembled subunits that connect in a straightforward sequence, balancing modularity benefits with assembly simplicity.
4Ease of repair
If modular crankshafts are used, then ease of repair is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The modular design enables easy replacement of individual crankshaft segments, but each module incorporates precision-machined coupling surfaces, alignment pins, and standardized connection interfaces that ensure accurate reassembly. This maintains the necessary manufacturing precision at critical interfaces while allowing simplified maintenance through module replacement.
Solution Approach 2:
The modular crankshaft components are pre-assembled and pre-aligned as complete modules before delivery to the field. This preliminary assembly ensures that precision requirements are met during controlled manufacturing conditions, while field maintenance only requires replacing entire pre-synchronized modules, eliminating the need for complex precision alignment operations during repairs.
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.