Modular Fluid End Valve Modules for Faster Mud Pump Replacement
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Solution Overview
Problem
The high cost and time-consuming process of replacing worn-out fluid end modules in mud pumps, particularly due to their heavy weight and complex access requirements, lead to significant maintenance challenges and operational inefficiencies.
Innovation Solution
Dividing the fluid end module into a support unit and two valve modules (suction and pressure modules) that can be releasably connected, allowing for individual replacement and simplifying maintenance by reducing the weight and complexity of components to be handled, with the support unit serving as a universal adapter for various mud pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fluid end module is designed as a complete replacement unit, then the pump can be restored to full functionality, but the replacement process becomes extremely time-consuming and costly due to the heavy mass (1,000 kg and more) that needs to be moved
Solution Approach 1:
The fluid end module is divided into multiple separate components including a piston rod connection element, a connection element with valve assembly, and a cylinder head. This segmentation allows individual components to be replaced independently rather than replacing the entire assembly, significantly reducing replacement time and effort while maintaining pump functionality.
2Loss of time
If the fluid end module is divided into smaller components, then replacement time and effort are reduced, but the device complexity increases due to multiple connection elements and assembly steps
Solution Approach 1:
The fluid end module is divided into multiple separate components including a piston rod connection element, a connection element with valve assembly, and a cylinder head. This segmentation allows individual components to be replaced independently rather than replacing the entire assembly, significantly reducing replacement time and effort while maintaining pump functionality.
3Strength
If heavy screw connections are used to secure the fluid end module, then the connection strength is sufficient to handle high pressure, but the screw connections become difficult to access and loosen
Solution Approach 1:
A connection element serves as an intermediary component between the piston rod connection element and the cylinder head. This intermediate element provides accessible connection points for securing the assembly while distributing the mechanical loads, making the connection both strong and accessible for maintenance operations.
Data Source
AI summary
A water part module for attaching to a piston pump, which has a support unit that can be releasably attached to the piston pump and at least respectively one suction module and pressure module that is releasably connected to the support unit. The support unit and each suction module and each pressure module are designed such that the suction and pressure modules are interchangeable with one another. Each suction and pressure module have at least two planed side faces of which one acts as a lower connection face and a side face adjoining the lower connection face acts as a lateral connection face. A duct inside the respective suction and pressure module, which can be closed and opened by a valve in the respective suction and pressure module, ends on one side in the lower connection face and on the other side in the lateral connection face.