Modular Power End Assembly for Stress and Lubrication Failures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-pressure hydraulic fracturing pumps face issues with power end failures, particularly at the mount plate, due to stress concentration and poor lubrication, leading to frequent repairs and replacements.
Innovation Solution
A modular power end assembly with two sets of stay rods for compression, individual replaceable connect plates and crosshead frames, and a closed lubrication system to distribute lubricant effectively and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece frame is used, then structural strength is improved, but weight and material costs increase
Solution Approach 1:
The power end is divided into modular components including a frame, crosshead assembly, and crank assembly that can be assembled together using stay rods and fasteners. This segmentation reduces weight and material costs while maintaining structural strength through proper design of connection elements.
2Strength
If a one-piece frame is used, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The power end is divided into modular components including a frame, crosshead assembly, and crank assembly that can be manufactured separately and assembled together using stay rods and fasteners. This segmentation reduces manufacturing complexity and cost while maintaining structural strength through proper design of connection elements.
3Device complexity
If traditional lubrication system is used, then simplicity is maintained, but lubrication uniformity decreases leading to accelerated wear
Solution Approach 1:
The lubrication system uses the pumped fluid itself to lubricate the crosshead and crank assemblies, eliminating the need for separate lubrication components. The fluid is distributed through channels in the frame and assemblies, providing uniform lubrication that reduces wear while maintaining system simplicity.
4Ease of repair
If modular components are used, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The power end is divided into modular components including a frame, crosshead assembly, and crank assembly that can be easily disassembled and reassembled using stay rods and fasteners. This segmentation improves ease of repair and maintenance while keeping the assembly complexity manageable through standardized connection elements.
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 modular design allows for easier replacement of failed components, reduces stress and deflection, and improves lubrication distribution, leading to increased service life and reduced maintenance intervals of the power end assembly.
Implementation Method 1
a closed lubrication system to distribute lubricant effectively and reduce wear
Implementation Method 2
A modular power end assembly with two sets of stay rods for compression
Data Source
AI summary
A power end assembly includes a crankshaft section, a crosshead section, and a connector section coupled together by one, two, or more sets of stay rods. The power end may include one or more support plates that are coupled to the crankshaft section and/or crosshead section. The crosshead section includes a plurality of individual crosshead frames. The connector section may include a plurality of individual connector plates or may be a unitary connector plate. The power end is configured to be coupled to a fluid end assembly by coupling the fluid end assembly to the connector plates.