Modular Power End Assembly for Lower Stress and Easier Repair
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Solution Overview
Problem
Existing hydraulic fracturing pumps face failures at the mount plate due to stress concentration and poor lubrication systems, leading to frequent repairs and replacements, and are heavy due to one-piece frames.
Innovation Solution
A modular power end assembly with individual components, such as connect plates and crosshead frames, held together by stay rods, allowing for component replacement and using separate lubrication systems for each section, reducing stress and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece frame is used for the power end assembly, then the structural strength is improved, but the weight increases and stress concentration occurs at the mount plate
Solution Approach 1:
The power end assembly is divided into modular components including connect plates, crosshead frames, and stay rods that can be assembled together. This segmentation reduces the weight compared to a one-piece frame while distributing stress across multiple connection points rather than concentrating it at the mount plate.
2Strength
If a one-piece frame is used for the power end assembly, then the structural strength is improved, but the stress concentration at the mount plate leads to frequent failures
Solution Approach 1:
The assembly is segmented into modular components with multiple connection points using stay rods, which distributes the mechanical stress across the structure rather than concentrating it at a single mount plate, thereby reducing failure rate.
Solution Approach 2:
Different materials are used for specific components based on their functional requirements. For example, connect plates and crosshead frames are made from materials optimized for their specific stress and wear conditions, improving overall reliability while allowing each component to perform its specific function optimally.
3Device complexity
If a single lubrication system is used for the entire power end assembly, then the device complexity is reduced, but the lubrication effectiveness decreases leading to poor lubrication at certain sections
Solution Approach 1:
The lubrication system is divided into separate sections, each with its own lubrication circuit. This ensures that each modular component (connect plates, crosshead frames, etc.) receives adequate lubrication independently, improving lubrication effectiveness without requiring a single complex centralized system.
4Ease of repair
If individual components are used in the modular design, then the ease of repair is improved, but the device complexity increases
Solution Approach 1:
The power end assembly is designed as a collection of discrete modular components (connect plates, crosshead frames, stay rods) that can be independently removed and replaced. This segmentation greatly improves ease of repair while the standardized connection methods keep the overall assembly complexity manageable.
Solution Approach 2:
The modular components are designed with standardized interfaces and connection methods that can be used across different sections of the assembly. This universality allows for simplified assembly procedures and reduces the complexity of handling multiple unique connection types, thereby improving ease of repair without proportionally increasing device complexity.
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.