Modular Power End Assembly for Pump Wear and Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-pressure hydraulic fracturing pumps face issues with component failure due to stress concentration at threaded holes and uneven lubrication distribution, leading to accelerated wear and reduced maintenance intervals.
Innovation Solution
A modular power end assembly with individually replaceable components, using multiple sets of stay rods for compression and improved lubrication distribution, and strategic material selection for weight reduction and enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional integrated power end assembly is used, then structural strength is maintained, but weight and physical dimensions are excessive
Solution Approach 1:
The power end assembly is divided into modular components including a crank section, crosshead section, and connector section that can be assembled and disassembled. This segmentation allows weight reduction by only installing necessary components for each specific application while maintaining structural strength through proper modular connection design using stay rods and support plates.
2Ease of repair
If modular components are used, then maintenance efficiency is improved, but device complexity increases
Solution Approach 1:
The assembly is segmented into modular sections (crank section, crosshead section, connector section) that can be independently removed and replaced. This allows failed components to be replaced without discarding the entire assembly, improving maintenance efficiency while the standardized modular interface design keeps the overall system complexity manageable.
Solution Approach 2:
Individual modular components can be discarded when failed and replaced with new or refurbished units, while the remaining functional modules are retained and reused. This extends component life and reduces waste by allowing selective replacement rather than complete assembly replacement.
3Reliability
If traditional lubrication distribution is used, then manufacturing simplicity is maintained, but component wear accelerates
Solution Approach 1:
The lubrication system is designed to provide targeted lubrication to specific high-wear areas such as the crosshead and crankshaft journals through dedicated lubrication ports and channels. This local quality approach ensures critical components receive adequate lubrication to extend component life, while the overall lubrication system remains relatively simple to manufacture.
4Reliability
If stress concentration at threaded holes is not addressed, then manufacturing simplicity is maintained, but component failure increases
Solution Approach 1:
Reinforcement features such as strengthened threaded hole designs and local structural reinforcements are implemented at specific high-stress locations where components are attached. This local quality approach addresses stress concentration at critical points without requiring complex design changes throughout the entire assembly, maintaining manufacturing simplicity while improving reliability.
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 reduces physical dimensions and weight, extends component life, and improves maintenance efficiency by allowing for component replacement without discarding the entire assembly, while optimizing lubrication distribution for reduced wear and increased operational reliability.
Implementation Method 1
using multiple 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.