Modular Power End Assembly for Stress and Wear Reduction

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Solution Overview

Problem

Existing hydraulic fracturing pumps face issues with failure at mount plates due to stress concentration, thread failure, and uneven lubrication leading to accelerated wear and reduced maintenance intervals, exacerbated by the heavy and non-modular design of power end assemblies.

Innovation Solution

A modular power end assembly with individually replaceable components, such as connect plates and crosshead frames, held together by stay rods, which distribute stress and provide independent lubrication systems, using different materials for optimal performance and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a heavy non-modular power end assembly is used, then strength and stability are improved, but weight and maintenance complexity increase

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The power end assembly is divided into modular components including connect plates, crosshead frames, and other replaceable parts that can be independently manufactured, assembled, and replaced. This segmentation reduces overall weight while maintaining structural strength through optimized component design.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If a non-modular design is used, then structural integrity is improved, but ease of repair and maintenance are worsened

Engineering Contradiction:

Improvestructural integrityVSAvoidease of repair

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The assembly采用模块化设计，将power end分割为可独立更换的组件（如connect plates、crosshead frames等），使得维修时只需更换故障模块而非整体更换，从而在保持结构完整性的同时大幅提升了维修便利性

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

设计允许将磨损或损坏的模块（如mount plates、connect plates）从系统中移除并更换为全新或再制造的模块，延长了整体系统的使用寿命，减少了停机时间

Inventive Principle:

Principle #34Discarding and recovering

3Ease of manufacture

If traditional mount plate design is used, then manufacturing simplicity is improved, but reliability is worsened due to stress concentration

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

将mount plate功能分散到多个标准化connect plates和crosshead frames模块中，每个模块承受部分载荷，避免了应力集中在单一部件上，提高了整体可靠性

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

采用高强度合金钢材料制造关键承载部件，通过材料复合和热处理工艺（如调质处理、表面硬化）提升部件的强度和耐磨性，同时保持制造过程的标准化

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If uneven lubrication is used, then manufacturing simplicity is improved, but wear and maintenance frequency increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwear

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

为每个模块配备独立的润滑系统，确保润滑剂能够均匀分布到所有摩擦表面，避免了传统集中式润滑系统的死角和润滑不足问题，减少了磨损

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

润滑系统设计中包含自动监测和调节功能，能够根据部件运行状态自动调整润滑剂供给，确保各部位获得充足的润滑，延长了部件使用寿命

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250243854A1Modular power end

Publication Date: 2025.07.31 KERR MACHINE CO

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.