Modular Piston Pump Water Part for Easier Valve Replacement
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Solution Overview
Problem
The complex and labor-intensive process of replacing worn-out components in high-pressure piston pumps, such as mud pumps, due to heavy wear from abrasive drilling fluids and drill cuttings, particularly in modular designs where individual water part modules are difficult to exchange and require significant manual effort and weight handling.
Innovation Solution
A three-component modular design for the water part module, comprising a carrier unit and detachable suction and pressure valve modules, allowing for individual replacement of valve modules while maintaining the carrier unit in place, reducing the mass to be moved during maintenance and simplifying the process by enabling identical modules to function as either suction or pressure modules based on attachment location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the water part module is designed as a monoblock or two-piece modular structure, then the structural integrity and sealing performance are improved, but the complexity and labor intensity of replacing worn components increases significantly
Solution Approach 1:
The water part module is segmented into three independently replaceable components: the carrier unit (which remains installed), the suction valve module, and the pressure valve module. This segmentation allows worn valve modules to be replaced individually without removing the entire water part module or the carrier unit, significantly reducing replacement complexity and labor intensity while maintaining structural integrity through the carrier unit's mounting structure.
2Reliability
If the complete water part is replaced, then all worn components are renewed, but the complexity and time required for replacement increases due to the large mass to be moved
Solution Approach 1:
The water part is divided into a stationary carrier unit and movable valve modules. Only the necessary valve modules (suction and/or pressure) are removed and replaced, while the carrier unit remains installed. This selective replacement of only the worn components rather than the entire water part significantly reduces replacement time and effort.
Solution Approach 2:
The valve modules are extracted as separate, detachable components from the carrier unit. The carrier unit provides mounting structures (such as threaded holes or flanged connections) that allow the valve modules to be easily removed and replaced. This extraction design enables rapid replacement of only the necessary components without handling the entire water part assembly.
3Ease of repair
If the water part is designed as a two-piece structure with suction and pressure parts, then the replacement of individual parts becomes possible, but the masses to be moved remain considerable (1,000 kg and more for the pressure part)
Solution Approach 1:
The water part is further segmented into the carrier unit and separate valve modules. The valve modules are designed as compact, lightweight components that can be individually replaced. Only the necessary valve module(s) are removed and replaced, significantly reducing the weight that must be handled compared to replacing entire two-piece modules weighing thousands of kilograms.
Solution Approach 2:
The carrier unit is designed as a universal mounting structure that can accommodate different valve modules. The carrier unit remains installed and provides standardized mounting interfaces, allowing different suction and pressure valve modules to be attached as needed. This universal design enables flexible component replacement without requiring replacement of the entire assembly.
Data Source
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AI summary
A water part module (12) for attaching to a piston pump, which comprises a support unit (14) that can be releasably attached to the piston pump and at least respectively one suction module (16) and pressure module (18) that is or can be releasably connected to the support unit (14), wherein the support unit (14) and the or each suction module (16) and the or each pressure module (18) are designed such that the suction and pressure modules (16, 18) are interchangeable with one another, wherein each suction and pressure module (16, 18) has at least two planed side faces of which one acts as the lower connection face and a side face adjoining the lower connection face acts as the lateral connection face, and wherein a duct (26) inside the respective suction and pressure module (16, 18), which can be closed and opened by means of a valve (34) in the respective suction and pressure module (16, 18), ends on one side in the lower connection face and on the other side in the lateral connection face.