Modular Stator Inserts for Abrasive Wear in Helical Gear Devices
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Solution Overview
Problem
Existing stator designs for progressing cavity pumps face challenges with abrasive wear, leading to frequent replacements and high manufacturing costs, particularly due to the complexity of elastomer injection and material limitations in rigid stators.
Innovation Solution
A modular stator assembly with interchangeable inserts that fit inside a metal stator tube, eliminating the need for elastomer injection and allowing for various materials and configurations, enabling easy replacement of worn inserts in the field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomer injection is used to line the stator, then abrasion resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The stator is divided into a rigid stator body and separate replaceable elastomer liners. The liners are segmented components that can be independently manufactured and replaced without replacing the entire stator assembly. This segmentation allows the elastomer lining to be produced through simpler injection molding processes rather than complex in-situ injection, reducing manufacturing complexity while maintaining abrasion resistance.
Solution Approach 2:
The elastomer liner is extracted as a separate removable component from the stator assembly. This allows the liner to be manufactured independently using simpler processes and replaced separately when worn, eliminating the need for complex elastomer injection equipment and processes required for integral stator designs. The liner can be removed and replaced in the field without specialized equipment.
2Ease of manufacture
If rigid stator construction is used, then manufacturing simplicity is improved, but material selection and abrasion resistance are limited
Solution Approach 1:
The stator employs a composite construction combining a rigid stator body (typically metal) with elastomer liners. This composite approach allows each component to be manufactured from optimal materials using appropriate processes - the rigid body provides structural support while the elastomer liner provides abrasion resistance and can be selected in various material compositions to match specific application requirements, greatly expanding material selection versatility.
Solution Approach 2:
By segmenting the stator into a rigid body and separate elastomer liner components, each can be manufactured using the most suitable process and material. The rigid body can be cast or machined from metal, while the liner can be injection molded from various elastomer compositions. This segmentation enables greater material versatility without complicating the overall manufacturing process, as each component is produced independently using standardized processes.
3Reliability
If complete stator replacement is required due to wear, then reliability is maintained, but downtime and waste increase
Solution Approach 1:
The elastomer liner is extracted as a separate replaceable component that can be removed and replaced independently of the rigid stator body. When the liner becomes worn, only the liner needs to be replaced rather than the entire stator assembly. This significantly reduces replacement time and allows the rigid stator body to be reused, minimizing downtime and reducing waste of the structural component.
Solution Approach 2:
The design enables selective discarding of only the worn elastomer liner while recovering and reusing the rigid stator body. The liner is discarded when worn, but the expensive rigid stator structure is recovered and can be reused multiple times with new liners. This extends the overall life of the stator assembly and reduces waste, while the quick liner replacement process minimizes downtime.
4Strength
If elastomer liners are made integral to the stator, then structural integrity is improved, but repairability and field replacement are worsened
Solution Approach 1:
The stator is segmented into an integral rigid body and separate elastomer liner components. The rigid body maintains structural integrity as a single piece, while the liner is a separate component that fits within the rigid body's cavity. This segmentation allows the structural component to remain intact and reusable, while the liner can be independently removed and replaced in the field without specialized equipment or complex procedures.
Solution Approach 2:
The elastomer liner is extracted as a removable component from the stator assembly, allowing it to be taken out and replaced separately. The liner is designed to fit within the rigid stator body's cavity and can be removed by simple extraction forces, enabling field replacement without damaging or disassembling the rigid stator structure. This maintains the structural integrity of the rigid body while greatly improving repairability.
Data Source
AI summary
A stator segment is provided for a helical gear device. The stator segment includes a stator tube and modular stator inserts. The stator tube has an inner profile with at least two internal sides that extend longitudinally along an interior of the stator tube. The modular stator inserts each have an outer profile that substantially matches and fits within the inner profile of the stator tube. The modular stator inserts also each have an interior helical profile that defines a central opening. The modular stator inserts are configured to be removably inserted longitudinally into the stator tube along the inner profile of the stator tube. The inner profile aligns the modular stator inserts to form a continuous helical chamber and prevents rotation of the modular stator inserts relative to the stator tube.