Electric Off-Axis Opposing Piston Actuator Pumping System
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Solution Overview
Problem
Conventional fracking pumps experience flow ripple due to pulsating flow rates, leading to increased component failure rates and high wear on valves, as they require numerous strokes per unit time to maintain a desired flow rate, limiting stroke distance and durability.
Innovation Solution
A pumping system comprising multiple electric linear-actuator driven pumping units with coordinated phases to achieve a substantially constant flow rate, utilizing a controller to adjust motion profiles and share torque load, ensuring even wear and real-time compensation for flow ripple, while allowing for longer stroke distances and simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional reciprocating pumps use crankshaft and connecting rod mechanism with multiple pistons, then the flow rate can be smoothed out, but flow ripple still occurs causing pressure pulses that increase component failure rates
Solution Approach 1:
The patent replaces the conventional crankshaft and connecting rod mechanism with a linear actuator that directly drives the piston in axial reciprocating motion. This substitution eliminates the mechanical conversion from rotational to linear motion, thereby eliminating flow ripple and pressure pulses that cause component failures.
Solution Approach 2:
The patent extracts and removes the crankshaft and connecting rod mechanism from the pumping system, retaining only the essential linear reciprocating motion function. This extraction eliminates the source of flow ripple while preserving the pumping capability.
2Productivity
If conventional pumps use a large number of pistons with offset pulses to smooth flow, then total flow rate is improved, but valve wear increases due to many strokes per unit time
Solution Approach 1:
The patent segments the pumping system into multiple independent pumping units, each with its own linear actuator and piston. These units operate with offset phases to smooth the total flow rate while each unit can use longer strokes, reducing the frequency of valve operations and wear.
Solution Approach 2:
The patent employs dynamic coordination of multiple pumping units with variable stroke rates and phases. The controller adjusts each unit's operation dynamically to maintain constant total flow while optimizing individual valve wear through longer, fewer strokes per unit.
3Productivity
If conventional pumps require many strokes per unit time to achieve desired flow rate, then flow rate is maintained, but stroke distance is limited and wear on valves increases
Solution Approach 1:
The patent uses dynamic control of multiple pumping units to allow each unit to operate with longer stroke distances at lower frequencies. The controller coordinates the phases and stroke rates of individual units to maintain the desired total flow rate while extending the stroke distance of each piston.
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 system maintains a constant flow rate, reduces valve wear, and allows for operation with one unit offline, enhancing durability and ease of maintenance by smoothing flow ripple and extending valve lifespan.
Implementation Method 1
The linear actuator within the central cavity is configured to translate the shaft
Implementation Method 2
Bellows may extend between the housing and the arms, surrounding the shaft and sealing the cavity
Data Source
AI summary
A pumping system for fracking fluid is designed to provide nearly constant flow rate. The pumping system includes a set of linear actuator pumping units, each driven by an electric motor. Each pumping unit includes a first set of pumping chambers that expel fluid when the linear actuator is moving in a first direction and a second set of pumping chambers that expel fluid when the linear actuator is moving in an opposite direction. The speeds of the actuators are coordinated such that a total flow rate of the pumping system is substantially constant.