Optical Alignment System for Beam Pumping Units
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Solution Overview
Problem
Current methods for aligning beam pumping units with wellheads are prone to misalignment due to weather conditions and subjective human observation, leading to increased wear and potential leaks in the stuffing box, which can result in environmental hazards.
Innovation Solution
An optical alignment system that includes a target assembly attached to the pump and an emitter assembly with a laser that projects visible lines onto the target assembly, allowing for precise longitudinal and lateral adjustments to ensure proper alignment between the pump and the wellhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plumb bob is used for alignment, then the alignment method is simple and low-cost, but the alignment precision deteriorates due to weather conditions and subjective observation
Solution Approach 1:
The patent replaces the mechanical plumb bob alignment system with an optical laser alignment system. The laser emitter projects a visible beam that serves as a stable reference line, eliminating the problems of plumb bob sway in wind and subjective visual judgment. The laser provides an objective, precise, and weather-resistant alignment reference while maintaining operational simplicity.
Solution Approach 2:
The patent changes the physical parameter of the alignment reference from a mechanical hanging weight (plumb bob) to an optical beam (laser). This parameter change transforms the alignment method from one susceptible to gravitational and atmospheric disturbances to one that provides a stable, straight, and visible reference line that is not affected by weather conditions.
2Ease of manufacture
If the plumb bob alignment method is used, then the equipment cost is low, but the reliability of alignment deteriorates due to environmental factors
Solution Approach 1:
The patent substitutes the mechanical plumb bob system with an optical laser system that provides reliable alignment independent of environmental factors. The laser beam remains stable and straight regardless of wind or weather conditions, ensuring consistent and reliable alignment results.
Solution Approach 2:
The patent introduces a laser emitter as an intermediary device between the alignment reference point and the observer. This intermediary provides a stable, visible, and objective reference that eliminates the need for subjective visual judgment of a plumb bob's position, thereby improving alignment reliability.
3Ease of operation
If manual observation of plumb bob position is used, then the alignment process is simple, but the measurement precision deteriorates due to subjective eye judgment
Solution Approach 1:
The patent replaces the subjective visual observation of a plumb bob with an objective optical laser beam. The laser provides a clearly defined reference line that can be precisely observed and measured, eliminating human eye judgment errors while maintaining the simplicity of the alignment process.
Solution Approach 2:
The patent utilizes the visible light property of the laser beam, which appears as a distinct colored line (typically red or green) that provides high visual contrast and clarity. This makes the reference line easily distinguishable and precisely measurable, eliminating the ambiguity of observing a thin plumb bob string against complex backgrounds.
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 provides a cost-effective and reliable method for accurately aligning the pump with the wellhead, reducing wear and the risk of leaks by ensuring precise positioning, thus enhancing operational safety and efficiency.
Implementation Method 1
emitting a beam of light from the emitter assembly to the target assembly
Data Source
AI summary
A method for aligning a pump with a wellhead begins with the steps of attaching a target assembly to the pump and attaching an emitter assembly to the wellhead. The method continues with the step of emitting a beam of light from the emitter assembly to the target assembly. The method concludes with the step of determining the position of the pump with respect to the wellhead by evaluating the projection of the light beam on the target assembly. Based on this determination, the pump can be accurately aligned with the wellhead.