Plunger Pump Oil Circulation with Uniform Heating and Quality Feedback
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Solution Overview
Problem
Existing electric-driven fracturing devices face issues with poor oil heating efficiency, oil deterioration, and lack of real-time quality monitoring, leading to increased abrasion of plunger pumps and inefficient operations.
Innovation Solution
An oil circulation system with an integrated electric heater, overflow valve, quality detector, and controller, which monitors oil quality and provides real-time feedback for timely replacement and heating optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an electric heater is added inside a lubricating oil tank for heating, then the lubricating oil can be heated, but the poor thermal conductivity of the lubricating oil causes localized high temperature, deteriorating the lubricating oil
Solution Approach 1:
The patent introduces a heat conduction plate as an intermediary between the electric heater and the lubricating oil. The heat conduction plate has good thermal conductivity and distributes the heat uniformly across the oil tank, preventing localized high temperature zones that would deteriorate the lubricating oil. This mediator solves the contradiction by enabling effective heating while maintaining oil quality.
Solution Approach 2:
The patent divides the heating function into multiple heating regions by placing multiple heating plates or a grid of heating elements across the oil tank bottom. This creates uniform local heating zones throughout the oil, preventing concentration of heat in any single location and thereby avoiding oil deterioration while still achieving the required temperature rise.
2Temperature
If the heating time is extended to ensure adequate heating, then more complete heating is achieved, but the waiting time before plunger pump operation increases
Solution Approach 1:
The patent implements a circulation pump that continuously circulates the lubricating oil through the heated zones in the oil tank. This continuous circulation ensures that all oil passes through the heating regions repeatedly, achieving uniform temperature distribution more quickly without requiring extended heating time. The useful heating action is maintained continuously and efficiently.
Solution Approach 2:
The circulation system creates periodic flow cycles where oil is continuously pumped from the tank, passed through heating zones, and returned to the tank. This periodic circulation pattern accelerates heat distribution throughout the oil volume, reducing the time required to achieve adequate heating uniformity compared to static heating.
3Device complexity
If no oil quality monitoring is implemented, then the system is simpler, but the lubricating oil deterioration goes undetected leading to increased plunger pump abrasion
Solution Approach 1:
The patent incorporates oil quality detectors that continuously monitor parameters such as oil temperature, viscosity, and contamination levels. This feedback system provides real-time information about oil condition to the control system, which can then trigger alerts or automatic actions when oil quality deteriorates, protecting the plunger pump from damage caused by degraded lubrication.
Solution Approach 2:
The system includes automatic oil change functionality where the control system, based on detector feedback, can automatically initiate oil replacement procedures when quality thresholds are exceeded. This self-service capability allows the system to monitor and maintain its own lubrication quality without requiring constant manual intervention, balancing simplicity with reliability.
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
Ensures efficient and timely lubrication of plunger pumps, reducing abrasion and extending device life, while optimizing heating and reducing operational costs through intelligent oil management.
Implementation Method 1
the existing electric-driven fracturing device uses an electric heater added inside a lubricating oil tank for heating
Implementation Method 2
the power member is adjusted to do work on the oil, to provide heat energy to the oil
Data Source
AI summary
An oil circulation system is configured to supply lubrication oil to a plunger pump. The oil circulation system includes an oil tank, and the oil tank is provided with an electric heater. The oil circulation system further includes: a main circulation circuit. Two ends of the main circulation circuit are configured to respectively communicate with an oil outlet and an oil inlet of the oil tank, and the main circulation circuit is provided with a power member, and an overflow valve, disposed on the main circulation circuit and located on an oil outflow side of the power member.