Pneumatic Pump Cycle Counting via Pressure Sensor Signals
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Solution Overview
Problem
Existing pneumatic pumps in subterranean wells lack effective cycle counters that accurately track the number of cycles, which is crucial for determining pump maintenance needs and performance.
Innovation Solution
The implementation of pneumatic pump cycle counters with piezoresistive pressure sensors on the air inlet line and/or exhaust air pressure sensors, coupled with processing units and transmitters, to measure and transmit pressure changes, allowing for the calculation and transmission of pump cycle counts and other relevant data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pneumatic pumps operate in subterranean wells without accurate cycle counters, then pump maintenance timing cannot be determined, but installing cycle counters increases device complexity
Solution Approach 1:
The patent replaces complex mechanical cycle counting mechanisms with electronic pressure sensing and digital signal processing. The piezoresistive pressure sensor detects pressure changes during pump cycles, and the microprocessor counts cycles by analyzing voltage signal transitions, eliminating the need for mechanical counters and reducing overall system complexity.
Solution Approach 2:
The patent introduces a pressure-reducing regulator as an intermediary component between the compressed air source and the pump. This regulator stabilizes the air pressure before it reaches the pump, creating more consistent operating conditions that improve the accuracy of cycle detection while protecting the sensitive electronic components from pressure fluctuations.
2Measurement precision
If piezoresistive pressure sensors are used to detect pump cycles, then cycle count precision is improved, but sensor placement requirements increase device complexity
Solution Approach 1:
The pressure sensor serves multiple functions: it detects pump cycle pressure changes, monitors overall system pressure status, and provides input for the pressure-reducing regulator operation. This multi-functionality reduces the need for separate sensors for each function, simplifying the overall device complexity while maintaining high measurement precision for cycle counting.
Solution Approach 2:
The system uses the existing compressed air supply infrastructure and pressure variations already present in the pump operation to provide cycle counting information. The piezoresistive sensor leverages the natural pressure fluctuations during pump cycles without requiring additional actuators or complex measurement setups, allowing the system to self-monitor using its own operational characteristics.
3Loss of information
If wireless transmitters are added to send cycle count data, then remote monitoring capability is improved, but energy consumption increases
Solution Approach 1:
The wireless transmitter operates periodically rather than continuously, sending cycle count data at predetermined time intervals or when specific thresholds are reached. This periodic transmission mode significantly reduces energy consumption compared to continuous transmission while still providing effective remote monitoring capability, allowing pump maintenance needs to be tracked without depleting battery power rapidly.
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
Enables precise monitoring of pump cycles, facilitating timely maintenance and optimizing performance by providing accurate cycle count data through wireless communication to a data repository.
Implementation Method 1
a piezoresistive pressure sensor in operative contact with air within the air inlet line and proximate to the inline pressure-reducing regulator
Data Source
AI summary
This invention provides pneumatic pump cycle counters, methods for assembling pneumatic pump cycle counters, and methods for obtaining pump counts with the pneumatic pump cycle counters for wells and other systems that are equipped with pneumatic pumps.