Modular Power End Structure for Threaded-Hole Stress Relief
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Solution Overview
Problem
High-pressure hydraulic fracturing pumps face issues with component failure due to stress concentration at threaded holes and poor lubrication distribution, leading to uneven wear and reduced maintenance intervals.
Innovation Solution
A modular power end assembly with individually replaceable components, using multiple sets of stay rods for compression and improved lubrication distribution, and strategic material selection for weight reduction and enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional integrated power end assembly is used, then structural strength is maintained, but weight and physical dimensions are excessive
Solution Approach 1:
The power end assembly is divided into multiple modular components including crank sections, crosshead sections, connector sections, and fluid end sections. Each section can be independently manufactured, assembled, and replaced. This segmentation reduces the weight of individual components while maintaining the overall structural strength through optimized connection points and distributed load paths.
2Stability of the object's composition
If stay rods are positioned far from plunger axes, then assembly stability is improved, but stress concentration and deflection increase
Solution Approach 1:
The stay rods are positioned asymmetrically relative to the plunger axes, with offset distances specifically optimized to balance assembly stability with stress distribution. This asymmetric positioning creates a geometric configuration that reduces deflection and stress concentration at critical threaded hole locations while maintaining overall structural stability during operation.
3Device complexity
If lubrication system is simplified, then device complexity is reduced, but lubrication distribution becomes uneven
Solution Approach 1:
The lubrication system incorporates locally optimized features including strategically positioned lubrication ports, varied channel diameters, and specific flow path geometries at different locations within the power end assembly. This local quality approach ensures uniform lubrication distribution to all critical surfaces without requiring a complex multi-system architecture, maintaining reliability while controlling device complexity.
4Ease of repair
If modular components are used, then maintenance efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The power end assembly is segmented into standardized modular components with uniform connection interfaces and mounting patterns. This segmentation enables individual sections to be manufactured separately using optimized processes, then assembled into complete assemblies. The modular design significantly improves maintenance efficiency by allowing replacement of only failed sections rather than entire assemblies, while manufacturing complexity is managed through standardization of interfaces and batch production of common components.
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 modular design reduces stress concentrations, extends component life, and improves lubrication efficiency, leading to reduced maintenance needs and increased operational reliability.
Implementation Method 1
A modular power end assembly with individually replaceable components, using multiple sets of stay rods for compression
Data Source
AI summary
A power end assembly includes a crankshaft section, a crosshead section, and a connector section coupled together by one, two, or more sets of stay rods. The power end may include one or more support plates that are coupled to the crankshaft section and/or crosshead section. The crosshead section includes a plurality of individual crosshead frames. The connector section may include a plurality of individual connector plates or may be a unitary connector plate. The power end is configured to be coupled to a fluid end assembly by coupling the fluid end assembly to the connector plates.