Powered Pump Plug Puller With Anti-Rotation Threaded Rod
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Solution Overview
Problem
Existing mechanical plug pullers for hydraulic fracturing pumps require manual rotation of multiple revolutions, leading to user fatigue and increased injury risk due to their cumbersome design and inability to be driven by power tools.
Innovation Solution
A plug removal tool with a reaction bar assembly, drive assembly, and threaded rod assembly, allowing for rotation by an external power device, with anti-rotation features to prevent the threaded rod from rotating during linear movement, reducing manual effort and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If standard mechanically operated plug pullers are used, then plug removal is achieved, but user fatigue and injury risk increase due to multiple manual revolutions
Solution Approach 1:
The patent replaces the manual mechanical rotation system with a power tool-driven system. The drive assembly includes a drive socket that accepts a power tool, allowing an electric or pneumatic motor to perform the rotational work instead of manual effort. This substitution eliminates user fatigue while maintaining the mechanical advantage needed for plug removal.
Solution Approach 2:
The patent introduces dynamic components including a rotatable drive assembly that can be powered externally, and a threaded rod that converts rotational motion to linear motion dynamically. The system transitions from static manual cranking to dynamic powered operation, enabling faster plug removal without increasing physical strain on the user.
2Productivity
If standard mechanically operated plug pullers are used, then plug removal is achieved, but the process becomes cumbersome and time consuming
Solution Approach 1:
The patent divides the plug removal system into distinct functional modules: a reaction bar assembly for providing reaction force, a drive assembly for powered rotation, and a threaded rod assembly for linear motion. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation despite the increased overall capability.
Solution Approach 2:
The patent introduces a threaded rod as an intermediary mechanism between the rotational drive assembly and the linear motion needed for plug removal. This intermediary converts the high-speed rotation from the power tool into controlled linear motion, enabling fast plug removal while managing the complexity through a well-defined mechanical transformation.
3Ease of operation
If the threaded rod is allowed to rotate freely during drive assembly rotation, then the mechanism is simpler, but linear movement cannot be achieved
Solution Approach 1:
The patent employs asymmetric features on the threaded rod and corresponding features on the reaction bar or drive assembly to prevent rotation. The anti-rotation feature creates a unique geometric relationship that allows linear motion while blocking rotational movement, adding minimal complexity to ensure the threaded rod moves only in the desired linear direction.
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 tool significantly reduces the time and physical strain required for plug removal and installation, enhancing efficiency and safety by utilizing power tools to drive the assembly, compared to traditional manually operated tools.
Implementation Method 1
The threaded rod assembly is configured to be connectable to the plug and to move linearly between a forward extended position and a rearward retracted position relative to the drive assembly and the reaction bar assembly
Implementation Method 2
The drive assembly is configured to be rotated by an external power device or tool, such as an impact driver
Data Source
AI summary
Plug removal and installation tools and methods of operating such to remove suction port plugs and discharge port plugs from a fluid end on a pump (e.g., hydraulic fracturing positive displacement pump) and to insert new plugs are disclosed. The plug removal tool includes a reaction bar assembly, a drive assembly, and a threaded rod assembly. The plug removal tool may be operated by rotating the drive assembly using a high torque, powered impact tool to reduce the time, labor, and fatigue associated with manually removing plugs from a pump using a traditional manually operated plug removal tool. The drive assembly is rotatable independently of the threaded rod assembly and reaction bar assembly. Rotation of the drive assembly results in linear movement of the threaded rod assembly to extend and retract the threaded rod assembly relative to the drive assembly and reaction bar assembly.