Press-Fit Thrust Bearing Bushing for Thermal Lock and Bidirectional Load
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Solution Overview
Problem
Conventional press-fit thrust bearings in electric submersible pump assemblies face issues with dislodgement due to thermal expansion, misalignment, and high operational temperatures, leading to performance degradation and reduced operational life, as they require expensive hardened ceramic materials and complex machining processes.
Innovation Solution
A press-fit thrust bearing system featuring a single bushing with a protruding band and a non-rotating guide sleeve, both made of the same material as the diffuser, which interlocks to prevent rotation and dislodgement, allowing for both upthrust and downthrust load handling without the need for dual bushings, simplifying machining and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hardened ceramic thrust bearings are used, then thrust load carrying capability is improved, but manufacturing complexity and cost increase due to special tooling and dual bushing requirements
Solution Approach 1:
The patent combines two separate bushings into a single integrated bushing component that handles both upthrust and downthrust loads. This single bushing includes a first bushing portion for upthrust and a second bushing portion for downthrust, eliminating the need for dual bushing installations and special tooling while maintaining full thrust load carrying capability.
Solution Approach 2:
The single bushing is designed to perform multiple functions: it carries both upward and downward thrust loads, provides radial support, and eliminates the need for separate tooling operations. The bushing acts as a universal component that replaces what previously required two specialized components and complex installation procedures.
2Reliability
If conventional press-fit bushings are used, then thrust support is provided, but reliability decreases due to dislodgement from thermal expansion
Solution Approach 1:
The bushing features a protruding band with a different cross-sectional area than the main bushing body. This localized structural variation creates a mechanical lock or interference fit feature that prevents thermal dislodgement while maintaining the press-fit installation method. The protruding band acts as a thermal lock that engages with the diffuser bore to prevent axial movement during thermal expansion.
Solution Approach 2:
The protruding band is designed to engage with the diffuser bore during the initial press-fit installation, creating a preliminary mechanical lock that prevents future thermal dislodgement. This preliminary action during installation ensures that subsequent thermal expansion cycles cannot dislodge the bushing from its seated position.
3Force
If dual bushing configuration is used, then both upthrust and downthrust are handled, but material cost and assembly complexity increase
Solution Approach 1:
The patent merges two separate bushing components into a single integrated bushing that handles both upthrust and downthrust. The single bushing includes distinct portions for each thrust direction, eliminating the need for two separate hardened ceramic bushings and reducing material quantity, assembly steps, and overall system cost.
4Manufacturing precision
If conventional bushing installation is used, then thrust bearing function is achieved, but manufacturing precision requirements increase due to misalignment risks
Solution Approach 1:
The bushing is segmented into distinct functional portions: a first bushing portion for upthrust, a second bushing portion for downthrust, and a protruding band for thermal lock. This segmentation allows each portion to be optimized for its specific function while the overall design simplifies installation by eliminating the need for complex dual-bushing alignment procedures.
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 solution enhances the operational flow rate and thrust handling capability, reduces material costs, and simplifies assembly and installation by eliminating the need for dual bushings and special tooling, while maintaining stability across high temperature ranges.
Implementation Method 1
Conventional press-fit thrust bearings in electric submersible pump assemblies face issues with dislodgement due to thermal expansion
Implementation Method 2
A press-fit thrust bearing system featuring a single bushing with a protruding band and a non-rotating guide sleeve, both made of the same material as the diffuser, which interlocks to prevent rotation and dislodgement
Data Source
AI summary
A press-fit thrust bearing system and apparatus. A press-fit thrust bearing for an electric submersible pump includes a protruding band extending around a midsection of a bushing, the protruding band extending inward towards a drive shaft, outward towards a diffuser, or both. When extending outwardly, the band is press-fit into the diffuser to prevent dislodgment of the bushing. A non-rotating guide sleeve extends around the bushing above the protruding band, the guide sleeve interlocking with the protruding band to prevent rotation of the bushing. The guide sleeve includes a projection, the protruding band has a channel and the projection mates with the channel to form the interlock. A pair of flanged, rotatable bearing sleeves extend inwards of the single bushing and are keyed to the drive shaft. The top and bottom faces of the bushing serve as thrust handling surfaces.