Magnetorheological Pump Drivetrain Damping for Torque Vibration Control
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Solution Overview
Problem
Current damper systems for reciprocating pump assemblies in well servicing are inadequate in reducing vibrations efficiently, often requiring large and heavy components that exceed weight limits on transportation vehicles and are difficult to couple and service, leading to excessive wear and costly replacements.
Innovation Solution
A damper control system that includes sensors, processors, and electromagnets to detect torque variations in the pump drivetrain and send control signals to negate inertia, using a magnetorheological fluid to apply variable drag forces to a flywheel, thereby reducing vibrations before they escalate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current viscoelastic dampers are used to reduce vibrations in the pump drivetrain, then vibrations are dampened, but the dampers have slow response times and require large, heavy components
Solution Approach 1:
The patent replaces traditional mechanical viscoelastic dampers with an active control system using sensors, processors, and electromagnets. This substitution enables real-time detection and response to torque variations, achieving fast response times while using lighter components compared to passive mechanical dampers
Solution Approach 2:
The patent implements a feedback control system where sensors detect torque variations in real-time, the processor analyzes the signals, and electromagnets apply corrective forces. This closed-loop feedback mechanism enables rapid response to vibrations at their onset, resolving the slow response time issue of traditional dampers
2Reliability
If current viscoelastic dampers are used to reduce vibrations in the pump drivetrain, then vibrations are dampened, but large, heavy components are required that exceed weight limits on transportation vehicles
Solution Approach 1:
The patent replaces heavy mechanical viscoelastic dampers with an active control system using sensors, processors, and electromagnets. This substitution achieves effective vibration dampening while dramatically reducing component weight, allowing the system to meet transportation weight limits without requiring road permits
Solution Approach 2:
The patent changes the fundamental operating parameters from passive mechanical damping to active electromagnetic control. This parameter change enables the system to achieve the same vibration dampening effectiveness with significantly lighter components, resolving the weight limit issue
3Reliability
If current viscoelastic dampers are used to reduce vibrations in the pump drivetrain, then vibrations are dampened, but the dampers are difficult to couple and service
Solution Approach 1:
The patent segments the vibration control function into separate modular components: sensors mounted on the drivetrain, a processor unit, and electromagnets positioned near the crankshaft. This segmentation allows each component to be independently installed, adjusted, and serviced, greatly improving ease of operation compared to integrated viscoelastic dampers
Solution Approach 2:
The patent replaces the monolithic mechanical structure of viscoelastic dampers with distributed electromagnetic components. This substitution enables easier coupling to the drivetrain and simpler servicing procedures, as individual sensors and electromagnets can be accessed and replaced without dismantling heavy damper assemblies
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 system effectively dampens vibrations at their onset, reducing wear on equipment, extending the lifespan of components, and avoiding costly replacements while meeting weight and transportation constraints.
Implementation Method 1
using a magnetorheological fluid to apply variable drag forces to a flywheel
Implementation Method 2
send control signals to one or more electromagnets positioned proximate the second end portion of the crankshaft
Data Source
AI summary
In one aspect, there is provided a damper control system for a reciprocating pump assembly according to which control signals are sent to electromagnets. In another aspect, there is provided a method of dampening vibrations in a pump drivetrain according to which a beginning of torque variation is detected and at least a portion of the torque variation is negated. In another aspect, signals or data associated with pump characteristics are received from sensors, torque characteristics and damper response voltages per degree of crank angle are calculated, and control signals are sent to electromagnets. In another aspect, a damper system includes a fluid chamber configured to receive a magnetorheological fluid; a flywheel disposed at least partially within the fluid chamber and adapted to be operably coupled to a fluid pump crankshaft; and a magnetic device proximate the flywheel. The magnetic device applies a variable drag force to the flywheel.