Pump Gear Train Backlash Measurement via Crankshaft Locking
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Solution Overview
Problem
Mud pumps in well construction systems experience wear and degradation due to high mechanical power and torque transfer, leading to late detection of gear train wear and potential pump failure, which interrupts or lowers drilling efficiency.
Innovation Solution
A system that includes a rotational position sensor, a locking device, and a processing device to measure backlash in the gear train by locking the crankshaft and determining the rotational distance between specific positions, allowing for early detection of gear train wear and operational health assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gear train operates continuously to transfer high mechanical power and torque, then the productivity of the pump unit is improved, but the gear train experiences wear and degradation leading to late detection and potential pump failure
Solution Approach 1:
The system performs preliminary detection of gear train wear by measuring backlash before severe damage occurs. The rotational position sensor continuously monitors the backlash between gear teeth, and the processing device analyzes these measurements to detect early signs of wear, allowing maintenance to be scheduled before pump failure occurs.
Solution Approach 2:
The system establishes a feedback loop where the rotational position sensor provides continuous measurements of gear train backlash to the processing device. The processing device compares measured backlash values against threshold criteria and provides feedback signals to indicate when wear detection criteria are met, enabling real-time monitoring and response to gear train degradation.
2Power
If the gear train operates under high torque conditions, then the power transmission capability is improved, but wear and degradation occur leading to late detection
Solution Approach 1:
The system replaces traditional mechanical inspection methods with an electronic sensing and processing system. The rotational position sensor provides precise electrical measurements of gear tooth position, and the processing device uses algorithmic analysis to detect wear patterns, substituting manual mechanical assessment with automated electronic detection that operates continuously under load conditions.
3Ease of operation
If pump failure is allowed to occur naturally, then operational simplicity is maintained, but drilling operations are interrupted and efficiency is lowered
Solution Approach 1:
The system enables the pump unit to self-monitor its own operational health through the rotational position sensor and processing device that continuously assess gear train condition. The system performs self-diagnosis by comparing measured backlash against wear detection criteria, allowing the equipment to identify its own degradation and trigger maintenance alerts without external inspection, thus maintaining operational simplicity while preventing productivity loss.
Data Source
AI summary
Apparatus and methods for measuring backlash of a gear train of a pump unit for pumping a fluid. An example method may include locking a crankshaft of the pump unit such that the crankshaft cannot rotate. The method may further include commencing operation of a processing device to receive rotational position measurements indicative of rotational position of an output shaft of a prime mover, cause the prime mover to rotate the output shaft in a first direction until the output shaft reaches a first rotational position, and cause the prime mover to rotate the output shaft in a second direction until the output shaft reaches a second rotational position. The processing device may then determine backlash of the gear train by determining rotational distance between the first rotational position of the output shaft and the second rotational position of the output shaft.