Self-Monitoring Pump Leakage Control via Dynamic Gap Adjustment

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Solution Overview

Problem

Existing rotodynamic pumps face issues with fluid recirculation and wear between rotating and non-rotating elements, particularly in slurry applications, due to lack of effective automatic adjustment mechanisms, leading to performance decline and increased maintenance needs.

Innovation Solution

An automatic adjustment system with sensors and actuation mechanisms that monitor and adjust the gap between rotating and non-rotating elements, using devices like proximity sensors, vibration sensors, and actuation mechanisms to maintain optimal clearance and reduce wear, allowing for both automatic and predictive adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual adjustment mechanisms are used for leakage restricting devices, then device complexity is reduced, but productivity decreases due to frequent manual intervention and monitoring

Engineering Contradiction:

Improveadjustment mechanism complexityVSAvoidpump operational efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The leakage restricting device incorporates automatic adjustment mechanisms that self-regulate the gap between rotating and non-rotating elements based on monitored conditions, eliminating the need for manual intervention and maintaining optimal performance continuously

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Sensors monitor conditions such as vibration, temperature, or gap dimensions and provide feedback to the control system, which automatically adjusts the leakage restricting device to maintain optimal gap dimensions, creating a closed-loop control system that responds to actual operating conditions

Inventive Principle:

Principle #23Feedback

2Productivity

If automatic adjustment systems with sensors are implemented, then productivity is improved through continuous optimization, but device complexity increases due to additional monitoring and control components

Engineering Contradiction:

Improvepump operational efficiencyVSAvoidmonitoring and control system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sensor system is designed to monitor multiple parameters (vibration, temperature, gap dimensions) simultaneously using a single integrated monitoring platform, reducing the number of separate systems needed while maintaining comprehensive oversight of pump conditions

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Traditional mechanical adjustment mechanisms are replaced with electronically controlled actuation systems that can be precisely controlled and monitored, enabling more accurate and responsive gap adjustment while reducing mechanical wear and maintenance requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If the gap between rotating and non-rotating elements is reduced to minimize leakage, then fluid recirculation is reduced, but wear increases due to closer contact between elements

Engineering Contradiction:

Improvefluid recirculation lossVSAvoidwear between components

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The gap dimensions are made dynamically adjustable rather than fixed, allowing the system to optimize the balance between leakage reduction and wear prevention by automatically adjusting gap size based on operating conditions such as load, speed, and material being pumped

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The leakage restricting device automatically adjusts its own position to maintain optimal gap dimensions, sensing conditions that indicate excessive leakage or approaching wear thresholds and self-correcting to prevent both energy loss and component damage

Inventive Principle:

Principle #25Self-service

4Device complexity

If fixed leakage restricting devices are used, then device complexity is minimized, but adaptability decreases when operating conditions change or wear occurs

Engineering Contradiction:

Improveadjustment mechanism complexityVSAvoidresponse to operational conditions

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The leakage restricting device transitions from a fixed configuration to a dynamically adjustable system that can modify gap dimensions in response to changing operating conditions, material properties, and wear patterns, maintaining optimal performance throughout the equipment lifecycle

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Sensors continuously monitor operating conditions and provide feedback to the control system, which automatically adjusts the leakage restricting device to adapt to changing conditions such as variations in pumped material, temperature changes, or component wear, eliminating the need for manual reconfiguration

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS7871241B2Self-monitoring system for evaluating and controlling adjustment requirements of leakage restricting devices in rotodynamic pumps

Publication Date: 2011.01.18 WEIR SLURRY GROUP INC

AI summary

A self-monitoring adjustment system is provided for evaluating and effecting adjustment of the leakage restricting mechanism between the rotating and non-rotating elements of a rotodynamic pump to restrict leakage and to establish desired gap dimensions between the rotating and non-rotating elements of the pump. The adjustment system is structured to be self-monitoring for determination of when an adjustment of the leakage restricting mechanism is warranted by the conditions of the pump, and is structured with adjusting mechanisms that are self-adjusting responsive to the monitored conditions of the pump, though manual adjustment is also enabled.