Modular Pump Rod Column Assembly With Wedge Bolt Fastening
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Solution Overview
Problem
Traditional reciprocating mud pumps suffer from excessive wear and failure due to inadequate fastening of components, leading to high maintenance costs and time-consuming replacements, with existing solutions either being costly or requiring specialized tooling.
Innovation Solution
A modular reciprocating pump rod column system with a simplified design that allows manual operation using basic tools, featuring a wedge bolt mechanism and a single directional axial force system, reducing wear and enabling easy replacement of worn components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional clamp areas are used to fasten rod components, then the components can be assembled, but wear develops leading to inadequate fastening and excessive movement
Solution Approach 1:
The rod column is divided into modular segments (piston rod, extension rod, crosshead) that can be independently replaced. The clamp areas are segmented into replaceable clamp assemblies rather than integral parts, allowing worn clamps to be replaced without replacing the entire rod column.
Solution Approach 2:
The fastening mechanism transitions from friction-based clamping to positive mechanical engagement using tapered pins and wedge bolts. This changes the fastening parameter from relying on surface friction to relying on geometric locking, dramatically improving reliability and wear resistance.
2Productivity
If traditional rod column design is used, then the pump can operate, but component replacement is time-consuming and expensive
Solution Approach 1:
The rod column is segmented into modular components that can be independently replaced. Worn parts such as clamps, pins, and rod sections can be swapped out quickly without replacing the entire assembly, significantly reducing maintenance time and cost.
Solution Approach 2:
Wear components are designed with preliminary alignment features and standardized interfaces. The tapered pins and wedge bolts are pre-configured to self-align during assembly, eliminating time-consuming alignment procedures during maintenance operations.
3Ease of operation
If excessive movement between piston and crosshead occurs, then the pump continues to operate, but premature failure of piston and liner results
Solution Approach 1:
The fastening mechanism changes from friction-based clamping to geometric locking using tapered pins and wedge bolts. This parameter change ensures rigid, precise alignment between piston and crosshead, eliminating excessive movement and maintaining concentricity throughout operation.
Solution Approach 2:
Tapered pins and wedge bolts use conical geometry to create self-centering, self-aligning connections. The curved/tapered surfaces naturally guide components into proper alignment, ensuring piston and liner concentricity while maintaining ease of assembly and operation.
4Strength
If high pressure hydraulic pumps with special hydraulic connectors are used, then connection strength is improved, but costs increase and specialized tooling is required
Solution Approach 1:
The invention uses simple, inexpensive mechanical fasteners (wedge bolts, tapered pins, clamps) that can be quickly replaced when worn. Rather than using expensive, complex hydraulic connectors, the system employs straightforward mechanical elements that achieve sufficient connection strength while allowing rapid, tool-minimal maintenance.
Solution Approach 2:
Instead of using complex hydraulic connectors to achieve strong connections, the invention inverts the approach by using simple mechanical fasteners with optimized geometry (tapered pins, wedge bolts) that provide adequate strength through mechanical advantage and geometric locking, eliminating the need for specialized hydraulic systems.
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 provides cost-effective and efficient operation with reduced maintenance, eliminating the need for specialized tooling and extending the lifespan of the pump by minimizing wear and simplifying component replacements.
Implementation Method 1
featuring a wedge bolt mechanism and a single directional axial force system
Data Source
AI summary
A modular reciprocating pump rod column assembly and system are presented. The present disclosure provides the state of the art with a hydraulically actuated extension rod assembly with a piston and a hydraulically actuated extension rod assembly with a plunger. The rod column assembly that can be converted to plunger and vis-versa. The hydraulic system provides for spring compression based on a hydraulic piston installed inside the primary extension rod. As hydraulic pressure is applied through a port located in the end cap, it is fed through a cross port drilled in the extension rod assembly to the blind end of the internal piston. When pressurized the piston moves forward, compressing the springs against the end cap when in turn extends the center shaft, relieving tension on the forward and rear rod column pins. Releasing the hydraulic pressure allows the springs to extend, retracting the center shaft.