Progressing Cavity Pump Rotor Coupling for Field Assembly
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Solution Overview
Problem
Conventional progressing cavity pumps/motors with elongate rotor sections face difficulties in transportation and field assembly due to the need for precise rotational alignment and welding, which is challenging and requires specialized tools.
Innovation Solution
A coupling assembly that interconnects upper and lower rotor sections using a drive adapter and socket adapter with alignment and locking mechanisms, allowing for rotational alignment and secure connection without the need for welding or specialized tools, enabling efficient field assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an elongate rotor is divided into multiple sections for easier transportation, then the ease of operation during field assembly improves, but the difficulty of achieving precise rotational alignment increases
Solution Approach 1:
A coupling assembly serves as an intermediary component between rotor sections, incorporating alignment features such as keyed connections or tapered interfaces that automatically establish precise rotational alignment when sections are assembled in the field, eliminating the need for complex alignment procedures
Solution Approach 2:
Alignment features are pre-built into the coupling assembly and rotor section interfaces during manufacturing, so that when sections are assembled in the field, the precise rotational alignment is achieved automatically through the pre-configured alignment mechanisms rather than requiring field alignment operations
2Strength
If rotor sections are connected using welding to ensure strong connection, then the strength of the connection improves, but the ease of manufacture and operation deteriorates due to requirement of specialized tools and procedures
Solution Approach 1:
The welding process is replaced with a mechanical coupling assembly that uses threaded connections, bayonet mounts, or other mechanical fastening mechanisms to join rotor sections, providing equivalent or superior connection strength while eliminating the need for welding equipment and specialized procedures
Solution Approach 2:
The coupling assembly is designed to be self-aligning and self-securing through features such as tapered interfaces that automatically center sections, or locking mechanisms that automatically engage when sections are brought together, eliminating the need for specialized tools or 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 coupling assembly ensures reliable rotational alignment and axial fixation of rotor sections, facilitating efficient field assembly and operation of progressing cavity pumps/motors, particularly suitable for long-length applications where precise alignment and torque transmission are critical.
Implementation Method 1
torque is transmitted between the drive adapter and the socket adapter, and thus between the rotor sections
Data Source
AI summary
A progressing cavity pump/motor includes a stator tube (12), a rotor (20) within the stator tube, and a coupling assembly (30) interconnecting the upper and lower rotor sections. The coupling includes a drive adapter (32) and a socket adapter (36) for transmitting torque between the upper and lower rotor sections, and at least one alignment surface (60) in cooperation with a mating surface to rotationally position the drive adapter within the socket adapter at a selected circumferential position. The pump/motor may be reliably assembled in the field while maintaining precise axial and rotational positioning of the rotor sections.