Pumpjack Load Cell System Bridle Geometry Stabilization
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Solution Overview
Problem
Conventional load cells used in pumpjacks for measuring rod load are inaccurate and require dangerous, time-consuming replacement processes, as they do not maintain a consistent bridle geometry, leading to unpredictable tension measurements.
Innovation Solution
A load cell system comprising a tension load cell fixed to the bridle between two bridle cables and a strut that maintains constant lateral spacing, ensuring accurate rod load measurement by stabilizing the bridle geometry and allowing for safe and quick replacement without removing the upper rod clamp.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional tension load cells are used to measure rod load, then the measurement process is simplified, but the measurement accuracy deteriorates due to inconsistent bridle geometry
Solution Approach 1:
A strut is introduced as an intermediary component between the horsehead and the bridle cables. This strut acts as a mediator that enforces constant lateral spacing between the bridle cables, thereby maintaining consistent bridle geometry during pumpjack operation. The strut translates the position of one bridle cable to maintain proper spacing relative to the other cable, ensuring accurate load measurements without complicating the measurement process.
Solution Approach 2:
The invention changes the geometric parameters of the bridle system by enforcing constant lateral spacing between bridle cables through the strut. This parameter control ensures that the bridle geometry remains consistent during operation, which directly improves measurement accuracy while maintaining the simplicity of the tension load cell measurement method.
2Measurement precision
If compression load cells are used with upper rod clamp, then rod load measurement is achieved, but replacement time increases due to clamp removal requirements
Solution Approach 1:
The invention extracts the load cell from the compression-based system between the rod clamp and bridle plate, and relocates it to a tension-based system on the bridle cables. This extraction allows the load cell to be replaced independently without removing the upper rod clamp, significantly reducing replacement time while maintaining measurement precision through tension measurement.
Solution Approach 2:
The invention inverts the measurement approach by switching from compression load cells (measuring compressive force) to tension load cells (measuring tensile force). This inversion allows the load cell to be positioned on the bridle cables where it can be replaced without interfering with the rod clamp assembly, thus reducing maintenance downtime while preserving measurement accuracy.
3Ease of manufacture
If tension load cells deflect bridle cables laterally inward, then installation is simplified, but measurement accuracy deteriorates due to variable bridle geometry
Solution Approach 1:
The strut serves as a mediator that counteracts the lateral deflection effect. While the tension load cell deflects the bridle cables inward, the strut pushes outward to maintain constant lateral spacing. This mediation ensures that the bridle geometry remains consistent despite the presence of the load cell, preserving measurement accuracy while keeping the installation simple.
Solution Approach 2:
The strut provides preliminary anti-action by pre-establishing constant lateral spacing between the bridle cables. This prevents the bridle geometry from becoming variable during operation, countering the potential negative effect of load cell installation on measurement accuracy while maintaining installation simplicity.
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 accurate rod load measurements and facilitates safe, rapid replacement of load cells, reducing downtime and technician requirements by maintaining consistent geometric parameters during pumpjack operation.
Implementation Method 1
The tension load cell has a first end portion connected to a first bridle cable and a second end portion connected to a second bridle cable and is configured to generate an output signal representative of a tension imparted on the tension load cell by the first and second bridle cables
Data Source
AI summary
A load cell system for measuring rod load in a pumpjack. The system includes a tension load cell operatively coupled to a bridle between first and second bridle cables at a location longitudinally spaced between a horsehead and a bridle plate of the pumpjack. The bridle plate is coupled to the first bridle cable at a first connection point and the tension load cell is coupled to the first bridle cable at a second connection point longitudinally spaced between the bridle plate and the horsehead. The load cell system defines a third connection point longitudinally spaced between the second connection point and the horsehead. The load cell system is configured to maintain substantially constant longitudinal distances between the second connection point and each of the first and third connection points during operation of the horsehead. The load cell system is further configured to maintain a substantially constant lateral distance between the first and second bridle cables at the third connection point during operation of the horsehead.