Rail-Mounted Zipper Manifold for Modular Component Handling
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Solution Overview
Problem
The existing zipper manifolds, consisting of large and heavy valves and pressure-containing assets, pose hazards and inefficiencies during repositioning, assembly, and disassembly, necessitating a system that can efficiently move and reconfigure these components.
Innovation Solution
A modular, self-contained, integrated, and collapsible trailer-mounted zipper manifold system utilizing a series of rails to independently and selectively move injection head modules, mixing blocks, and valve assemblies, with a crane system for efficient replacement and reconfiguration, and an integrated housing for automation and greasing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zipper manifolds use large and heavy valves and pressure-containing assets, then pressure containment capability is improved, but safety and operational efficiency during repositioning and assembly deteriorate
Solution Approach 1:
The zipper manifold system is divided into modular components including multiple valve assemblies (first, second, third, fourth valve assemblies), injection head modules, and mixing blocks that can be independently handled and repositioned. Each module maintains pressure containment capability while reducing individual component weight and size for safer handling.
Solution Approach 2:
A rail system serves as an intermediary mechanism between the heavy pressure-containing components and the operators. The rails provide guided movement and support during repositioning operations, reducing the physical burden on operators and minimizing safety hazards associated with manual handling of heavy components.
2Reliability
If zipper manifolds use large and heavy valves, then pressure containment capability is improved, but operational efficiency during assembly and disassembly deteriorates
Solution Approach 1:
The system is segmented into standardized modular components with uniform connection interfaces. Valve assemblies, injection head modules, and mixing blocks can be quickly assembled and disassembled by connecting and disconnecting at predefined interfaces, significantly improving operational efficiency while maintaining pressure containment through standardized sealing mechanisms.
Solution Approach 2:
The rail system enables dynamic repositioning of components during assembly and disassembly operations. Components can be moved along the rails to optimal positions for connection and disconnection, reducing manual lifting and repositioning efforts, thereby improving assembly and disassembly efficiency without compromising pressure containment integrity.
3Ease of operation
If a modular rail-based system is implemented, then ease of movement and reconfiguration is improved, but device complexity increases
Solution Approach 1:
The rail system serves multiple functions: it provides guided movement for heavy components, supports components at various heights (upper and lower rails), enables independent repositioning of different modules, and facilitates both assembly and disassembly operations. This multi-functionality justifies the added structural complexity by providing comprehensive operational flexibility and ease of reconfiguration.
Solution Approach 2:
The system employs a hierarchical rail structure with main rails and secondary rails nested together. The secondary rails are positioned above and below the main rails, creating a nested configuration that maximizes space utilization while providing multiple levels of component support and movement capability, thereby managing complexity through organized structural nesting.
Data Source
AI summary
A mounting system for zipper manifold that includes rails. Embodiments may include mixing block and injection head modules that are configured to move on a trailer.