Modular Power End Assembly With Replaceable Crosshead Frames
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Solution Overview
Problem
Existing hydraulic fracturing pumps face challenges such as high failure rates at the mount plate due to stress concentration, poor lubrication leading to uneven wear, and the need for major repairs or replacement.
Innovation Solution
A modular power end assembly with individual connect plates, crosshead frames, and crosshead assemblies that can be replaced independently, using multiple sets of stay rods for compression and lubrication distribution, and employing different materials for various components to optimize performance and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a modular design with individual connect plates and crosshead frames is used, then ease of repair and maintenance is improved, but device complexity increases
Solution Approach 1:
The power end assembly is divided into modular components including individual connect plates, crosshead frames, and crosshead assemblies that can be independently replaced. This segmentation allows specific worn or failed parts to be swapped out without replacing the entire assembly, directly improving ease of repair while the standardized modular interfaces help manage the increased device complexity.
2Reliability
If multiple sets of stay rods are used for compression, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple sets of stay rods are strategically positioned at different locations within the power end assembly to provide localized compression and support where needed. This distributed approach improves reliability by ensuring even stress distribution and preventing failure at critical mounting points, while the standardized stay rod design helps manage the added complexity.
3Strength
If different materials are used for various components, then strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
Different materials are selected for specific components based on their functional requirements - for example, wear-resistant materials for crosshead frames that contact moving parts, high-strength materials for stay rods under compression, and corrosion-resistant materials for connect plates. This targeted material selection improves overall assembly strength and durability, while standardized dimensions and interfaces across different materials help manage manufacturing precision requirements.
Data Source
AI summary
A power end assembly includes a crankshaft section, a crosshead section, and a connector section coupled together by one, two, or more sets of stay rods. The power end may include one or more support plates that are coupled to the crankshaft section and/or crosshead section. The crosshead section includes a plurality of individual crosshead frames. The connector section may include a plurality of individual connector plates or may be a unitary connector plate. The power end is configured to be coupled to a fluid end assembly by coupling the fluid end assembly to the connector plates.