Self-Locking Plug Assembly for High-Pressure Seal Retention
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Solution Overview
Problem
Existing pump systems, particularly in hydraulic fracturing, face issues with leaks and operational problems due to movement and load cycling at interfaces, leading to failures in sealing mechanisms, as they rely on threaded fasteners which are prone to cracking or loosening under pressure.
Innovation Solution
The implementation of a plug assembly with a lock ring and retaining plate that utilizes the natural outward pressure of the fluid end to create a self-locking mechanism, eliminating the need for axial loading from external fasteners and threaded interfaces, by driving the lock ring radially outward into a groove for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded fasteners are used to secure the plug, then the plug can be installed and secured, but the threaded interfaces are prone to cracking or loosening under pressure and load cycling
Solution Approach 1:
The patent replaces the threaded fastening system with a friction-based mechanical interference system. The plug body is pressed directly against the pump body through axial force application, creating a friction lock that prevents loosening under pressure cycling. This eliminates the threaded interface vulnerability while maintaining secure attachment.
Solution Approach 2:
The plug assembly includes a self-locking mechanism where the plug body's own geometry and the applied axial force create a self-reinforcing friction lock. As pressure increases, the friction force increases proportionally, automatically compensating for load cycling without requiring additional active components or adjustments.
2Reliability
If axial loading from external fasteners is used, then the plug can be secured, but the system becomes more complex and prone to failure at threaded interfaces
Solution Approach 1:
The patent extracts and eliminates the threaded fastener components from the system. Instead of using bolts, nuts, or threaded connections, the design relies on direct mechanical interference between the plug body and pump body, significantly simplifying the assembly and removing failure-prone elements.
Solution Approach 2:
The plug body is designed to integrate directly with the pump body through a friction-based interface, merging the fastening function into the plug assembly itself. This eliminates separate fastener components and creates a unified, simpler structure where the plug serves both as a sealing element and a mechanically secured component.
3Reliability
If the plug relies on torque or threaded connections, then initial installation is possible, but the connection may loosen under increased pressure and load cycling
Solution Approach 1:
The patent replaces the torque-dependent threaded connection system with a friction-based mechanical interference system. The axial force pressed against the plug body creates continuous friction contact that maintains connection stability independent of torque application, preventing loosening under pressure cycling and load variations.
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
This configuration enhances the sealing and loading on the plug, reducing the likelihood of leakage and system failure, as it maintains the plug's position even under increased pressure and load cycling without relying on torque or threaded connections.
Implementation Method 1
the lock ring positioned to be driven radially outward responsive to a longitudinal force applied to the plug body
Implementation Method 2
self-locking mechanism... maintaining the plug's position even under increased pressure and load cycling
Data Source
AI summary
A fluid end, includes a plunger reciprocating within a first bore, the plunger increasing a pressure of a fluid within a pressure chamber. The fluid end also includes a second bore. The fluid end further includes a plug assembly associated with the second bore. The plug assembly includes a plug body positioned within the second bore. The plug assembly also includes a lock ring positioned, at least in part, within the second bore, the lock ring positioned to be driven radially outward responsive to a longitudinal force applied to the plug body.