Spring-Actuated Shaft Coupling for Bidirectional Axial Loading
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Solution Overview
Problem
Electric submersible pump (ESP) systems face challenges in efficiently managing bidirectional loading on inner shafts, requiring additional and costly thrust bearings to isolate motor sections from both compressive and tensile forces, which complicates assembly and increases costs.
Innovation Solution
A locking coupling assembly is introduced that mechanically fixes the axial distance between shafts, allowing for the transfer of both tensile and compressive forces, eliminating the need for additional thrust bearings by using a shaft locking mechanism to cycle loading from tension to compression during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional thrust bearings are used to counteract tensile loading, then the motor section is protected from bidirectional forces, but the system cost increases and assembly becomes more complex
Solution Approach 1:
The patent combines the functions of torque transmission and axial force management into a single coupling assembly. The coupling includes both circumferential load transmission elements (splines or keys) and axial load management elements (locking mechanism with locking surfaces), merging what were previously separate functions handled by multiple components including thrust bearings.
Solution Approach 2:
The coupling assembly is designed to perform multiple functions: transmitting torque through circumferential elements, managing compressive axial loads through locking surfaces, and preventing separation under tensile loads through the locking mechanism. This multi-functional design eliminates the need for separate thrust bearings to handle bidirectional axial forces.
2Reliability
If additional thrust bearings are used to counteract tensile loading, then bidirectional forces are managed, but system cost increases
Solution Approach 1:
The patent combines the functions of torque transmission and axial force management into a single coupling assembly. The coupling includes both circumferential load transmission elements (splines or keys) and axial load management elements (locking mechanism with locking surfaces), merging what were previously separate functions handled by multiple components including thrust bearings.
Solution Approach 2:
The coupling assembly is designed to perform multiple functions: transmitting torque through circumferential elements, managing compressive axial loads through locking surfaces, and preventing separation under tensile loads through the locking mechanism. This multi-functional design eliminates the need for separate thrust bearings to handle bidirectional axial forces.
3Ease of manufacture
If typical couplings are used that only transmit compressive loading, then assembly is simple, but the system cannot handle tensile loading in injection configurations
Solution Approach 1:
The coupling incorporates a dynamic locking mechanism that can adapt to different loading conditions. The locking surfaces and locking elements are designed to engage under both compressive and tensile axial loads, allowing the coupling to dynamically respond to bidirectional forces while maintaining a relatively simple assembly process.
Solution Approach 2:
The coupling assembly is designed to perform multiple functions: transmitting torque through circumferential elements, managing compressive axial loads through locking surfaces, and preventing separation under tensile loads through the locking mechanism. This multi-functional design eliminates the need for separate thrust bearings to handle bidirectional axial forces.
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 solution simplifies the assembly of ESP systems, reduces costs by eliminating the need for extra thrust bearings, and effectively manages bidirectional forces along the inner shafts, enhancing the operational efficiency and reliability of ESP systems.
Implementation Method 1
a spring positioned within the coupling and biased against the locking element to bias the locking element in the unlocked position
Implementation Method 2
a plunger positioned within the coupling and configured to move the locking element from the locked position to the unlocked position and from the unlocked position to the locked position
Data Source
AI summary
An electrical submersible pump assembly comprising a first section and a second section with an outer housing and a drive shaft. A coupling assembly comprising a coupling, a first and a second locking keys, and a plunger assembly mechanically couples the first drive shaft to the second drive shaft. The coupling is cylindrical in shape with splines configured to transfer torque from the first drive shaft to the second drive shaft. The plunger assembly extends the first and second set of locking keys from a key port in the first shaft and second shaft into a groove within the coupling. The coupling assembly is configured to transfer tensile stress from the first drive shaft to the second drive shaft in response to extending the first locking key in the first groove and the second locking key in the second groove of the coupling.