Shaker Bed Angular Positioning via Air-Over-Fluid System
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Solution Overview
Problem
Existing shaker separators face challenges in efficiently raising and lowering the discharge end of the shaker bed to manage sticky and coarse solids, often requiring manual or hazardous hydraulic systems, which are time-consuming and unsafe, especially in hazardous drilling environments.
Innovation Solution
An air-over-fluid hydraulic system that uses pressurized air to control fluid communication between a hydraulic tank and bellows, allowing for quick and safe angular positioning of the shaker bed's discharge end, with a lift control assembly that includes valves to raise and lower the bed while maintaining lateral levelness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation techniques (hand wheels or jacks) are used to raise and lower the discharge end of the shaker bed, then the system structure is simple, but the operation time is excessive and productivity is reduced
Solution Approach 1:
The patent employs a pneumatic-hydraulic system where compressed air acts on a diaphragm in a air-operated hydraulic pump, which in turn drives a hydraulic piston to raise and lower the discharge end of the shaker bed. This pneumatic-hydraulic mechanism enables rapid bed positioning while maintaining relatively simple system structure, directly resolving the contradiction between positioning speed and system complexity
Solution Approach 2:
The system uses adjustable positioning that allows the discharge end to be dynamically raised or lowered during operation. The quick-acting pneumatic-hydraulic mechanism enables the bed angle to be changed on-demand based on operational requirements, transforming a static system into a dynamic one that improves productivity without excessive complexity
2Productivity
If hydraulic lifts are used to raise and lower the discharge end, then the positioning speed is improved, but the system complexity increases and operation becomes more difficult
Solution Approach 1:
The pneumatic-hydraulic system is designed to be self-regulating through the inherent properties of compressed air and hydraulic fluid. The operator simply activates the system, and the air pressure automatically drives the hydraulic mechanism to the required position, eliminating the need for operator finesse or complex manual adjustments while maintaining fast positioning speed
Solution Approach 2:
The patent replaces complex mechanical linkages and manual control mechanisms with a pneumatic-hydraulic system that uses fluid pressure transmission. This substitution simplifies the control interface and reduces the skill level required for operation while maintaining rapid positioning capability
3Extent of automation
If solenoids are used in the positioning system, then the automation level is improved, but safety is compromised due to hazardous locations
Solution Approach 1:
The system uses intrinsically safe pneumatic-hydraulic components that operate without electrical solenoids in the hazardous zone. Compressed air serves as the actuating medium, eliminating ignition sources while maintaining automated positioning functionality. This approach achieves automation without compromising safety in explosive atmospheres
Solution Approach 2:
The patent introduces compressed air as an intermediary medium between the control system and the hydraulic mechanism. This intermediary allows automated control signals to be transmitted safely through pneumatic valves to actuate the hydraulic system, providing automation while maintaining safety by eliminating direct electrical components in the hazardous environment
4Ease of manufacture
If the discharge end is lowered to remove sticky solids, then solids removal efficiency is improved, but mud flow rate decreases and productivity is reduced
Solution Approach 1:
The system dynamically adjusts the discharge end position based on the type of solids being processed. For sticky solids, the discharge end is lowered to improve removal; for coarse solids, it is raised to maximize flow rate. This dynamic adaptability allows the system to optimize both solids removal efficiency and productivity for different material conditions
5Productivity
If the discharge end is raised to maximize mud flow rate, then productivity is improved, but sticky solids accumulate on the screen and cause breakage
Solution Approach 1:
The adjustable discharge end position allows the system to adapt to different operating conditions. When processing sticky solids, the discharge end can be lowered to prevent accumulation and screen breakage, while maintaining relatively high productivity. This dynamic adjustment protects screen integrity while preserving operational efficiency
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
Enables rapid and safe adjustment of the shaker bed's angle to optimize mud flow and minimize losses, improving operational efficiency and safety by automating the process and eliminating the need for hazardous components.
Implementation Method 1
an air source providing pressurized air, an hydraulic tank in selective communication with the air source and containing a quantity of fluid, at least one bellow in selective fluid communication with the hydraulic tank
Implementation Method 2
an air source providing pressurized air, when the tank control valve is actuated, air is communicated into the hydraulic tank to displace fluid therein
Implementation Method 3
wherein the weight of the discharge end compresses the at least one bellow to force fluid from the at least one bellow to the hydraulic tank, thereby lowering the discharge end
Data Source
AI summary
An apparatus for angularly positioning a shaker bed, including a discharge end, includes an air source providing pressurized air, an hydraulic tank in selective communication with the air source and containing a quantity of fluid, at least one bellow in selective fluid communication with the hydraulic tank, and a lift control assembly controlling communication of pressurized air between the air source and the hydraulic tank and controlling communication of fluid between the hydraulic tank and the at least one bellow.