Solar-Powered Wireless Load Cell Adapter for Rod Pump Systems

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Solution Overview

Problem

Existing rod pumping systems face challenges in measuring the load on polished rods due to cumbersome and difficult-to-replace load cells that completely encircle the rods, and inclinometers are hindered by external power supplies that are prone to damage and difficult installation.

Innovation Solution

A wireless load cell adapter with a solar-powered, self-contained power supply, integrated position sensor, and wireless transmitter that attaches to existing load cells, allowing for easy installation and operation without external power sources or wires, enabling the measurement and transmission of load and position data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a load cell completely encircles the polished rod, then accurate load measurement is achieved, but removal and replacement becomes difficult and time-consuming

Engineering Contradiction:

Improveload measurement accuracyVSAvoidload cell replacement ease

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system is divided into two independent parts: the existing load cell that remains installed on the polished rod, and a new adapter unit that attaches to the load cell. This segmentation allows the load cell to maintain its measurement function while the adapter provides wireless capabilities without requiring removal of the load cell itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adapter serves as an intermediary device between the load cell and the monitoring system. It connects to the load cell via cable, receives power and signal data, then wirelessly transmits this information to remote monitoring equipment, eliminating the need for direct wired connections from the load cell.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If an external power supply is used for the inclinometer, then the inclinometer can be powered, but the external wires are easily damaged and water can leak into the device

Engineering Contradiction:

Improveinclinometer power supplyVSAvoidinclinometer protection from damage and water

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The adapter incorporates an integrated power supply system with solar panel and rechargeable battery that powers itself autonomously. The solar panel charges the battery during daylight hours, which then powers the adapter's electronic components including the wireless transmitter, eliminating dependence on external power sources and vulnerable wiring.

Inventive Principle:

Principle #25Self-service

3Loss of information

If wired load cells are used, then load data can be transmitted, but the wires can be broken by wind and mechanical stress

Engineering Contradiction:

Improveload signal transmissionVSAvoidwire durability against wind and stress

Core Design Contradiction:

Loss of informationVSReliability

Solution Approach 1:

The mechanical wired connection system is replaced with an electronic wireless transmission system. The adapter receives the load signal through a cable connection to the load cell, then uses a wireless transmitter to send data remotely, eliminating the need for long exposed wires that are vulnerable to wind and mechanical stress.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If an inclinometer with external power supply is installed, then position measurement is possible, but installation becomes difficult and placement must be precise

Engineering Contradiction:

Improveposition measurement accuracyVSAvoidinclinometer installation ease

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The adapter combines multiple functions into a single integrated unit: it attaches to the load cell, provides power through integrated solar panel and battery, houses the inclinometer for position sensing, and includes wireless transmission capability. This consolidation simplifies installation compared to separate components with external wiring.

Inventive Principle:

Principle #5Merging (Combining)

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

Facilitates efficient and accurate monitoring of load and position data, reducing maintenance needs and improving system reliability by eliminating the need for external power sources and wires, while allowing for easier installation and operation.

Implementation Method 1

a power supply configured to provide power to the adapter and the load cell, the power supply including a solar panel on the outer shell

Methodology Applied

Scientific EffectSolar energy conversion: Photovoltaic Effect

Data Source

PatentUS9983076B2Solar battery wireless load cell adapter

Publication Date: 2018.05.29 BODE INTELLIGENCE TECH CO LTD

AI summary

An adapter for a load cell in a rod pump system includes an outer shell including a mounting portion configured to attach to the load cell on a polished rod, a power supply configured to provide power to the adapter and the load cell, the power supply including a solar panel on the outer shell, a cable configured to connect to the load cell, the adapter configured to provide power to the load cell via the cable, and the adapter configured to receive a load signal from the load cell via the cable, a signal processor configured to receive and process the load signal and to output load signal data representative of a load experienced by the load cell, and a wireless transmitter to transmit the load signal data.