Split Plunger Pump Modules for Fast Performance Reconfiguration
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Solution Overview
Problem
Existing plunger pumps require complete replacement when adapting to different working conditions, prime movers, or changing performance parameters, leading to high costs and operational inefficiencies due to non-standardized external interfaces and housing sizes.
Innovation Solution
A split-type plunger pump design with platform-based external interfaces allows individual modules to be replaced with different specifications, enabling adaptation to various power sources and working conditions without altering the entire pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire plunger pump is replaced to adapt to different working conditions or performance parameters, then the adaptability and performance requirements are met, but the operational costs and time consumption increase significantly
Solution Approach 1:
The plunger pump is divided into modular components (power end assembly and fluid end assembly) that can be independently replaced. The power end assembly includes the crankcase, crosshead box, and reduction gearbox, while the fluid end assembly includes the plunger, valves, and fluid chambers. This segmentation allows users to replace only the specific module that needs adaptation rather than the entire pump system.
Solution Approach 2:
The patent creates universal interface standards and mounting patterns that allow different specifications of assemblies to be interchangeable. The power end assembly is designed with standardized interfaces that can accommodate various fluid end assemblies with different performance parameters (displacement, pressure, stroke), making the system multi-functional and adaptable to different working conditions.
2Adaptability or versatility
If the entire plunger pump is replaced to change performance parameters such as displacement or pressure, then the desired performance is achieved, but the operational costs increase
Solution Approach 1:
The pump system is segmented into replaceable assemblies where only the fluid end assembly needs to be changed to modify performance parameters such as displacement or pressure. The expensive power end assembly remains in place, significantly reducing the cost of performance adaptation compared to replacing the entire pump.
Solution Approach 2:
The patent enables parameter changes (displacement, pressure, stroke) by swapping fluid end assemblies with different specifications while keeping the power end assembly constant. This allows users to adjust performance parameters without incurring the full cost of replacing the entire pump system.
3Adaptability or versatility
If different stroke requirements are met by replacing components individually, then the stroke adaptation is achieved, but the housing sizes and external interface positions differ requiring complete pump replacement
Solution Approach 1:
The power end assembly is designed with universal housing dimensions and standardized external interface positions that remain constant across different models. This universality allows fluid end assemblies with different stroke requirements to be mounted on the same power end assembly without requiring changes to the housing or interface positions, simplifying the overall system design.
4Adaptability or versatility
If the reduction gearbox is changed to accommodate electric motor drive, then the prime mover transition is achieved, but the gearbox housing size limitations prevent gear adjustment requiring complete pump replacement
Solution Approach 1:
The reduction gearbox is segmented as part of the replaceable power end assembly. When transitioning between prime movers (e.g., from diesel engine to electric motor), the entire power end assembly can be replaced with a different specification that includes the appropriate reduction gearbox, while the fluid end assembly remains unchanged. This segmentation simplifies the adaptation process compared to trying to modify the gearbox within the existing housing.
5Adaptability or versatility
If the entire plunger pump is replaced to adapt to different prime movers, then the prime mover compatibility is achieved, but the operational inefficiency increases
Solution Approach 1:
The separation of the power end assembly from the fluid end assembly allows independent replacement of the power end to match different prime movers. This means users can quickly swap between diesel engine-driven and electric motor-driven configurations without disturbing the fluid end components, significantly improving operational efficiency compared to replacing the entire pump system.
Data Source
AI summary
A split-type plunger pump includes: a first module including a reduction gearbox assembly, an input side interface thereof being connected to a power source; a second module including a crankcase assembly, an input side interface thereof being connected to an output side interface of the first module; a third module including a crosshead box assembly, an input side interface thereof being connected to an output side interface of the second module; and a fourth module including a fluid end assembly, an input side interface thereof being connected to an output side interface of the third module. The reduction gearbox assembly, the crankcase assembly, the crosshead box assembly, and the fluid end assembly are sequentially connected.