Splitter Shaft Retrofit for Fracking Transmission Reliability
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Solution Overview
Problem
Transmissions, particularly those used in high-stress applications like fracking units, suffer from premature failure of components such as the main bearing and splitter shaft due to inadequate design and inefficient lubrication systems, leading to short lifespan.
Innovation Solution
The design includes a thicker radial thickness for the splitter shaft and a larger bearing hub to accommodate larger bearings, along with a repurposed lubrication system that directs lubrication directly to critical components through a new tube and spray orifice.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the radial thickness of the splitter shaft outer wall is increased, then the strength and structural integrity of the splitter shaft is improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The patent applies parameter changes by modifying the radial thickness of the splitter shaft outer wall from a standard dimension to an increased thickness of 0.50-0.75 inches. This parameter change directly addresses the strength issue while maintaining the overall design framework, allowing the shaft to withstand high torque loads without premature failure.
2Reliability
If larger bearings are accommodated through a larger bearing hub, then the reliability and lifespan of the transmission is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent applies local quality by creating a bearing hub with a specifically enlarged inner diameter (5.0-6.0 inches) only where the bearing requires accommodation. The rest of the transmission housing maintains its original design, allowing larger bearings to be installed in the critical center section without redesigning the entire transmission structure.
3Duration of action of moving object
If a new lubrication tube with spray orifice is installed to directly lubricate bearings, then the lubrication efficiency and component lifespan is improved, but the device complexity and installation steps increase
Solution Approach 1:
The patent introduces a new lubrication tube with a spray orifice as an intermediary component between the existing lubrication line and the bearing surfaces. This intermediary device delivers lubrication directly to the bearing contact points, improving lubrication efficiency without requiring a complete redesign of the lubrication system.
Solution Approach 2:
The lubrication system is segmented into the existing lubrication line and a new add-on tube with spray orifice. This segmentation allows the new lubrication pathway to be installed independently, targeting specific bearing areas without disrupting the overall lubrication system architecture.
4Power
If the transmission is designed for high-stress applications, then the power handling capability is improved, but the component failure rate increases due to premature wear
Solution Approach 1:
The patent applies beforehand cushioning by installing a pilot bearing within the cavity of the splitter shaft before the main bearing operates. This pilot bearing cushions and supports the pilot member, preventing premature failure and extending the life of the main bearing under high-stress conditions.
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 design significantly increases the lifespan and reduces failure rates of transmission components by enhancing structural integrity and efficient lubrication, resulting in a longer-lasting transmission.
Implementation Method 1
A spray orifice can be attached to a terminal end of the tube to direct lubrication directly onto bearings or other components within the center section
Data Source
AI summary
An improved transmission is provided including a splitter shaft having a concentric cavity defined in a distal end thereof and an outer wall surrounding the cavity. The outer wall has an increased thickness in order to reduce failure and fracturing in the outer wall area. A bearing hub adapted for supporting a larger bearing is also provided. The improved transmission may include a system for utilizing existing lubrication lines in order to lubricate a center section of the transmission. The components of the present invention may be provided as part of a kit for retrofitting an existing transmission in order to reduce failures and increase lifespan.