Stator Transducer Embedding in Progressive Cavity Pumps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing stators with profiled helical bores for progressive cavity pumps or motors are complex and do not easily accommodate the integration of transducers, limiting their ability to monitor downhole conditions and perform effectively under high stress and strain, especially in drilling operations where space and durability are critical.
Innovation Solution
A method of forming a stator with a cast material body that includes embedding transducers within the cast material, allowing for the direct insertion of sensors and actuators during the molding process, which simplifies the integration of sensing and actuation capabilities and enhances the stator's durability and monitoring capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining methods are used to produce stators with profiled helical bores, then the stator body can be manufactured with required precision, but the process becomes complex and does not accommodate transducer integration
Solution Approach 1:
The patent combines the stator body manufacturing process with transducer integration by embedding transducers within the cast material during the molding process. This merging of operations eliminates the need for separate machining and transducer installation steps, directly resolving the contradiction between ease of manufacture and device complexity.
Solution Approach 2:
The transducers are positioned and embedded within the cast material before the material fully cures. This preliminary action allows transducers to be integrated during the forming process itself, rather than requiring subsequent complex machining operations, thereby simplifying the overall manufacturing process.
2Reliability
If transducers are integrated into the stator body, then monitoring capabilities are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges transducer integration with the stator manufacturing process by embedding transducers within the cast material during molding. This approach enhances monitoring capability while avoiding the need for separate, complex installation procedures, thus resolving the contradiction between reliability improvement and manufacturing complexity.
3Adaptability or versatility
If complicated machining is performed on the stator body, then transducers can be installed, but the manufacturing cost and time increase
Solution Approach 1:
The patent performs the transducer embedding action preliminarily during the casting process, before the stator body is fully formed and cured. This eliminates the need for subsequent complicated machining operations to create mounting holes or cavities, thereby maintaining manufacturing efficiency while achieving transducer inclusion.
Solution Approach 2:
The patent combines transducer installation with the stator manufacturing process into a single integrated operation. By embedding transducers during the molding process rather than installing them afterward through machining, the patent maintains high productivity while achieving the versatility of transducer inclusion.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a stator (100-1000) with a profiled helical bore (106,206,306,606,706,806,906,1006) having a cast material layer (102;202;302;602;702;802;902;1002) with transducers (104A-104D;304;604A-604D;710;804;904A-904C;1010) disposed therein and describes the methods of forming such stators. Cast material can be fluidic during displacing of a transducer therein. Cast material layer 202 can include housings (218,222) disposed therein and/or a cavity 226 formed therein. Transducer can be a sensor (104A-104C) and/or an actuator 104D. Transducer 804 can extend axially along a length of the stator 800. Transducer or plurality of transducers (904A-904C) can extend along a helical path. Additionally or alternatively, sleeve 1008 can include a transducer 1010.