Strain Gauge Pump Housing Deformity Monitoring
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Solution Overview
Problem
Current hydraulic fracturing sites lack reliable data for optimal maintenance and inspection scheduling of equipment, leading to potential operational inefficiencies and fraudulent warranty claims due to the absence of accurate operational data.
Innovation Solution
A universal monitoring system comprising sensors and data analysis logic integrated into various fracturing site equipment, such as positive displacement pumps, to collect and transmit real-time operational data, including pressure, cycle count, and pump speed, using a combination of strain gauges, accelerometers, and other sensors, communicating via wired or wireless protocols for remote analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no monitoring system is installed on equipment, then device complexity is reduced, but reliable operational data cannot be obtained for maintenance scheduling
Solution Approach 1:
The patent employs a universal monitoring device that can be applied to multiple types of fracturing equipment (pumps, mixers, tanks, trailers) with a single standardized design. This multi-functional approach enables reliable data collection across diverse equipment without requiring separate specialized monitoring systems for each device type, thus improving data reliability while controlling system complexity.
Solution Approach 2:
The patent replaces manual inspection and falsifiable paper records with automated electronic sensing systems including strain gauges, accelerometers, pressure sensors, and wireless transmission. This substitution of mechanical/manual processes with electronic automation provides reliable, tamper-resistant operational data while reducing the complexity of manual data collection and verification procedures.
2Measurement precision
If manual inspection and record-keeping are used, then device complexity is minimized, but data accuracy is compromised leading to fraudulent warranty claims
Solution Approach 1:
The monitoring device automatically collects, records, and transmits operational data without human intervention. Sensors continuously measure parameters such as cycle count, pressure, and vibration, and the system autonomously transmits this data via wireless communication. This self-service capability eliminates manual data entry and falsification, ensuring high measurement precision while keeping the system relatively simple through automated operation.
Solution Approach 2:
The patent implements continuous feedback loops where sensors monitor equipment parameters in real-time, transmit data wirelessly to remote locations, and enable immediate analysis. This automated feedback mechanism ensures accurate measurement of operational parameters and provides continuous verification of equipment status, preventing fraudulent claims while maintaining manageable system complexity through standardized protocols.
3Productivity
If comprehensive monitoring is implemented, then maintenance scheduling optimization is achieved, but loss of time for data collection and analysis increases
Solution Approach 1:
The monitoring device continuously collects and pre-processes operational data in real-time during equipment operation, storing cycle counts, pressure readings, and vibration patterns before maintenance is needed. This preliminary data collection and preparation eliminates the need for time-consuming manual data gathering when maintenance scheduling decisions must be made, thus improving maintenance efficiency while minimizing time loss through advance automated data acquisition.
Solution Approach 2:
The patent introduces wireless communication as an intermediary that automatically transmits operational data from the equipment to remote analysis systems. This intermediary eliminates the need for manual data retrieval and initial processing, allowing maintenance personnel to access pre-collected data instantly. The wireless intermediary streamlines the data flow, improving maintenance scheduling productivity while reducing the time invested in data collection and preliminary analysis.
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 timely and optimal maintenance scheduling, reduces fraudulent claims by providing accurate operational data, and improves equipment performance through real-time monitoring and analysis.
Implementation Method 1
A universal monitoring device includes a strain gauge mounted or attached directly to the metal housing of, for example, the fluid end of the pump, and sensitive enough to detect deformity in the pump housing due to the alternating high and low pressures
Implementation Method 2
A universal monitoring device includes an accelerometer configured to sense movement or vibration of the pump and provide this data to a microcontroller
Data Source
AI summary
A universal monitoring system applicable to a variety of hydraulic fracturing equipment includes an accelerometer mounted on a housing of a positive displacement pump and configured to sense a vibration associated with the positive displacement pump on start-up and generate a wake-up signal. A processor is communicatively coupled to the accelerometer and configured to initiate execution upon receiving the wake-up signal. A pressure strain gauge is mounted directly on the pump housing and is configured to sense deformity in the pump housing caused by alternating high and low pressures within the pump housing and generate sensor data. The processor is configured to receive the sensor data from the pressure strain gauge and configured to analyze the sensor data and determine a cycle count value for the positive displacement pump, and there is at least one communication interface coupled to the processor configured to transmit the sensor data and cycle count value to another device.