Recirculating Superhard Bearing Assembly for Pump Thrust Wear
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Solution Overview
Problem
Conventional thrust bearing assemblies in horizontal surface pumps experience rapid wear and contamination issues due to high rotational speeds and loads, leading to frequent failures and increased maintenance costs, as they lack sufficient surface area and are prone to oil deterioration.
Innovation Solution
The use of bearing assemblies with superhard materials, such as polycrystalline diamond compacts, integrated with a recirculation system that utilizes process fluid for cooling, lubrication, and flushing, reducing the need for regular oil checks and extending the life of the bearings by controlling fluid flow and preventing overheating or erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrodynamic bearings and roller element bearings are used in thrust chambers, then the pump can operate with thrust support, but the bearings wear out quickly due to high rotational speeds and loads
Solution Approach 1:
The patent changes the material parameter of the bearing elements from conventional materials to superhard materials (such as polycrystalline diamond compact or cubic boron nitride), which fundamentally alters the wear resistance and load-bearing capabilities, enabling the bearings to withstand high rotational speeds and loads without rapid wear
Solution Approach 2:
The patent employs composite material structures where superhard material bearing elements are integrated with metal substrates or housings, combining the extreme hardness and wear resistance of superhard materials with the toughness and structural integrity of metals, creating bearings that can survive harsh operating conditions
2Force
If conventional bearings with limited surface area are used, then the device structure remains simple, but the bearings cannot carry the required loads
Solution Approach 1:
The patent transitions from conventional point or line contact bearings to bearings with extended surface areas through dimensional expansion, such as using thrust bearing plates with large contact surfaces or journal bearings with extended cylindrical surfaces, thereby increasing the load-distributing area to handle high loads
3Reliability
If conventional thrust chambers with oil lubrication are used, then the bearings can function, but oil contamination and deterioration occur leading to bearing failure
Solution Approach 1:
The patent utilizes hydraulic principles by introducing a recirculating fluid system where process fluid or dedicated lubricant is pumped through channels to continuously flush and cool the superhard bearing elements, removing contaminants and heat to prevent oil deterioration and bearing failure
Solution Approach 2:
The patent implements a recirculating fluid system where the lubricating fluid is continuously circulated, filtered to remove contaminants, and reused, thereby preventing oil contamination accumulation and extending bearing life through continuous cleaning and thermal management
4Reliability
If planned preventative maintenance with oil replacement is implemented, then bearing deterioration is controlled, but equipment uptime is reduced and maintenance expenses increase
Solution Approach 1:
The patent implements a self-lubricating and self-cooling system where the recirculating fluid continuously cleans and cools the bearing elements, and the superhard materials inherently resist wear without requiring frequent external intervention, enabling the bearings to operate extended periods without maintenance shutdowns
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
The solution provides extended bearing life, reduced maintenance costs, and improved operational efficiency by using process fluid for thermal regulation and lubrication, while minimizing contamination risks and wear, thus enhancing the reliability and uptime of horizontal surface pumps.
Implementation Method 1
a recirculation line extending into the bearing housing... positioned to pass the fluid through the one or more bearing element
Implementation Method 2
a fluid pathway between the fluid inlet and the fluid outlet... recirculation line is positioned to pass the fluid through the one or more bearing element
Implementation Method 3
The one or more bearing element may comprise a superhard material... configured to support the shaft in an axial and radial direction
Implementation Method 4
recirculation line is positioned to pass the fluid through the one or more bearing element
Implementation Method 5
The one or more bearing element may comprise a superhard material and a shaft extending through at least a portion of the bearing housing, where the shaft is configured to be driven by a prime mover
Data Source
AI summary
Bearing assemblies, apparatuses, systems, and methods include bearing assemblies having one or more bearing element in a bearing housing for supporting a shaft extending through at least a portion of the bearing housing. The bearing assembly including a recirculation line for delivering fluid into the bearing housing at a location separate from a fluid inlet of the bearing housing to at least partially thermally regulate, lubricate, and/or flush the one or more bearing elements during operation of the shaft.