Axial Thrust Bearing Load Distribution via Segmented Collars
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Solution Overview
Problem
Existing bearing systems for electrical submersible pumps (ESPs) face challenges in properly distributing and regulating axial thrust loads between thrust bearing units, leading to either overloading or uneven wear due to size constraints in wellbores.
Innovation Solution
A bearing system comprising a shaft with axially spaced thrust collars and bearing units, where a mechanical component between the units allows for axial movement and load distribution between the first and second bearing units, ensuring even load distribution and regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thrust bearing unit with larger diameter is used to increase load bearing capacity, then the load bearing capacity is improved, but the wellbore size constraint prevents using larger diameter bearings
Solution Approach 1:
The patent divides a single large-diameter thrust bearing into multiple smaller-diameter thrust bearings arranged in parallel. This segmentation allows the system to achieve the load-bearing capacity of a large bearing while using smaller individual bearing units that fit within the wellbore size constraints. The multiple bearings work together to distribute and support the total thrust load.
2Strength
If multiple thrust bearing units are used to enhance load bearing capacity, then the load bearing capacity is improved, but the thrust load is not properly distributed resulting in overloading or uneven wear
Solution Approach 1:
The patent employs a dynamic load distribution mechanism where the thrust bearing units are connected through a common structure that allows automatic load balancing. As one bearing experiences increased load, the connecting structure adjusts to redistribute the load to other bearings, ensuring even wear and preventing overloading of individual units. This dynamic adjustment maintains reliability while enhancing overall load capacity.
Data Source
AI summary
A system for distributing an axial load between load-limiting thrust bearing units is disclosed. The system includes a shaft disposed at least partially within a housing. Further, the system includes a first thrust collar and a second thrust collar axially spaced apart from each other and coupled to the shaft. The first thrust collar and/or the second thrust collar are disposed within the housing. The system further includes a first bearing unit disposed between the first thrust collar and a first side of the second thrust collar. The first bearing unit is disposed proximate to the first thrust collar. Further, the system includes a second bearing unit disposed proximate to a second side opposite to the first side of the second thrust collar. The system further includes a mechanical component disposed between the first bearing unit and the second bearing unit.