Multi-part Valve Assembly Friction Welding Cost Reduction
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Solution Overview
Problem
Conventional valve assemblies for reciprocating positive displacement pumps, such as mud pumps and fracking pumps, are costly to manufacture due to the use of expensive materials and processes, and often require multiple components that increase assembly complexity and potential failure points, limiting cost-effective and efficient solutions.
Innovation Solution
A multi-part valve assembly using a combination of inexpensive pieces made from high carbon or high carbon alloy steel, which can be induction or flame hardened, assembled using solid state inertia or friction welding, and featuring a retaining pin, guide, valve, insert, and retainer cap configuration that eliminates the need for extensive heat treatment and carburization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valve assemblies use expensive materials and multiple components, then durability and reliability are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The valve assembly is divided into multiple components (valve body, valve member, guides, springs, seals) that can be manufactured separately using cost-effective processes and then assembled. This segmentation allows each component to be optimized independently while maintaining overall reliability through proper design of connections and interfaces.
Solution Approach 2:
Multiple functional components are combined into integrated assemblies where possible, such as combining guides with valve members or integrating sealing elements into component structures. This reduces the total number of separate parts while maintaining the necessary functional complexity and reliability.
2Strength
If conventional valve assemblies use expensive materials and heat treatment processes, then hardness and wear resistance are improved, but manufacturing cost increases
Solution Approach 1:
Hardness and wear resistance are applied only to specific contact surfaces and areas subject to wear through selective heat treatment or surface hardening processes, rather than treating entire components. This local quality approach maintains the necessary durability while significantly reducing manufacturing costs compared to full-component heat treatment.
Solution Approach 2:
The patent employs various material parameter changes and selection strategies, using different steel grades and heat treatment parameters optimized for specific component requirements. This allows achieving necessary hardness and wear resistance at lower cost by matching material properties precisely to functional needs rather than using expensive materials throughout.
3Strength
If conventional valve assemblies require carburization and extensive heat treatment, then surface hardness is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent extracts and eliminates the carburization process from the manufacturing sequence, replacing it with more efficient heat treatment methods that achieve the necessary surface hardness without the extended time and cost associated with conventional carburization. This extraction of the unnecessary process step directly improves manufacturing productivity.
Solution Approach 2:
The patent skips the lengthy carburization process entirely and uses accelerated heat treatment methods that achieve comparable or sufficient surface hardness in significantly reduced time. This rushing through the manufacturing process by eliminating non-essential steps improves overall production efficiency and reduces manufacturing costs.
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 reduces manufacturing costs by using easier-to-machine materials, eliminates the need for costly heat treatment processes, and simplifies assembly while maintaining the necessary hardness only in specific areas, enhancing the durability and efficiency of the valve assembly.
Implementation Method 1
assembled using solid state inertia or friction welding
Implementation Method 2
assembled using solid state inertia or friction welding
Implementation Method 3
made from high carbon or high carbon alloy steel, which can be induction or flame hardened
Implementation Method 4
made from high carbon or high carbon alloy steel, which can be induction or flame hardened
Data Source
AI summary
The present disclosure discloses a multi-component valve system for use in pumps such as fracking pumps for use in subterranean resource production. The assembly includes a retaining pin having a retaining cap on its upper end. Located on the retaining pin are an insert retainer, an insert beneath the insert retainer, a valve beneath the insert, and a guide beneath the valve. The guide has a generally truncated pyramid shape, and a central portion on its upper end. The central portion is centered on the retaining pin. The retaining pin has an expanded lower end to secure the valve assembly together.