Variable Torque Converter for Borehole Pumping
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Solution Overview
Problem
Existing fluid pump systems used in borehole operations face challenges in controlling maximum torque delivery and rate of torque change, leading to issues such as engine stalling, pre-ignition knock, and overpressure events.
Innovation Solution
A fluid pump system that incorporates a constant speed power mechanism, a fluid pump, a control system, and a variable torque converter. The variable torque converter reduces the torque generated by the constant speed power mechanism before it is used by the fluid pump, allowing for controlled torque delivery and adjustment based on input parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant speed power mechanism is used to power the pump, then the power source is simple and reliable, but the torque delivery cannot be controlled and sudden load changes can stall the engine or cause pre-ignition knock
Solution Approach 1:
A torque converter is introduced as an intermediary device between the constant speed power mechanism and the pump. This torque converter includes a pump impeller coupled to the power mechanism and a pump runner coupled to the pump, with torque conversion fluid circulating between them. The fluid coupling allows torque to be transferred while enabling control of torque delivery characteristics, resolving the contradiction between engine reliability and torque control capability.
2Device complexity
If the pump is directly coupled to the power mechanism, then the system is simple, but sudden increases or decreases in load can cause engine stalling or pre-ignition knock
Solution Approach 1:
The torque converter acts as a buffer between the power mechanism and pump, using fluid coupling to smooth out sudden load changes. The circulation of torque conversion fluid between the impeller and runner creates a decoupling effect that prevents direct transmission of shock loads, thereby improving operation stability without significantly increasing system complexity.
Solution Approach 2:
The torque converter provides beforehand cushioning by absorbing and dampening load variations before they reach the power mechanism. The fluid coupling inherently provides cushioning against sudden load increases or decreases, preventing engine stalling or pre-ignition knock before these events can occur.
3Productivity
If maximum torque is always delivered to the pump, then the pumping efficiency is maximized, but overpressure events can occur during certain operations
Solution Approach 1:
The torque converter enables dynamic torque adjustment based on operating conditions. By varying the fluid coupling characteristics and torque conversion ratio, the system can deliver maximum torque when needed for pumping efficiency while reducing torque delivery when overpressure conditions exist, thus resolving the contradiction between productivity and overpressure risk.
Solution Approach 2:
The torque converter allows change in torque transmission parameters based on system needs. The fluid coupling characteristics can be adjusted to modify the torque conversion ratio, enabling the system to adapt torque delivery to match actual pumping requirements and avoid overpressure events while maintaining high pumping efficiency when appropriate.
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 system enables efficient and safe operation by allowing for precise control of torque delivery, reducing the risk of engine stalling and overpressure events, and minimizing wear and tear on equipment.
Implementation Method 1
a variable torque converter capable of reducing the torque generated by the constant speed power mechanism using a torque oil
Data Source
AI summary
When conducting borehole operations, such as drilling, injection, or hydraulic fracturing, using a variable torque converter to reduce the torque force output of a constant speed engine or motor would enable a more efficient use of resources and lower costs due to less wear and tear on equipment. The fluid pump system at the borehole can utilize the variable torque converter, receiving operating commands from a control system, to reduce the torque delivered to the fluid pump to maintain operational parameters, such as a rate of change of load on the engine or motor, a maximum fluid pressure measured at the pump or downhole, or other operational parameters. The variable torque converter can be part of a transmission system, or be located before or after the transmission system. The variable torque converter can utilize torque oil or a magnetic system to control the torque force being delivered.