Abstract:
A pumping unit has a drive train comprising a very large mass including large diameter series connected sheaves, one of which is a large crank sheave. The crank sheave is directly connected to a pitman arm which oscillates a walking beam, which in turn reciprocates a horsehead attached to a bridle. The bridle is connected to a polished rod associated with a downhole pump. The crank wheel, pitman arm, and rocking beam are arranged respective to one another to cause the tail bearing to oscillate predominantly in the second quadrant, and to cause the center of gravity of the pitman arm to be located predominantly between the vertical axis of the crank wheel and the Samson post bearing. The geometry of the crank wheel, pitman arm, and rocking beam provides substantially constant, positional of the polish rod on the downstroke, with rapid positional occurring at peak polish rod velocity, which causes a longer downhole pump stroke because of the induced elongation of the sucker rod string.

Description:
RELATIONSHIP TO OTHER PATENT APPLICATIONS 
     This patent application is a continuation of 550,452, now abandoned, filed Nov. 8, 1963, which was a continuation in part of patent application Ser. No. 237,533; filed Feb. 23, 1981, now abandoned. 
     Subsequently another patent application, also entitled &#34;Belt Driven Pumping Unit&#34; 941,582, has been acknowledged as filed Nov. 26, 1984, disclosing the subject matter that is common to the two prior applications. 
    
    
     BACKGROUND OF THE INVENTION 
     Most prior art methods of driving a pumping unit usually include a gear box or a chain and sprockett arrangement for part of the drive train. Heretofore, it has been impractical to employ endless belts made of fabric and rubber-like material because the structural integrity of these prior art endless belts unduly limit the torque associated with the very low rpm requirements of a pumping unit. 
     Recently, Goodyear Rubber Company has marketed a new belt called &#34;Torque Team Plus&#34; which overcomes the problem of stretching at low rpm torque capabilities. These improved belts exhibit good structural characteristics in transferring torque at the low rpm requirements of a pumpjack unit. 
     The present invention provides an efficient belt driven pumping unit which combines the function of a crank arm, counter-weights, support, and sheave all into one common unit, thereby reducing production cost and space requirements, and providing a new pumpjack unit which has many unobvious and unexpected advantages over the prior art. 
     THE PRIOR ART 
     The following is a list of the prior cited references: 
     Eyler et al, U.S. Pat. No. 3,406,581 
     Carlson et al, U.S. Pat. No. 4,238,966 
     Jones, U.S. Pat. No. 4,051,736 
     Keltner, U.S. Pat. No. 2,526,561 
     Hebbard, U.S. Pat. No. 1,286,617 
     Nickerson et al, U.S. Pat. No. 162,406 
     Wright, U.S. Pat. No. 713,269 
     Lloyd, U.S. Pat. No. 1,257,897 
     Malbaff, U.S. Pat. No. 1,501,226 
     Bier, U.S. Pat. No. 2,256,605 
     Kane, U.S. Pat. No. 2,805,580 
     Callahan, U.S. Pat. No. 1,564,320 
     Taylor, Sr., U.S. Pat. No. 2,244,812 
     Vaughn, U.S. Pat. No. 1,865,290 
     Archer et al, U.S. Pat. No. 1,931,747 
     Chastain, U.S. Pat. No. 3,222,940 
     Maier, U.S. Pat. No. 2,153,094 
     Keefover, U.S. Pat. No. 1,561,723 
     Smith et al, U.S. Pat. No. 1,781,347 
     Kane, U.S. Pat. No. 2,805,580 
     Ross, U.S. Pat. No. 3,006,201 
     Ross, U.S. Pat. No. 3,221,569 
     Brown, U.S. Pat. No. 3,234,723 
     Grable, U.S. Pat. No. 4,024,913 
     Chancellor, U.S. Pat. No. 4,121,471 
     Carlson, et al 966; Eyler et al 581; Nickerson 406; Hebbard 617; Lloyd 897; Wright 269; and Malbaff 226 appear to be the most pertinent of the above cited prior art; however, these prior art references fail to disclose the pumpjack unit claimed herein. 
     See also the three sheet brochure entitled &#34;Grooves, Inc. Model 114&#34; distributed probably about September/October 1982, referring to type BW pumping units. 
     SUMMARY OF THE INVENTION 
     A belt driven pumping unit comprising a belt driven large flywheel sheave connected to a large crank sheave by another endless belt. A walking beam is journaled to a Sampson post and connected to the crank sheave by a Pittman arm, so that the crank sheave oscillates the walking beam which in turn rocks a horsehead. A bridle connected to the horsehead and to a polish rod reciprocates a downhole pump. 
     The flywheel sheave comprises a hub supported from a flange by a plurality of spokes. The spokes are formed by adjacent spaced apart cutouts. The crank sheave also includes a hub spaced from a flange by means of a plurality of spokes. The cutouts from each of the sheaves are accumulated and utilized as a counter-weight within the crank sheave. 
     The crank of the crank sheave is located on only one side of the sheave, and in a manner which enables power to be transmitted from the outer surface of the crank sheave flange, through the crank and Pittman arm, and into the walking beam and horsehead, thereby providing a high torque for the pumping unit, while eliminating the necessity of large power transmission through a hub, key, or shaft mechanism. The crank sheave is journaled on the side opposite the crank. This new combination of elements provides unexpected advantages in the pumping unit described herein. 
     The flywheel sheave, which is the first large sheave in the power train, acts as an energy storage and energy dampening arrangement which provides a smooth flow of power throughout the pumping system. Because of this flywheel effect, an overall cyclic load factor of the system is achieved and a smaller horsepower motor may be installed in order to attain the same motion comparable to that of a conventional pumping unit. 
     The cutouts which form the spokes in the flywheel sheave and crank sheave are utilized as the counterweights on the crank sheave. 
     The dimensional relationship between the crankshaft, tailbearing center, Sampson shaft center, and Pittman arm link results in a complex motion that generates a more rapid downstroke and a slower upstroke, wherein the crank sheave turns approximately 165 degrees, for example, to achieve the downstroke and approximately 195 degrees, for example, for the upstroke. This dimensional relationship provides a constant acceleration of the polish rod on the downstroke, with rapid deceleration occurring at the peak polish rod velocity, which effectively elongates the downhole pump stroke. These desirable characteristics provide unforeseen and unexpected advantages by reducing the peak acceleration loads on the sucker rod, which in turn decreases sucker rod fatigue while increasing sucker rod life. THe geometry of the coacting components of the pumpjack unit causes the tailbearing to remain predominantly in the second geometrical quadrant, and also causes the center of gravity of the Pittman arm to desirably increase the structural unbalance on the upstroke and decrease on the downstroke of the system. 
     Accordingly, a primary object of the present invention is the provision of a belt driven pumping unit which utilizes large belt driven sheaves in the power train. 
     Another object of the present invention is the provision of an efficient and economical pumpjack unit having a belt driven crank sheave which provides the function of a crank arm, counter weight, support, and sheave, all combined into one common member, thereby reducing the production cost and space requirements. 
     Still another object of the present invention is the provision of a power train for a pumping unit which includes two large belt driven sheaves, each having spokes formed thereon, and wherein the drops from spoking the sheave are used as a counterweight on the crank sheave, thereby reducing material waste. 
     A further object of this invention is the provision of an improved belt driven power train for a pumping unit which utilizes a large relative fast turning flywheel sheave for storing high rotational energy in order to drive a relatively slow turning, large crank sheave, which in turn reciprocates a horsehead of a walking beam. 
     A still further object of the present invention is the provision of a pumping unit having a tailbearing which operates predominantly in the second geometric quadrant, and which has a Pittman arm arranged so that the center of gravity thereof adds to the structural unbalance on the upstroke and decrease on the downstroke of the pumping unit. 
     An additional object of this invention is to provide a pumping unit with a polish rod velocity profile which is substantially of constant acceleration up to the peak velocity, and which then rapidly decelerates in a manner to stretch the rod string, to thereby effectively elongate the downhole pump stroke. 
     These and various other objects and advantages of the invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings. 
     The above objects are attained in accordance with the present invention by the provision of a combination of elements which are fabricated in a manner substantially as described in the above abstract and summary. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a belt driven pumpjack unit, made in accordance with the present invention; 
     FIG. 2 is a side elevational view of a pumping unit such as disclosed in FIG. 1 and having a modified bridle included thereon; 
     FIG. 3 is a top plan view of the pumping unit disclosed in FIG. 1; 
     FIG. 4 is an end view of the pumping unit disclosed in FIGS. 1 and 3; 
     FIG. 5 is an enlarged, side elevational view of part of the apparatus disclosed in the foregoing figures; 
     FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5; 
     FIGS. 7, 9, 11, and 13 diagrammatically illustrate a side view of various different types of pumpjack units; 
     FIGS. 8, 10, 12, and 14, respectively, diagrammatically illustrate the polish rod velocity profile obtained from the pumpjack units of FIGS. 7, 9, 11, and 13, respectively; and, 
     FIGS. 15-19 are diagrammatically illustrations of the pumpjack unit seen in FIGS. 1-14, shown in various different positions of operation. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In FIGS. 1-4 of the drawings, there is disclosed a pumping unit 10 supported from a base or frame 12. The unit includes a Sampson post 14 which supports a walking beam 15 having a horsehead 16 formed at one end thereof. A Sampson shaft center 18 supports a medial portion of the walking beam 15 in journaled relationship therewith, while one end of a Pittman arm 20 is journaled to the tailbearing center 22 of the walking beam. 
     A wrist pin center 24 is journaled to the other end of the Pittman arm. The wrist pin is connected to crank 26, which in turn is connected to a very large diameter crank sheave 28. A very large diameter flywheel sheave 30 is operatively positioned in spaced relationship respective to a motor 32 and to the before mentioned crank sheave. 
     As best seen illustrated in FIGS. 1 and 2, the crank sheave includes removable counterweights, 34 and 36, positioned at an angle of approximately 50° respective to one another and at an angle of approximately 75° respective to the wrist pin center 24. The relative location of the counterweights can be changed respective to one another and the wrist pin to achieve other pumping characteristics, if desired. 
     As seen in FIGS. 5 and 6, cutouts 38 form the illustrated spokes 40 of the crank sheave, and provides the before mentioned counterweights 34 and 36. Bolts 42 are diametrically received within radial slot 44 for adjustably anchoring the counterweights 34 and 36 to the crank sheave. The position of the slots and counterweights may be varied to optimize the maximum counterweight effect achieved by the employment of minimum counterweights 34 and 36, or to adjust the relative angular position of the cutouts respective to the crank pin 24. 
     The crank sheave 28 includes a hub 46. A crank 26, in the form of a radial arm, is attached to and extends from the hub radially, and extends outwardly into attached relationship respective to the sheave flange 50. The sheave flange has an outer peripheral surface which may be grooved at 52, if desired, complementary respective to an endless belt 70. A jacking bolt 54 can be used to position the counterweights along the radial slot 44, if desired. 
     Looking again now to FIGS. 1 and 3, in conjunction with other figures of the drawings, it will be noted that spaced upright standards 56 and 58 are provided with journals 60 and 62 for receiving opposed ends of the flywheel sheave shaft in low friction relationship therewith. Small diameter belt 64 connects the flywheel sheave to the motor 32. Small sheave 66 (FIG. 3) is affixed to the flywheel sheave shaft 68 for causing the endless belt 70 to drive the crank sheave. 
     The crank sheave includes spaced journals 72 located on only one side of the crank sheave which receives crank sheave shaft 74 in low friction relationship therewith so that the crank sheave is journaled in supported relationship respective to the main frame 12. The other side of the crank sheave is provided with the crank pin 24. 
     As seen in the embodiment of FIG. 1, a bridle is attached to the horsehead and to a clamp 78, made in accordance with the present invention. The bridle receives a polish rod 80 which extends through a packing gland and into a wellhead 82, in a manner known to those skilled in the art. 
     Brake assembly 84 is connected to frictionally engage the opposed faces of the flywheel sheave flange, so that the pumping apparatus can be secured against rotation when the unit is not in operation. 
     In the embodiment of FIG. 2, the bridle is seen to include a cable 86 having one end roved about the horsehead 16 with the other end being connected to a pulley 87 by means of a connector 88. The pulley 87 is pinned to the connector 88 by a pin 89. The pulley 87 moves from position 90 to position 90&#39; as the horsehead 16 oscillates in a vertical plane. 
     A flexible polish rod 91 has one marginal end 92 roved about pulley 87 and pulley 94. The terminal end of the polish rod 91 can be directly attached to the main frame, but preferably is attached to a drum 95. Drum 95 is attached to the frame 12, and when the drum is rotated, the effective length of the flexible polish rod 91 is changed. The other marginal end 96 of the flexible polish rod 91 extends through a packing gland 98 of wellhead 100. The flexible polish rod 91 is available from Dupont Corp. as a Kevlar ™ rope which is subsequently coated with plastic or neoprene rubber, or the like. 
     The geometry of the horsehead, rocking beam, Sampson shaft center, and tailbearing center are arranged respective to one another and to the Pittman arm to achieve a motion which reciprocates the rod string more rapidly on the downstroke as compared to the upstroke. The crank sheave in the illustrated example of FIGS. 1-4 turns about 165° on the downstroke and about 195° on the upstroke. This characteristic can be changed to achieve variation in the relative stroke time intervals as follows: 
     The wrist pin center 24, crank shaft center 74, and tailbearing center 22 lie along a common line when viewed at the end of the upstroke and at the end of the downstroke. These two common lines converge at a location 74. On the downstroke, the tailbearing center 22 moves towards a vertical line drawn through the Sampson shaft journal 18 an amount depending upon the relative position or location of the centers 18, 22, 24, and 74. This relationship determines the magnitude of the displacement angle B of the tailbearing, which in turn determines the relative amount of rotation of the crank sheave which is required to achieve the upstroke and downstroke of the polish rod. The tailbearing angle can therefore be changed to reflect an increase or decrease in the 165°/195° relationship; however, it has been found that 165°±10° and 195°±10° is the optimum relationship when all of the variables are considered, and 165/195 represents an efficient compromise. 
     The above described unique kineomatic (geometry) motion offers the advantage of a varying structural unbalance. As the crank wheel rotates (ccw with the wellhead to the right) from approximately the 320° to 150° position (upstroke) it moves the center of gravity of the Pittman arm away from the Sampson shaft, increasing the structural unbalance. As the crank wheel rotates from the 150° to 320° position during the downstroke, the center of gravity of the Pittman arm is moved toward the Sampson shaft. As the structural unbalance increases, the need for counterweight decreases and vice versa. One reason for moving the center of gravity of the Pittman arm so drastically is to provide for significant variance in the counterweight effect as it is influenced by the structural unbalance. 
     During the rod upstroke where counterweight effect is needed to help reduce power required to lift the rods, the result of increased structural unbalance is felt. On the downstroke when the counterweight is being lifted by rod fall and the prime mover, the decreasing structural unbalance is felt thereby reducing power consumption. The unique result of this geometrically controlled varying structural unbalance is that the pump unit requires less power from the prime mover for any given pumping condition. 
     FIGS. 7, 9, 11, and 13 illustrate various well known types of pumpjack units found in the industry. FIGS. 8, 10, 12, and 14, respectively, diagrammatically illustrate a typical plot of the polish rod velocity generated by the pumpjack unit of FIGS. 7, 9, 11, and 13, respectively. The diagrammatical representation of FIG. 7 is a prior art pumpjack unit having a cross yoke bearing 122 which moves approximately the same distance above and below the Sampson shaft and thereby describes angle B; and, imparts the polish rod with a velocity such as described by the plot of FIG. 8. 
     The pumpjack unit of FIG. 9 has a tailbearing 222 which moves substantially the same vertical distance respective to the Sampson post bearing 218; and, describes the angle B. The polish rod velocity generated by the pumpjack unit of FIG. 9 is seen in the plot of FIG. 10. 
     The pumpjack unit of FIG. 11 is made in accordance with the present invention, and has a tail bearing 22 which describes angle B. The polish rod velocity generated by the pumpjack unit of FIG. 11 is set forth in FIG. 12. It will be noted that the tail bearing 22 moves predominantly within the second geometrical quadrant, and describes a polish rod velocity curve seen in FIG. 12. 
     The pumpjack unit diagrammatically set forth in FIG. 13 has a tail bearing 322 which describes angle B during its movement; and, the polish rod velocity generated by the apparatus seen in FIG. 13 is set forth in the plot seen in FIG. 14. 
     In FIGS. 8, 10, 12, and 14, the horizontal axis is related to the non-dimensional polish rod velocity, while the vertical axis illustrates the polish rod position, and specifically is the percentage of polish rod position off the bottom. The downstroke commences at 101, continues at 102 and terminates at 103. The upstroke commences at 103, continues at 104, and terminates at 101. Hence, the curve to the right of the vertical axis represents the downstroke, while the curve to the left of the vertical axis illustrates the upstroke. 
     As seen in FIG. 12, at 101 and 102, the accelcration of the polish rod on the downstroke is relatively constant as compared to the prior art. The rapid deceleration starting at the peak velocity of the polish rod causes the clasticity of the rod string to extend the stroke of the downhole pump to a value not realized by the prior art. 
     In the plot of FIG. 12, at the beginning 101 of the downstroke, the polish rod has a relatively low velocity and constrant acceleration, wherein the polish rod velocity steadily increases to a maximum velocity of 1.39, which is approximately 32% from the bottom of the downstroke. The peak downward velocity therefore occurs at a different location respective to the plot set forth in FIGS. 8, 10, and 14. At a location approximately 32% from the bottom of the downstroke, the polish rod velocity is therefore greater than would be expected in the prior art pumpjack units of FIGS. 7, 9, and 13. The polish rod at approximately 32% off bottom rapidly decelerates, with the downstroke ending at position 103. The polish rod velocity achieves a maximum value of 0.88 on the upstroke. Accordingly, the velocity on the downstroke as compared to the velocity on the upstroke is a factor of 1.39÷0.88. This feature of the invention tends to encourage a longer downhole pump stroke, and results in higher production per stroke. This unique and unexpected action takes advantage of the elasticity of fiberglass and similar rod strings to increase the downhole pump stroke length. 
     The above features of the present pumpjack unit yields a lower maximum torque factor on the upstroke as compared to other pumpjack units of similar design. The lower the torque factor on the upstroke, the greater the mechanical advantage of the pumpjack unit. Low torque factors on the upstroke indicate that the prime mover is required to produce less torque, and thereby consume less power. The peak torque requirement is less than would otherwise be required, and a smaller amount of counterbalance weight is required to properly balance the unit. The reduction in counterbalance weight requires less power to lift the same weight on the downstroke. The lower torque on the upstroke provides a significant increase in efficiency and reduction in operating costs. 
     FIGS. 15-19 illustrate the varying geometry of the pumpjack unit previously seen illustrated in FIGS. 1-4. In FIG. 15, the center of gravity of the Pittman arm 20 describes the dot-dash path indicated by numeral 111. The horizontal axis H and vertical axis V drawn through the Sampson post bearing describe quadrants 1, 2, 3, and 4. It will be noted in FIG. 15-19 that the tail bearing describes an angle B of 105 degrees, and operates substantially within the second geometrical quadrant. FIG. 15 illustrates the tail bearing in its lowermost position, FIG. 16 illustrates the tail bearing location half-way through the downstroke, FIG. 17 illustrates the position of the tail bearing in the full downstroke position, FIG. 18 illustrates the position of the tail bearing 1/3 of the way through the upstroke, and FIG. 19 illustrates the position of the tail bearing 2/3 through the upstroke. 
     The location of the Pittman arm center of gravity describes a path 111 which is predominantly offset laterally respective to a vertical axis drawn through the crank sheave axis, and preferably is predominantly located between the Sampson post bearing 18 and the crank sheave axis. 
     The term &#34;structural unbalance&#34; as used herein is the magnitude of the weight which must be added to the bride to provide a state of equilibrium. It will be noted that this magnitude of structural unbalance changes with the changing geometry of the present novel pumpjack unit. 
     The maximum structural unbalance on the upstroke is at least three times greater than the minimum structural unbalance on the downstroke, as a result of the geometry of numbers 18, 22 24, and 74, which are arranged respective to one another whereby the center of gravity of the Pittman arm always moves towards the vertical axis of the Sampson post bearing on the downstroke, and moves away from the Sampson post bearing on the upstroke.