Patent Publication Number: US-2020277951-A1

Title: Pumping system with actuator

Description:
FIELD 
     The present disclosure relates generally to pumping systems. In particular, the present disclosure relates to pumping systems with an actuator to reduce a resistive torque load while a transmission shifts gears. 
     BACKGROUND 
     Motors can be used to provide power to pumps. To control or increase the speed of the pump, transmissions can be used to shift gears. When pumping fluid, the fluid flows through an entry valve into a recess which includes a plunger. The entry valve then closes, the plunger compresses the fluid, and the fluid flows through an exit valve under pressure. During such a procedure, the fluid imparts a resistive torque load on the transmission. As such, when increasing power and shifting gears under load, heat may be generated in the transmission converter and clutches, and the life of the transmission may be shortened. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein: 
         FIG. 1A  is a diagram illustrating a perspective view of an exemplary pumping system according to the present disclosure; 
         FIG. 1B  is a diagram illustrating a partial cross-sectional view of the pumping system of  FIG. 1A  according to the present disclosure; 
         FIG. 2A  is a diagram illustrating an exemplary pump with an entry valve in an open configuration according to the present disclosure; 
         FIG. 2B  is a diagram illustrating an exemplary pump with an entry valve in a closed configuration according to the present disclosure; 
         FIG. 3A  is a diagram illustrating an exemplary pump with an actuator actuated such that an entry valve is transitioned to an open configuration; 
         FIG. 3B  is a diagram illustrating an enlarged view of the entry valve and the actuator of  FIG. 3A ; and 
         FIG. 4  is a flow chart of a method for utilizing an exemplary pumping system. 
     
    
    
     DETAILED DESCRIPTION 
     It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the examples described herein. However, it will be understood by those of ordinary skill in the art that the examples described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure. 
     The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. 
     Disclosed herein is a pumping system. The pumping system includes a motor coupled with a transmission having a plurality of gears to provide power to a pump. The pump includes a housing with a chamber. A plunger is coupled with the motor and is translatable into and out of the chamber. The pump also includes an entry valve at an inlet to the chamber and an exit valve at an outlet to the chamber. The entry valve is transitionable between an open configuration where fluid can pass through the inlet into and out of the chamber and a closed configuration where fluid cannot pass through the inlet. The pump also includes an actuator which can transition the entry valve to the open configuration and/or hold the entry valve in the open configuration until released, independent of the pressure changes caused by the movement of the plunger. When the actuator is not actuated, the pump operates as normal. For example, as the plunger retracts from the chamber, a vacuum in the chamber is created, and the entry valve transitions to the open configuration. Fluid then flows through the inlet into the chamber. As the plunger extends into the chamber, the fluid is compressed, the entry valve closes, and at a predetermined pressure, the fluid flows through the outlet and the exit valve. 
     When the actuator is actuated, the entry valve is transitioned to the open configuration and/or held in the open configuration until the actuator is released, independent of the pressure changes caused by the movement of the plunger. As such, the fluid can flow into and out of the chamber through the inlet such that a resistive torque load created by the compression of the fluid is reduced. As such, the transmission can shift gears without experiencing as high, or none, of the resistive torque load. The transmission life can thus be extended. 
     The system can be employed in an exemplary pumping system  1  shown, for example, in  FIGS. 1A and 1B .  FIGS. 1A and 1B  illustrate a pumping system  1  which includes a fluidic channel  14 . The fluidic channel  14  can be a pipe, a wellbore, a hose, or any other suitable channel through which fluid can be transported. The fluidic channel  14  as illustrated in  FIGS. 1A and 1B  has a substantially circular cross-sectional shape, but can be any suitable shape such as rectangular, triangular, ovoid, or irregular shape. The fluidic channel  14  can be made of metal, plastic, or any suitable material such that the material does not burst from the pressure of the fluid. The fluidic channel  14  has one or more openings  15  through which fluid can flow. The openings  15  as illustrated in  FIGS. 1A and 1B  are substantially circular, but can be any suitable shape such as rectangular, triangular, or ovoid. While  FIGS. 1A and 1B  show  5  openings  15 , the fluidic channel  14  can have one, two, or more openings  15  as desired. The openings  15  of the fluidic channel  14  permit fluidic communication from the fluidic channel to the pump  100 . As illustrated in  FIGS. 1A and 1B , the fluidic channel  14  provides fluid to the pump  100 , and the pump  100  pumps the fluid to another avenue (not shown) through an outlet  22 . 
     A motor  10  (shown in  FIG. 1A ) is provided to impart power to the pump  100 . The motor  10  can be, for example, a diesel engine. In other examples, the motor  10  can be other suitable motors, for example, electric motors, natural gas or gasoline engines or motors  10  with less torque characteristics than diesel engines. For example, the motor  10  can be diesel engine. The motor  10  is coupled with a transmission  12  which has a plurality of gears  13 . The transmission  12  provides controlled application of the power from the motor  10 . The transmission  12  uses the gears  13  to convert the output from the motor  10  to varying speed and torque to the pump  100 .  FIG. 1A  illustrates a simple motor  10  and transmission  12  system, however any suitable motor  10  and transmission  12  system can be utilized. The transmission  12  provides different gears  13  with different gear ratios such that varying speed and torque can be provided to the pump  100 . Switching to the desired gears  13  can be controlled automatically or manually. Switching gears  13  includes connecting gears  13  with different gear ratios to the motor  10 . In doing so, different gears  13  will engage one another. 
     The motor  10  is coupled with a plunger  104  (shown in  FIGS. 1B-3B ) in the pump  100  which is translatable along a longitudinal axis by the motor  10  into and out of a chamber  102 . The translation of the plunger  104  into and out of the chamber  102  creates pressure changes within the chamber  102 . For example, when the plunger  104  retracts from the chamber  102 , the pressure within the chamber is decreased, and when the plunger  104  translates into the chamber  102 , the pressure within the chamber  102  is increased due to compression of fluid within the chamber  102 . 
     As shown in  FIG. 1B , the pump  100  has a housing  101 . The housing  101  of the pump  100  can be made of metal, plastic, or any other suitable material or combination of materials. Fluid flows from the fluidic channel  14  and through the opening  15  of the fluidic channel  14  to the pump  100 . The pump  100  includes an entry valve  106  at an inlet  20  in the housing  101  to the chamber  102 . The entry valve  106  can be transitionable between an open configuration permitting fluidic communication through the inlet  20  to the chamber  102  and a closed configuration preventing fluidic flow through the inlet  20  to the chamber  102 . The entry valve  106  can be a passive pressure valve that transitions to the open configuration when the pressure outside of the chamber  102  is greater than the pressure inside of the chamber  102 . When the pressure outside of the chamber  102  is less than the pressure inside the chamber, the entry valve  106  can transition to the closed configuration. Other suitable entry valves  106  can also be utilized, so long as the entry valve  106  is operable to transition between an open configuration and a closed configuration. 
     The pumping system  1  also includes an actuator  200 . The actuator  200  is coupled with the entry valve  106 . The actuator  200  is operable to hold or maintain the entry valve in the open configuration independent of the pressure changes between inside and outside the chamber  102 . The actuator  200  can be positioned within the pump  100  or, as illustrated in  FIGS. 1A and 1B , outside of the pump  100 , so long as the actuator  200  is coupled with the entry valve  106 . 
       FIGS. 2A and 2B  illustrate the pump  100  operating as normal, for example when the actuator  200  is not actuated such that the actuator  200  is not holding the entry valve  106  in the open configuration. 
     In  FIG. 2A , the plunger  104  is retracted from the chamber  102 . The plunger  104  is opposite an abutment  1040  across the chamber  102 . As the plunger  104  is retracting, the pressure inside the chamber  102  decreases. As such, the pressure inside the chamber  102  becomes less than the pressure outside of the chamber  102 , for example at the opening  15  which has fluid  500  from the fluidic channel  14 . The pressure differential causes the entry valve  106  to transition to the open configuration  1000  such that the fluid  500  can pass through the inlet  20  into chamber  102 . The entry valve  106  abuts an entry bias  1060  which is operable to bias the entry valve  106  to the closed configuration. As such, to transition the entry valve  106  to the open configuration, the force from the pressure opposite the entry valve  106  in relation to the chamber  102  overcomes the biasing force enacted on the entry valve  106  by the entry bias  1060 . The entry bias  1060  can be, for example, a spring. 
     Also due to the pressure differential created by the retraction of the plunger  104 , an exit valve  108  at an outlet  22  in the housing  101  to the chamber  102  transitions to a closed configuration to prohibit fluid flow through the outlet  22  from the chamber  102 . The exit valve  108 , as illustrated in  FIG. 2A , abuts an exit bias  1080 . The exit bias  1080  biases the exit valve  108  to a closed configuration. The exit bias  1080  can be, for example, a spring. 
     While a pump  100  with a passive valve system with the entry valve  106  and the exit valve  108  being suction valves is described herein, other valve systems can be utilized so long as the entry valve and the exit valve are operable to transition between an open configuration and a closed configuration to permit fluid flow through the inlet and outlet, respectively. For example, the entry valve  106  and exit valve  108  can be mechanically linked to the plunger  104  such that when the plunger  104  retract, the entry valve  106  transitions to an open configuration and the exit valve transitions to a closed configuration. An exemplary pump  100  may be a Halliburton HT- 400 . 
     In  FIG. 2B , the plunger  104  extends into the chamber  102  by the motor  10 . When the plunger  104  extends, the fluid  500  within the chamber  102  is compressed. As such, the pressure within the chamber  102  increases. At a predetermined pressure, the entry valve  106  transitions to the closed configuration  2000  to prevent fluid flow through the inlet  20 . Also, at the predetermined pressure, the exit valve  108  transitions to an open configuration to permit fluid flow through the outlet  22 . In other words, the fluid  500  is pumped out of the chamber  102  through the outlet  22  at a predetermined pressure within the chamber  102 . The plunger  104  can extend at least partially into the chamber  102 . In at least one example, the plunger  104  can extend into the chamber  102  such that the plunger becomes proximate the cylinder cover  1040 . 
     The compression of the fluid  500  when the plunger  104  extends into the chamber  102  and before the exit valve  108  opens creates a resistive force against the extension of the plunger  104  into the chamber  102 . As such, a resistive torque load is imparted on the transmission  12  and motor  13 . When the transmission  12  shifts gears  13 , the resistive torque load can cause heat to be generated as the transmission clutches and torque converter disengage and re-engage during the shift sequence. Accordingly, the life of the transmission  12  may be reduced, leading to increased transmission failures. 
     To reduce pressure within the chamber  102  and subsequently the resistive torque load, the actuator  200  can be actuated at least when the plunger  104  is extending into the chamber  102 , as illustrated in  FIGS. 3A and 3B . 
     The actuator  200  includes an actuation cylinder  206 , and a protrusion  204 . The protrusion  204  is coupled with the entry valve  106 . The actuation cylinder  206  can be a pneumatic cylinder, a hydraulic cylinder, or any other suitable mechanism to enact a force to trigger the protrusion  204  to transition and/or hold the entry valve  106  in the open configuration  1000 . For the actuation cylinder  206  to push the protrusion  204  to extend from the actuator  200 , the actuation cylinder  206  must enact a force on the protrusion  204  that is greater than the force of the entry bias  1060  and valve drag in the fluid stream. As such, when the actuator  200  is actuated, the actuation cylinder  206  imparts a force on the protrusion  204  against the entry valve  106 , and the protrusion transitions and/or holds the entry valve  106  in the open configuration  1000 . In the illustrated example of  FIGS. 3A and 3B , the protrusion  204 , when the actuator  200  is actuated, pushes the entry valve  106  to the open configuration  1000  such that fluid can flow through the inlet  20 , independent of the pressure changes created by the translation of the plunger  104 . As such, the plunger  104  translating in and out of the chamber  102  may still compress the fluid to an extend but at a reduced amount, and the actuator  200  is operable to hold the entry valve  106  in the open configuration  1000  and withstand the reduced pressure changes within the chamber  102 . 
     The pressure changes within the chamber  102  are reduced when the actuator  200  is actuated and the entry valve  106  is in the open configuration  1000  because the fluid is able to flow through the inlet  20 . In such a state, when the plunger  104  extends into the chamber  102 , the compression of the fluid and the pressure within the chamber  102  can be reduced for the fluid to exit the chamber  102 . The fluid is able to substantially freely flow through the inlet  20  into and out of the chamber  102 . To flow out of the chamber  102  through the inlet  20 , some forces may still need to be overcome such that it is not a purely free flow; however, the pressure created within the chamber  102  for the fluid to exit through the inlet  20  is reduced. 
     When the actuator  200  is actuated and the entry valve  106  is in the open configuration  1000 , the transmission  12  can shift gears  13  under the reduced resistive torque load. Shifting gears  13  under the reduced resistive torque load can reduce heat generation in transmission converter and clutches, simplify and reduce equipment risks of bringing pumps on-line, shift transmission ranges and return to lock-up without a resistive torque load, improve transmission life, enable use of motors with narrower torque bands, among other aspects. 
     Referring to  FIG. 4 , a flowchart is presented in accordance with an example embodiment. The method  400  is provided by way of example, as there are a variety of ways to carry out the method. The method  400  described below can be carried out using the configurations illustrated in  FIGS. 1A-3B , for example, and various elements of these figures are referenced in explaining example method  400 . Each block shown in  FIG. 4  represents one or more processes, methods or subroutines, carried out in the example method  400 . Furthermore, the illustrated order of blocks is illustrative only and the order of the blocks can change according to the present disclosure. Additional blocks may be added or fewer blocks may be utilized, without departing from this disclosure. The example method  400  can begin at block  402 . 
     At block  402 , a motor is provided. The motor is coupled with a transmission and a pump. The transmission includes a plurality of gears such that the transmission can switch gears to provide different power to the pump. The pump includes a housing with a chamber and a plunger coupled with the motor. The plunger is translatable along a longitudinal axis into and out of the chamber by the motor. As the plunger translates, the pressure inside the chamber changes. For example, as the plunger retracts out of the chamber, the pressure in the chamber decreases. As the plunger extends into the chamber, the compression of fluid causes the pressure in the chamber to increase. The pump also includes an entry valve at an inlet in the housing to the chamber and an exit valve at an outlet in the housing to the chamber. The entry valve is transitionable between an open configuration permitting fluid flow through the inlet to the chamber and a closed configuration preventing fluid flow through the inlet. The exit valve is operable to permit fluid flow through the outlet from the chamber at a predetermined pressure. When the pressure within the chamber is at or above a predetermined pressure, the exit valve can open to permit fluid flow through the outlet. 
     The pump further includes an actuator which is coupled with the entry valve. The actuator is operable to hold the entry valve in the open configuration independent of the pressure changes created by the translation of the plunger. The actuator includes an actuation cylinder and a protrusion. The protrusion can be coupled with the entry valve. The actuation cylinder can be, for example, a pneumatic cylinder or a hydraulic cylinder to trigger the protrusion to hold the entry valve in the open configuration. 
     When the plunger retracts out of the chamber and the pressure in the chamber decreases, the entry valve transitions to the open configuration and the exit valve transitions to the closed configuration such that fluid can flow through the inlet. 
     When the plunger extends into the chamber, the fluid within the chamber is compressed, increasing the pressure within the chamber. The entry valve transitions to the closed position to inhibit fluid flow through the inlet to the chamber. The pressure in the chamber continues to increase until a predetermined pressure is reached, and the exit valve transitions to the open configuration such that the fluid flows through the outlet. As the fluid within the chamber is compressed, the fluid resists the movement of the plunger, leading to a resistive torque load to be enacted on the transmission and motor. If the transmission switches gears while the resistive torque load is increased, then excessive slipping may occur, causing heat generation, and decreasing the life of the transmission. 
     To reduce the resistive torque load and increase transmission life, at block  404 , the actuator is actuated to hold the entry valve in the open configuration. The actuation cylinder, when the actuator is actuated, imparts a force on the protrusion against the entry valve and the entry bias, and the protrusion holds the entry valve in the open configuration. In at least one example, the protrusion can hold the entry valve in the open configuration by physically pushing the entry valve open. In other examples, the protrusion can trigger a mechanism such that the entry valve is held open. As such, when the plunger extends into the chamber, the fluid can flow through the inlet and reduces the resistive torque load. 
     At block  406 , the transmission switches gears while the actuator is actuated. In at least one example, the actuator can be actuated automatically when the transmission is going to switch gears. Also, the actuator can be actuated manually. 
     At block  408 , the actuator is released. The actuator can be released when the gear switch is complete. In other examples, the actuator can be released for a predetermined or desired amount of time. For example, if the actuator can be actuated such that the entry valve is held in the open configuration for the duration of the pumping system to reach the desired gear. 
     Numerous examples are provided herein to enhance understanding of the present disclosure. A specific set of statements are provided as follows. 
     Statement 1: A pumping system is disclosed comprising: a motor coupled with a transmission, the transmission having a plurality of gear ranges; a pump including: a housing with a chamber; a plunger coupled with the motor and the transmission, the translation of the plunger creating pressure changes in the chamber; an entry valve at an inlet in the housing to the chamber, the entry valve transitionable between an open configuration permitting fluid flow through the inlet to the chamber and a closed configuration preventing fluid flow through the inlet to the chamber; an exit valve at an outlet in the housing to the chamber, the exit valve permitting fluid flow through the outlet from the chamber at a predetermined pressure; and an actuator coupled with the entry valve, the actuator operable to hold the entry valve in the open configuration independent of the pressure changes created by the translation of the plunger. 
     Statement 2: A pumping system is disclosed according to Statement 1, wherein the actuator includes an actuation cylinder and a protrusion, wherein the protrusion is coupled with the entry valve. 
     Statement 3: A pumping system is disclosed according to Statement 2, wherein the actuation cylinder is one of a pneumatic cylinder or a hydraulic cylinder. 
     Statement 4: A pumping system is disclosed according to Statements 2 or 3, wherein the actuation cylinder, when the actuator is actuated, imparts a force on the protrusion against the entry valve, and the protrusion holds the entry valve in the open configuration. 
     Statement 5: A pumping system is disclosed according to any of preceding Statements 1-4, wherein the entry valve is coupled with an entry bias which biases the entry valve to the closed configuration. 
     Statement 6: A pumping system is disclosed according to Statement 5, wherein the plunger, when retracting, transitions the entry valve to the open configuration such that a fluid passes through the inlet into the chamber, wherein when the actuator is not actuated and as the plunger extends, the entry valve transitions to the closed configuration, and the fluid passes through the outlet when at the predetermined pressure. 
     Statement 7: A pumping system is disclosed according to claim  6 , wherein when the actuator is actuated, the entry valve is held in the open configuration independent of the translation of the plunger such that the fluid passes through the inlet, reducing a resistive torque load, wherein the transmission, when the entry valve is in the open configuration, shifts gears under the reduced resistive torque load. 
     Statement 8: A pump is disclosed comprising: a housing with a chamber; a plunger coupled with a motor and a transmission and translatable along a longitudinal axis into and out of the chamber by the motor; an entry valve at an inlet in the housing to the chamber, the entry valve transitionable between an open configuration permitting fluid flow through the inlet to the chamber and a closed configuration preventing fluid flow through the inlet to the chamber; an exit valve at an outlet in the housing to the chamber, the exit valve permitting fluid flow through the outlet from the chamber at a predetermined pressure; and an actuator coupled with the entry valve, the actuator operable to hold the entry valve in the open configuration independent of the pressure changes created by the translation of the plunger. 
     Statement 9: A pump is disclosed according to Statement 8, wherein the actuator includes an actuation cylinder and a protrusion, wherein the protrusion is coupled with the entry valve. 
     Statement 10: A pump is disclosed according to Statement 9, wherein the actuation cylinder is one of a pneumatic cylinder or a hydraulic cylinder. 
     Statement 11: A pump is disclosed according to Statements 9 or 10, wherein the actuation cylinder, when the actuator is actuated, imparts a force on the protrusion against the entry valve, and the protrusion holds the entry valve in the open configuration. 
     Statement 12: A pump is disclosed according to any of preceding Statements 8-11, wherein the entry valve is coupled with an entry bias which biases the entry valve to the closed configuration. 
     Statement 13: A pump is disclosed according to any of preceding Statements 8-12, wherein the plunger, when retracting from the chamber, transitions the entry valve the open configuration such that a fluid passes through the inlet into the chamber, wherein, when the actuator is not actuated and as the plunger extends into the chamber, the entry valve transitions to the closed configuration, and the fluid passes through the outlet at the predetermined pressure. 
     Statement 14: A pump is disclosed according to Statement 13, wherein when the actuator is actuated, the entry valve is held in the open configuration independent of the translation of the plunger such that the fluid passes through the entry valve, reducing a resistive torque load. 
     Statement 15: A method is disclosed comprising: providing a motor coupled with a transmission, the transmission having a plurality of gear ranges, and a pump, the pump includes: a housing with a chamber; a plunger coupled with the motor and the transmission, the plunger translatable along a longitudinal axis into and out of the chamber by the motor and transmission; an entry valve at an inlet in the housing to the chamber, the entry valve transitionable between an open configuration permitting fluid flow through the inlet to the chamber and a closed configuration preventing fluid flow through the inlet to the chamber; an exit valve at an outlet in the housing, the exit valve permitting fluid flow through the outlet from the chamber at a predetermined pressure; and an actuator coupled with the entry valve, the actuator operable to hold the entry valve in the open configuration independent of the pressure changes created by the translation of the plunger; actuating the actuator to hold the entry valve in the open configuration and permit fluid flow through the inlet such that a resistive torque load is reduced; shifting gears in the transmission under the reduced resistive torque load; and releasing the actuator. 
     Statement 16: A method is disclosed according to Statement 15, wherein the actuator includes an actuation cylinder and a protrusion, wherein the protrusion is coupled with the entry valve. 
     Statement 17: A method is disclosed according to Statement 16, wherein the actuation cylinder is one of a pneumatic cylinder or a hydraulic cylinder. 
     Statement 18: A method is disclosed according to Statements 16 or 17, further comprising, when the actuator is actuated, imparting a force on the protrusion against the entry valve, and holding the entry valve in the open configuration. 
     Statement 19: A method is disclosed according to any of preceding Statements 15-18, wherein the entry valve is coupled with an entry bias which biases the entry valve to the closed configuration. 
     Statement 20: A method is disclosed according to any of preceding Statements 15-19, further comprising: retracting the plunger from the chamber which transitions the entry valve, when the actuator is not actuated, to the open configuration such that a fluid passes through the inlet into the chamber, extending the plunger such that the entry valve, when the actuator is not actuated, transitions to the closed configuration, and the fluid passes through the outlet at the predetermined pressure. 
     The disclosures shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the examples described above may be modified within the scope of the appended claims.