CA2669870A1 - Rotor polishing system - Google Patents
Rotor polishing system Download PDFInfo
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- CA2669870A1 CA2669870A1 CA2669870A CA2669870A CA2669870A1 CA 2669870 A1 CA2669870 A1 CA 2669870A1 CA 2669870 A CA2669870 A CA 2669870A CA 2669870 A CA2669870 A CA 2669870A CA 2669870 A1 CA2669870 A1 CA 2669870A1
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- Canada
- Prior art keywords
- polishing system
- rotor
- polishing
- assembly
- progressive cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B27/00—Other grinding machines or devices
- B24B27/0015—Hanging grinding machines
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
The present invention describes an improved method and apparatus for polishing rotors. In various embodiments, the apparatus for polishing rotors is able to operate with a sanding belt or polishing wheel to achieve a desired finish. The apparatus for polishing rotors is effective at grinding and polishing progressive cavity pump (PCP) rotors used in industrial applications such as oil wells, gas wells or the like.
Description
ti ROTOR POLISHING SYSTEM
FIELD OF THE INVENTION
[0001] The present invention describes an improved method and apparatus for polishing rotors and specifically rotors for progressive cavity pumps (PCPs). In various embodiments, the apparatus for polishing rotors is able to operate with a sanding belt or polishing wheel to achieve a desired finish. The apparatus for polishing rotors is effective at grinding and polishing progressive cavity pump (PCP) rotors used in industrial applications such as oil wells, gas wells or the like.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] The present invention describes an improved method and apparatus for polishing rotors and specifically rotors for progressive cavity pumps (PCPs). In various embodiments, the apparatus for polishing rotors is able to operate with a sanding belt or polishing wheel to achieve a desired finish. The apparatus for polishing rotors is effective at grinding and polishing progressive cavity pump (PCP) rotors used in industrial applications such as oil wells, gas wells or the like.
BACKGROUND OF THE INVENTION
[0002] During oil-well production, in-line pumps such as progressive cavity pumps (PC
pumps or PCPs) are used to pump oil from the well bore to the surface. A
progressive cavity pump system includes a surface driven rotor mounted with a downhole stator that is rotationally secured to production casing so as to prevent rotation of the stator in response to the rotation of the rotor. The shapes of the rotor and stator form a series of sealed cavities within the stator. As the rotor is turned, the cavities progress to move fluid from the intake to the discharge end of the pump.
pumps or PCPs) are used to pump oil from the well bore to the surface. A
progressive cavity pump system includes a surface driven rotor mounted with a downhole stator that is rotationally secured to production casing so as to prevent rotation of the stator in response to the rotation of the rotor. The shapes of the rotor and stator form a series of sealed cavities within the stator. As the rotor is turned, the cavities progress to move fluid from the intake to the discharge end of the pump.
[0003] As is well known, a surface driven rotor must be tightly encased within a downhole stator for a PC pump to form sealed cavities and result in a positive displacement flow. The rotation of the rotor against the stator causes the erosion of material from the rotor resulting in degradation of the cavities' seal. A
reduced seal results in a reduction of the positive displacement flow rate and pressure at the discharge end of the pump.
reduced seal results in a reduction of the positive displacement flow rate and pressure at the discharge end of the pump.
[0004] Furthermore, oil is generally obtained from the geosphere and wells are often drilled through clay, rock, sand or the like (hereafter referred to as "mineral matter"). As a result, when oil is pumped from the well bore to the surface, fragments of mineral matter are incorporated into the oil stream resulting in an abrasive fluid. The abrasive fluid enters the PC pump and contacts the surface of the rotor causing further erosion of material on the rotor. Furthermore, fragments of mineral matter may become caught between the rotor and stator. As the rotor rotates against the stator, these fragments of mineral matter cause even further erosion of the material on the rotor.
Similarly, the erosion of the rotor caused by mineral matter will reduce the seal of the cavities resulting in a decreased positive flow rate and pressure at the discharge end of the pump.
Similarly, the erosion of the rotor caused by mineral matter will reduce the seal of the cavities resulting in a decreased positive flow rate and pressure at the discharge end of the pump.
[0005] Generally, rotors for PC pumps are expensive to manufacture and replace.
Preferably, a worn rotor is repaired when the positive flow rate and pressure at the discharge end of the pump have decreased to a specified level.
Preferably, a worn rotor is repaired when the positive flow rate and pressure at the discharge end of the pump have decreased to a specified level.
[0006] A common method of repairing a worn PCP rotor is chromium electroplating. The process of chromium electroplating may include degreasing to remove heavy soiling, manual cleaning to remove traces of dirt or impurities, one or more pretreatments, submersion in a vat containing chromium ions and the subsequent application of an electrical current to the rotor and chromium vat. The rotor is left in the vat with the electrical current until the desired thickness of chromium is achieved.
Finally, the rotor is removed and may be subjected to one or more post treatments.
Finally, the rotor is removed and may be subjected to one or more post treatments.
[0007] During operation, one or more sections of a rotor may incur more wear than other sections of the rotor. As a result these sections may require different thicknesses of chromium to be plated. Chromium plating is an electrochemical process that is difficult to control with respect to the thickness of chromium along the length of the rotor.
Furthermore, chromium plating may also result in small imperfections on the surface of the rotor. Therefore it is desirable to plate a rotor with chromium so that the entire rotor is a minimum thickness before grinding to remove excess chromium. Finally, a rotor is polished to ensure a consistent finish as required by the specifications of a PCP.
Furthermore, chromium plating may also result in small imperfections on the surface of the rotor. Therefore it is desirable to plate a rotor with chromium so that the entire rotor is a minimum thickness before grinding to remove excess chromium. Finally, a rotor is polished to ensure a consistent finish as required by the specifications of a PCP.
[0008] Schuler Incorporated (Schuler), a provider of metal forming products headquartered in Canon, Michigan, offers highly automated machinery to grind and polish a PCP rotor with a high level of precision. Schuler's technology can repair a PC
pump rotor to an exact specification, however there is generally a high cost associated with the purchase, operation and maintenance of the automated machinery.
pump rotor to an exact specification, however there is generally a high cost associated with the purchase, operation and maintenance of the automated machinery.
[0009] A review of the prior art indicates that while various systems for polishing rotors have been provided in the past, there continues to be a need for new designs of such systems that provide improvements over these past systems. In particular, there is a need for a highly effective semi-automatic polishing system that enables PCP
rotors to be polished in a cost-effective manner.
SUMMARY OF THE INVENTION
rotors to be polished in a cost-effective manner.
SUMMARY OF THE INVENTION
[0010] In accordance with the invention, there is provided a method and apparatus for polishing rotors and specifically rotors for progressive cavity pumps (PCPs).
[0011] More specifically, there is provided a progressive cavity pump (PCP) rotor polishing system comprising:
a frame;
a headstock assembly and tailstock assembly operatively connected to the frame, the headstock assembly and tailstock assembly for operatively supporting a PCP
rotor and enabling rotation of a PCP rotor mounted within the headstock and tailstock assemblies; and a saddle assembly operatively connected to the frame, the saddle assembly moveable along the frame and along the PCP rotor when mounted within the headstock and tailstock assemblies, the saddle assembly including a polishing system for engagement against the PCP rotor, wherein the polishing system is vertically and rotationally moveable with respect to the PCP rotor.
a frame;
a headstock assembly and tailstock assembly operatively connected to the frame, the headstock assembly and tailstock assembly for operatively supporting a PCP
rotor and enabling rotation of a PCP rotor mounted within the headstock and tailstock assemblies; and a saddle assembly operatively connected to the frame, the saddle assembly moveable along the frame and along the PCP rotor when mounted within the headstock and tailstock assemblies, the saddle assembly including a polishing system for engagement against the PCP rotor, wherein the polishing system is vertically and rotationally moveable with respect to the PCP rotor.
[0012] In one embodiment of the invention, the frame of the progressive cavity pump rotor polishing system includes a rail system operatively supporting the saddle assembly and polishing system.
[0013] In another embodiment, the rail system of the progressive cavity pump rotor polishing system is a double rail and the saddle assembly includes a wheel and bearing system mounted on the double rail.
[0014] In yet another embodiment, the saddle assembly of the progressive cavity pump rotor polishing system includes a vertical support member operatively connecting the polishing system to the saddle assembly, wherein the vertical support member enables vertical and rotational movement of the polishing system with respect to the saddle assembly.
[0015] Specifically, the polishing system of the progressive cavity pump rotor polishing system may be a belt sander or a polishing wheel.
[0016] In one embodiment of the invention, the wheel and bearing system of the progressive cavity pump rotor polishing system includes at least four wheel pairs for engagement with the double rail wherein each wheel pair respectively engage with an upper surface and lower surface of one rail and wherein the wheel pairs are horizontally displaced with respect to one another to provide vertical, horizontal and torsional stability to the saddle system relative to the double rail.
[0017] In another embodiment of the invention, the progressive cavity pump rotor polishing system further comprises a control system on the saddle assembly for operative control of the polishing system including start, stop and speed; and the headstock assembly including start, stop and speed.
[0018] In a further embodiment of the invention, the polishing system includes a variable frequency drive motor and the control system includes a display for providing a pressure reading of the relative force being applied to a rotor during polishing.
[0019] In yet another embodiment of the invention, the progressive cavity pump rotor polishing system further comprises a lower support rail enabling selective positioning of the tailstock assembly at a selected distance from the headstock assembly. The lower support rail may include rollers rotationally supporting a PCP rotor on the lower rail.
BRIEF DESCRIPTION OF THE FIGURES
BRIEF DESCRIPTION OF THE FIGURES
[0020] The invention is described with reference to the accompanying figures in which:
FIG. 1 is an isometric view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a frame assembly, a headstock assembly, a tailstock assembly, a saddle assembly and a polishing system.
FIG. 2 is a front view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a frame assembly, a headstock assembly, a tailstock assembly, a saddle assembly and a polishing system.
FIG. 3 is an end view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a headstock support member, a frame assembly and a headstock assembly.
FIG. 4 is an isometric view of a headstock assembly in accordance with a first embodiment of this invention.
FIG. 5 is an end view of a saddle assembly, a tailstock assembly, and a polishing system in accordance with a first embodiment of this invention.
FIG. 6 is an isometric view of a saddle assembly and polishing system in accordance with a first embodiment of this invention.
FIG. 6A is a side view of a saddle assembly, a power head assembly and a polishing system in accordance with a first embodiment of this invention.
FIG. 6B is a top view of a saddle assembly, a power head assembly and a polishing system in accordance with a first embodiment of this invention.
FIG. 7 is an isometric view of a tailstock assembly in accordance with a first embodiment of this invention.
FIG. 8 is an isometric view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 9 is a front view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 10 is an end view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 11 is an isometric view of the saddle assembly in accordance with a second embodiment of this invention.
FIG. 12 is a schematic view of the operator control panel in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
Overview (0021] With reference to the figures, an Apparatus for Polishing Rotors (AFPR) 10 for use in industrial applications is described. The system generally includes a frame assembly 12, a saddle assembly 200, a headstock assembly 300, a tailstock assembly 400 and an operator control panel 201, as best shown in FIGS. 1 and 2.
FIG. 1 is an isometric view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a frame assembly, a headstock assembly, a tailstock assembly, a saddle assembly and a polishing system.
FIG. 2 is a front view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a frame assembly, a headstock assembly, a tailstock assembly, a saddle assembly and a polishing system.
FIG. 3 is an end view of an Apparatus for polishing rotors in accordance with a first embodiment of this invention showing a headstock support member, a frame assembly and a headstock assembly.
FIG. 4 is an isometric view of a headstock assembly in accordance with a first embodiment of this invention.
FIG. 5 is an end view of a saddle assembly, a tailstock assembly, and a polishing system in accordance with a first embodiment of this invention.
FIG. 6 is an isometric view of a saddle assembly and polishing system in accordance with a first embodiment of this invention.
FIG. 6A is a side view of a saddle assembly, a power head assembly and a polishing system in accordance with a first embodiment of this invention.
FIG. 6B is a top view of a saddle assembly, a power head assembly and a polishing system in accordance with a first embodiment of this invention.
FIG. 7 is an isometric view of a tailstock assembly in accordance with a first embodiment of this invention.
FIG. 8 is an isometric view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 9 is a front view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 10 is an end view of an Apparatus for polishing rotors in accordance with a second embodiment of this invention.
FIG. 11 is an isometric view of the saddle assembly in accordance with a second embodiment of this invention.
FIG. 12 is a schematic view of the operator control panel in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
Overview (0021] With reference to the figures, an Apparatus for Polishing Rotors (AFPR) 10 for use in industrial applications is described. The system generally includes a frame assembly 12, a saddle assembly 200, a headstock assembly 300, a tailstock assembly 400 and an operator control panel 201, as best shown in FIGS. 1 and 2.
[0022] In operation, a PCP rotor (not shown) is mounted between the headstock assembly 300 and the tailstock assembly 400 such that the PCP rotor can rotate between the headstock and tailstock assemblies. The saddle assembly is operable to lower a polishing system against the PCP rotor such that the surface of the PCP rotor can be polished. In addition, the saddle assembly can be moved along the length of the PCP rotor which in conjunction with rotation of the PCP rotor enables the polishing system to come into contact with all external surfaces of the PCP rotor.
Frame Assembly [0023] Referring to FIG. 1, the frame assembly 12 generally includes at least one polisher support member 14, a headstock support member 16, a rail 18, an I-beam 20 and an outer protective skin 22. The polisher support member 14 and the headstock support member 16 generally provide structural support for the AFPR.
Frame Assembly [0023] Referring to FIG. 1, the frame assembly 12 generally includes at least one polisher support member 14, a headstock support member 16, a rail 18, an I-beam 20 and an outer protective skin 22. The polisher support member 14 and the headstock support member 16 generally provide structural support for the AFPR.
[0024] The rail 18 preferably includes two diamond shaped beams mounted generally horizontally beneath the top(s) of the polisher support member(s) 14 as best shown by FIG. 3. The I-beam 20 provides a support rail for the tailstock assembly allowing the tailstock assembly to slide along the length of the AFPR to accommodate rotors of different lengths.
[0025] The outer protective skin 22 is generally a sheet metal covering that contains shavings, sparks or the like from within the AFPR. The outer protective skin is mounted on the polisher support member(s) 14 and headstock support member 16 and is generally located at the rear of the AFPR.
Saddle Assembly [0026] In a first embodiment, as best shown in FIG. 5 and FIG. 6, the saddle assembly 200 generally includes a saddle frame 203, a power head assembly 210 and a polishing system 213.
Saddle Frame [0027] The saddle frame 203 preferably includes at least one U-shaped member 204, at least one saddle wheel 205, at least one horizontal saddle rail 206, at least one saddle tube 208 and a saddle platform 209.
Saddle Assembly [0026] In a first embodiment, as best shown in FIG. 5 and FIG. 6, the saddle assembly 200 generally includes a saddle frame 203, a power head assembly 210 and a polishing system 213.
Saddle Frame [0027] The saddle frame 203 preferably includes at least one U-shaped member 204, at least one saddle wheel 205, at least one horizontal saddle rail 206, at least one saddle tube 208 and a saddle platform 209.
[0028] In the preferred embodiment, there are two U-shaped members 204 that are connected by four horizontal saddle rails 206. Eight saddle wheels 205 are mounted on the horizontal saddle rails 206 in a generally box-like arrangement for sliding engagement with the rail 18 such that the saddle assembly can move horizontally along the length of the rail 18 with directional stability while preventing motion in the binormal and tangential directions. There are preferably two saddle tubes 208 mounted to the undersides of the two U-shaped members 204. Two saddle sleeves 207 are slidingly engaged with the saddle tubes 208 and connected by the saddle platform 209.
The saddle platform 209 and saddle sleeves 207 can slide as one unit horizontally along the length of the saddle tubes 208.
The saddle platform 209 and saddle sleeves 207 can slide as one unit horizontally along the length of the saddle tubes 208.
[0029] A rack 204c, pinion 204b and corresponding rail drive motor 204 is configured to the saddle assembly and frame 12 to enable controlled movement of the saddle assembly with respect to the frame.
Power Head Assembly [0030] As best shown in FIG. 6A and FIG. 6B, the power head assembly 210 is affixed to the underside of the saddle platform 209 and generally includes a power head motor 211, a power head belt 211 a, a power head pulley 211 b, a power head shaft 211 c, a power head support member 212a and a power head lifting member 212b.
[0031 ] The power head motor 211 drives the power head pulley 211 b to rotate in a clockwise or counterclockwise direction. The power head belt 211 a runs around the power head pulley 211 b and the power head shaft 211 c such that the rotation of the power head pulley is transferred through the power head belt to cause vertical movement of the power head shaft via an internal threaded shaft and nut (not shown).
Polishing System [0032] The polishing system is mounted laterally on the power head assembly 210 such that the polishing system can move vertically by means of the vertical movement of the power head assembly 210, and horizontally by means of the saddle sleeve 207 and saddle platform 209 sliding along the saddle tube 208. In one embodiment, the polishing system is a sander 213, as shown in FIG. 5. In a second embodiment, the polishing system is a polishing wheel, as best shown in FIG. 11.
Polishing Sander [0033] In one embodiment, the polishing system is a sander 213, as best shown in FIG.
6A. The sander 213 generally consists of a sander motor 214, a sander drive pulley 215, a sander idler pulley 216, a sander belt 217, a sander belt guard 218 and a belt pressure cylinder 219.
[0034] The sander belt encircles the sander drive pulley 215 and the sander idler pulley 216. The sander motor 214 is attached to the sander drive pulley 215, and drives the sander drive pulley which frictionally engages the sander belt 217 and causes the rotation of the sander belt about the sander idler pulley 216. The sander motor 214 is preferably a variable frequency drive (VFD) to allow for the sander belt to operate at various speeds. The sander belt guard 218 protects an operator from any debris coming off the sander belt while in operation and protects the sander belt from coming into contact with an external object, such as an operator or another machine. The sander belt pressure cylinder 219 partially supports the sander 213 to allow an operator to manually apply a more even pressure to the sander as explained in greater detail below.
The sander 213 may further include an appropriate handle (not shown) to allow an operator to move the sander into and out of an operative position.
[0035] As is well known to those of skill in the art, the sander belt 217 consists of a loop of sandpaper. The sandpaper is a coated abrasive generally consisting of a backing, an abrasive and an adhesive to bind the abrasive to the backing. Backings may consist of paper, cloth, biaxially-oriented polyethylene terephthalate polyester film (Mylar) or the like. Abrasives generally consist of one or a mix of the following: glass, flint, garnet, emery, aluminum oxide, silicon carbide, alumina-zirconia, chromium oxide, ceramic aluminum oxide or the like. Adhesives generally consist of glue or the like.
The sander belt 217 is sized to be frictionally engaged by the sander drive pulley 215 and the sander idler pulley 216.
Polishing Wheel [0036] In a second embodiment, the polishing system 213 consists of a polishing wheel 220 and a polishing wheel motor 221 that is attached to the power head 210 as shown in FIG. 11. The polishing wheel motor 221 turns the polishing wheel 220 and a polishing wheel cover 222 protects the polishing wheel 220 and the operator, similar to the protection the sander belt guard 218 provides in the first embodiment. The polishing wheel motor 221 is preferably a variable frequency drive (VFD) to allow for various speeds for the polishing wheel. A handle (not shown) is preferably provided to allow the operator to move the system into and out of an operative position.
[0037] The polishing wheel 220 may be composed of a variety of materials to provide different finishes for polishing the rotor 30. Materials may include, but are not limited to, felt, canvas or a fine abrasive. A polishing compound such as TripoliTM or RougeTM may also be used as required.
Headstock Assembly [0038] The headstock assembly 300 is mounted on the headstock support member at one end of the frame assembly 12 and generally includes a chuck 302, a sheave 306, one or more chuck belts 310, a headstock motor 308, and a chuck housing 304 that forms the support means for the other components of the headstock assembly, as best shown in FIG. 4. When the AFPR 10 is in use, one end of the PCP rotor may be attached to the chuck 302, which causes the PCP rotor to rotate while remaining in a horizontal plane.
[0039] The chuck belt(s) 310 is frictionally engaged in a loop around the headstock motor 308 and the sheave 306, and the sheave 306 is attached to the chuck 302.
In operation, the rotation of the headstock motor 308 drives the rotation of the chuck belt(s) 310, the sheave 306, and the chuck 302. The headstock motor 308 may be Variable Frequency Drive (VFD) to allow the chuck 302 and PCP rotor to rotate at different speeds as desired.
Tailstock Assembly [0040] Referring to FIG. 1, the tailstock assembly 400 is mounted at the opposite end of the frame assembly 12 to the headstock assembly 300 and is designed to hold one end of the PCP rotor in place while the AFPR is in operation. As shown in FIG. 7, the tailstock assembly 400 generally includes a ram 402, a ram sleeve 403, a handwheel 404 and a pylon 406, as known to those of skill in the art. The pylon 406 is mounted on the I-beam 20 and can move horizontally along the I-beam 20 to allow horizontal positioning of the tail stock assembly 400 as required to fit the length of the PCP rotor being polished. The ram sleeve 403 is mounted to the top of the pylon 406 and the ram 402 can move horizontally within the ram sleeve 403 by turning the handwheel 404 to aid in the operative engagement of the ram 402 with the PCP rotor.
Rotor Rollers [0041] In a further embodiment shown in FIG. 8, the headstock assembly 300, tail stock assembly 400 and I-Beam 20 may be replaced by one or more sets of rotor rollers 32 located along the bottom length of the frame that support a rotor 30. The sets of rotor rollers 32 rotate passively as the polishing system is frictionally engaged with a rotor.
Operator Control Panel [0042] In a preferred embodiment, an operator control panel 201 is mounted on the saddle assembly 200. The operator control panel 201 is best shown in FIG. 12.
The operator control panel will provide appropriate controls to enable the operator located at the polishing system to effectively control operation of the system. In particular, the control panel will preferably include appropriate controls to operate the headstock motor 308 to control the rotation of the PCP rotor (speed and direction), the polisher motor 214 or polishing wheel motor 221 (speed), the speed of traverse of the polishing system along the rails as well as vertical movement of the polishing system. An emergency stop button 500 will preferably be provided to allow an operator to shut-down the system and may include prohibiting means as understood to those skilled in the art to rapidly slow and subsequently stop the rotation of the headstock assembly 300, sander belt 217 or polishing wheel 220 and the translational movement of the saddle 203 or power head 210.
[0043] As shown in FIG. 12, the operator control panel 201 may specifically include controls for the headstock assembly 300 such as start 502, stop 503, forward 504, reverse 505 and speed 506. The speed 506 control may control the speed of the variable frequency drive (VFD) motor.
[0044] In addition, the operator control panel may further include controls for the sander motor or polishing wheel motor including start 508 and stop 509 and traverse speed 510 and traverse direction 510a, 510b.
[0045] In another embodiment, the control panel 201 may include a display, touch screen display or the like 511. In a preferred embodiment, the display will indicate the relative pressure an operator is applying to the polisher that may be measured from the operating frequency of the motor. Other control parameters may also be displayed.
Operation of the AFPR
[0046] In operation, the operator places the rotor 30 in the AFPR 10 using an appropriate lifting device (not shown) and positions one end of the rotor 30 at the headstock assembly 300 for operative attachment to the chuck 302. The tail stock assembly 400 is moved horizontally along the I-Beam 20 until the ram 402 contacts the rotor 30. The chuck 302 is tightened to secure the rotor in place and subsequently the handwheel 404 is turned until the ram 402 frictionally engages the rotor 30, allowing rotational movement of the rotor but preventing any horizontal or vertical movement.
[0047] Using the operator control panel 201, the operator sets the chuck 302 of the headstock assembly 300 to rotate, causing rotation of the rotor 30. The operator may rotate the rotor whenever the operator requires the rotor to rotate, or he/she may set the chuck to rotate continuously at any given speed or to rotate at given intervals. The operator may adjust the rotation of the chuck to provide an even and consistent polish to the rotor.
[0048] The saddle assembly 200 may be moved laterally along the rail 18 to position the power head assembly 210 and polishing system 213 above any given section of the rotor 30. The saddle assembly 200 may be moved along the rail 18 with the aid of the rail drive motor.
[0049] The power head assembly 210 is moved vertically by the power head motor of the polishing system 213 in a direction binormal to the rail 18 and saddle tube 208.
[0050] The pivoting vertical and horizontal pivoting motion of the power head is generally caused by the operator applying up/down and/or side to side pressure to one or more handles (not shown) located on the polishing system 213.
[0051] The polishing system 213 can be moved horizontally at a right angle to the rail 18 by means of the saddle sleeve 207 moving on the saddle tube 208, as previously described. This horizontal movement of the saddle sleeve 207 is generally accomplished by the operator manually applying pressure to the handle(s) on the polishing system 213. In one embodiment where the polishing system is a sander 213a, the operator moves the sander belt 217 down towards the rotor 30 by means of the handle(s) on the polishing system. When the sander belt 217 touches the rotor 30, the movement of the abrasive on the sander belt causes the removal of chrome from the rotor 30.
The operator may apply physical pressure on the polishing system as required to achieve the desired thickness of finish. Generally, the more pressure that is applied, the more chrome is removed.
[0052] In the second embodiment where the polishing system is a polishing wheel 220, the operator moves the polishing wheel 220 towards the rotor 30 with the handle(s). The operator may apply a polishing compound to the polishing wheel 220 or rotor 30 to aid in the polishing of the rotor. When the polishing wheel 220 touches the rotor 30, the rotational movement of the wheel causes the polishing of the rotor. The operator may apply physical pressure as required to achieve a desired finish.
[0053] In one embodiment, the rotor 30 may rotate slowly as the operator operates a sanding belt or polishing wheel. Alternatively, the operator may sand or polish an entire side of a rotor before rotating the chuck a few degrees and polishing another side of the same rotor.
[0054] To ensure the rotor is polished to desired dimensions, the operator generally uses a measurement device such as calipers, electronic lasers or the like to determine the thickness of the rotor. The operator may then make a decision to grind or polish an area more or less thoroughly.
[0055] The present system is advantaged over previous polishing systems by providing an effective and efficient polishing system that enables the rapid polishing of PCP rotors to desired finishes and tolerances. For example, a typical 20 foot PCP rotor that has been chrome plated may be polished to specification (typically 2 thousandths of an inch) in approximately less than 1 hour. A large power rotor of 20-25 feet could be polished in approximately 2.5 hours. Prior art systems would take approximately 30 hours to polish a large power rotor. As well as being substantially faster than prior art systems, the capital cost of the present semi-automatic system is much lower than fully automatic systems.
[0056] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.
Power Head Assembly [0030] As best shown in FIG. 6A and FIG. 6B, the power head assembly 210 is affixed to the underside of the saddle platform 209 and generally includes a power head motor 211, a power head belt 211 a, a power head pulley 211 b, a power head shaft 211 c, a power head support member 212a and a power head lifting member 212b.
[0031 ] The power head motor 211 drives the power head pulley 211 b to rotate in a clockwise or counterclockwise direction. The power head belt 211 a runs around the power head pulley 211 b and the power head shaft 211 c such that the rotation of the power head pulley is transferred through the power head belt to cause vertical movement of the power head shaft via an internal threaded shaft and nut (not shown).
Polishing System [0032] The polishing system is mounted laterally on the power head assembly 210 such that the polishing system can move vertically by means of the vertical movement of the power head assembly 210, and horizontally by means of the saddle sleeve 207 and saddle platform 209 sliding along the saddle tube 208. In one embodiment, the polishing system is a sander 213, as shown in FIG. 5. In a second embodiment, the polishing system is a polishing wheel, as best shown in FIG. 11.
Polishing Sander [0033] In one embodiment, the polishing system is a sander 213, as best shown in FIG.
6A. The sander 213 generally consists of a sander motor 214, a sander drive pulley 215, a sander idler pulley 216, a sander belt 217, a sander belt guard 218 and a belt pressure cylinder 219.
[0034] The sander belt encircles the sander drive pulley 215 and the sander idler pulley 216. The sander motor 214 is attached to the sander drive pulley 215, and drives the sander drive pulley which frictionally engages the sander belt 217 and causes the rotation of the sander belt about the sander idler pulley 216. The sander motor 214 is preferably a variable frequency drive (VFD) to allow for the sander belt to operate at various speeds. The sander belt guard 218 protects an operator from any debris coming off the sander belt while in operation and protects the sander belt from coming into contact with an external object, such as an operator or another machine. The sander belt pressure cylinder 219 partially supports the sander 213 to allow an operator to manually apply a more even pressure to the sander as explained in greater detail below.
The sander 213 may further include an appropriate handle (not shown) to allow an operator to move the sander into and out of an operative position.
[0035] As is well known to those of skill in the art, the sander belt 217 consists of a loop of sandpaper. The sandpaper is a coated abrasive generally consisting of a backing, an abrasive and an adhesive to bind the abrasive to the backing. Backings may consist of paper, cloth, biaxially-oriented polyethylene terephthalate polyester film (Mylar) or the like. Abrasives generally consist of one or a mix of the following: glass, flint, garnet, emery, aluminum oxide, silicon carbide, alumina-zirconia, chromium oxide, ceramic aluminum oxide or the like. Adhesives generally consist of glue or the like.
The sander belt 217 is sized to be frictionally engaged by the sander drive pulley 215 and the sander idler pulley 216.
Polishing Wheel [0036] In a second embodiment, the polishing system 213 consists of a polishing wheel 220 and a polishing wheel motor 221 that is attached to the power head 210 as shown in FIG. 11. The polishing wheel motor 221 turns the polishing wheel 220 and a polishing wheel cover 222 protects the polishing wheel 220 and the operator, similar to the protection the sander belt guard 218 provides in the first embodiment. The polishing wheel motor 221 is preferably a variable frequency drive (VFD) to allow for various speeds for the polishing wheel. A handle (not shown) is preferably provided to allow the operator to move the system into and out of an operative position.
[0037] The polishing wheel 220 may be composed of a variety of materials to provide different finishes for polishing the rotor 30. Materials may include, but are not limited to, felt, canvas or a fine abrasive. A polishing compound such as TripoliTM or RougeTM may also be used as required.
Headstock Assembly [0038] The headstock assembly 300 is mounted on the headstock support member at one end of the frame assembly 12 and generally includes a chuck 302, a sheave 306, one or more chuck belts 310, a headstock motor 308, and a chuck housing 304 that forms the support means for the other components of the headstock assembly, as best shown in FIG. 4. When the AFPR 10 is in use, one end of the PCP rotor may be attached to the chuck 302, which causes the PCP rotor to rotate while remaining in a horizontal plane.
[0039] The chuck belt(s) 310 is frictionally engaged in a loop around the headstock motor 308 and the sheave 306, and the sheave 306 is attached to the chuck 302.
In operation, the rotation of the headstock motor 308 drives the rotation of the chuck belt(s) 310, the sheave 306, and the chuck 302. The headstock motor 308 may be Variable Frequency Drive (VFD) to allow the chuck 302 and PCP rotor to rotate at different speeds as desired.
Tailstock Assembly [0040] Referring to FIG. 1, the tailstock assembly 400 is mounted at the opposite end of the frame assembly 12 to the headstock assembly 300 and is designed to hold one end of the PCP rotor in place while the AFPR is in operation. As shown in FIG. 7, the tailstock assembly 400 generally includes a ram 402, a ram sleeve 403, a handwheel 404 and a pylon 406, as known to those of skill in the art. The pylon 406 is mounted on the I-beam 20 and can move horizontally along the I-beam 20 to allow horizontal positioning of the tail stock assembly 400 as required to fit the length of the PCP rotor being polished. The ram sleeve 403 is mounted to the top of the pylon 406 and the ram 402 can move horizontally within the ram sleeve 403 by turning the handwheel 404 to aid in the operative engagement of the ram 402 with the PCP rotor.
Rotor Rollers [0041] In a further embodiment shown in FIG. 8, the headstock assembly 300, tail stock assembly 400 and I-Beam 20 may be replaced by one or more sets of rotor rollers 32 located along the bottom length of the frame that support a rotor 30. The sets of rotor rollers 32 rotate passively as the polishing system is frictionally engaged with a rotor.
Operator Control Panel [0042] In a preferred embodiment, an operator control panel 201 is mounted on the saddle assembly 200. The operator control panel 201 is best shown in FIG. 12.
The operator control panel will provide appropriate controls to enable the operator located at the polishing system to effectively control operation of the system. In particular, the control panel will preferably include appropriate controls to operate the headstock motor 308 to control the rotation of the PCP rotor (speed and direction), the polisher motor 214 or polishing wheel motor 221 (speed), the speed of traverse of the polishing system along the rails as well as vertical movement of the polishing system. An emergency stop button 500 will preferably be provided to allow an operator to shut-down the system and may include prohibiting means as understood to those skilled in the art to rapidly slow and subsequently stop the rotation of the headstock assembly 300, sander belt 217 or polishing wheel 220 and the translational movement of the saddle 203 or power head 210.
[0043] As shown in FIG. 12, the operator control panel 201 may specifically include controls for the headstock assembly 300 such as start 502, stop 503, forward 504, reverse 505 and speed 506. The speed 506 control may control the speed of the variable frequency drive (VFD) motor.
[0044] In addition, the operator control panel may further include controls for the sander motor or polishing wheel motor including start 508 and stop 509 and traverse speed 510 and traverse direction 510a, 510b.
[0045] In another embodiment, the control panel 201 may include a display, touch screen display or the like 511. In a preferred embodiment, the display will indicate the relative pressure an operator is applying to the polisher that may be measured from the operating frequency of the motor. Other control parameters may also be displayed.
Operation of the AFPR
[0046] In operation, the operator places the rotor 30 in the AFPR 10 using an appropriate lifting device (not shown) and positions one end of the rotor 30 at the headstock assembly 300 for operative attachment to the chuck 302. The tail stock assembly 400 is moved horizontally along the I-Beam 20 until the ram 402 contacts the rotor 30. The chuck 302 is tightened to secure the rotor in place and subsequently the handwheel 404 is turned until the ram 402 frictionally engages the rotor 30, allowing rotational movement of the rotor but preventing any horizontal or vertical movement.
[0047] Using the operator control panel 201, the operator sets the chuck 302 of the headstock assembly 300 to rotate, causing rotation of the rotor 30. The operator may rotate the rotor whenever the operator requires the rotor to rotate, or he/she may set the chuck to rotate continuously at any given speed or to rotate at given intervals. The operator may adjust the rotation of the chuck to provide an even and consistent polish to the rotor.
[0048] The saddle assembly 200 may be moved laterally along the rail 18 to position the power head assembly 210 and polishing system 213 above any given section of the rotor 30. The saddle assembly 200 may be moved along the rail 18 with the aid of the rail drive motor.
[0049] The power head assembly 210 is moved vertically by the power head motor of the polishing system 213 in a direction binormal to the rail 18 and saddle tube 208.
[0050] The pivoting vertical and horizontal pivoting motion of the power head is generally caused by the operator applying up/down and/or side to side pressure to one or more handles (not shown) located on the polishing system 213.
[0051] The polishing system 213 can be moved horizontally at a right angle to the rail 18 by means of the saddle sleeve 207 moving on the saddle tube 208, as previously described. This horizontal movement of the saddle sleeve 207 is generally accomplished by the operator manually applying pressure to the handle(s) on the polishing system 213. In one embodiment where the polishing system is a sander 213a, the operator moves the sander belt 217 down towards the rotor 30 by means of the handle(s) on the polishing system. When the sander belt 217 touches the rotor 30, the movement of the abrasive on the sander belt causes the removal of chrome from the rotor 30.
The operator may apply physical pressure on the polishing system as required to achieve the desired thickness of finish. Generally, the more pressure that is applied, the more chrome is removed.
[0052] In the second embodiment where the polishing system is a polishing wheel 220, the operator moves the polishing wheel 220 towards the rotor 30 with the handle(s). The operator may apply a polishing compound to the polishing wheel 220 or rotor 30 to aid in the polishing of the rotor. When the polishing wheel 220 touches the rotor 30, the rotational movement of the wheel causes the polishing of the rotor. The operator may apply physical pressure as required to achieve a desired finish.
[0053] In one embodiment, the rotor 30 may rotate slowly as the operator operates a sanding belt or polishing wheel. Alternatively, the operator may sand or polish an entire side of a rotor before rotating the chuck a few degrees and polishing another side of the same rotor.
[0054] To ensure the rotor is polished to desired dimensions, the operator generally uses a measurement device such as calipers, electronic lasers or the like to determine the thickness of the rotor. The operator may then make a decision to grind or polish an area more or less thoroughly.
[0055] The present system is advantaged over previous polishing systems by providing an effective and efficient polishing system that enables the rapid polishing of PCP rotors to desired finishes and tolerances. For example, a typical 20 foot PCP rotor that has been chrome plated may be polished to specification (typically 2 thousandths of an inch) in approximately less than 1 hour. A large power rotor of 20-25 feet could be polished in approximately 2.5 hours. Prior art systems would take approximately 30 hours to polish a large power rotor. As well as being substantially faster than prior art systems, the capital cost of the present semi-automatic system is much lower than fully automatic systems.
[0056] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.
Claims (16)
1. A progressive cavity pump (PCP) rotor polishing system comprising:
a frame;
a headstock assembly and tailstock assembly operatively connected to the frame, the headstock assembly and tailstock assembly for operatively supporting a PCP rotor and enabling rotation of a PCP rotor mounted within the headstock and tailstock assemblies;
a saddle assembly operatively connected to the frame, the saddle assembly moveable along the frame and along the PCP rotor when mounted within the headstock and tailstock assemblies, the saddle assembly including a polishing system for engagement against the PCP rotor, wherein the polishing system is vertically moveable and horizontally pivotable with respect to the PCP
rotor.
a frame;
a headstock assembly and tailstock assembly operatively connected to the frame, the headstock assembly and tailstock assembly for operatively supporting a PCP rotor and enabling rotation of a PCP rotor mounted within the headstock and tailstock assemblies;
a saddle assembly operatively connected to the frame, the saddle assembly moveable along the frame and along the PCP rotor when mounted within the headstock and tailstock assemblies, the saddle assembly including a polishing system for engagement against the PCP rotor, wherein the polishing system is vertically moveable and horizontally pivotable with respect to the PCP
rotor.
2. A progressive cavity pump rotor polishing system as in claim 1 wherein the frame includes a rail system operatively supporting the saddle assembly and polishing system.
3. A progressive cavity pump rotor polishing system as in claim 2 wherein the rail system is a double rail and the saddle assembly includes a wheel and bearing system mounted on the double rail.
4. A progressive cavity pump rotor polishing system as in claim 3 wherein the rail system includes a rack and pinion system and motor for operative control of the polishing system along the rail system.
5. A progressive cavity pump rotor polishing system as in any one of claims 1-wherein the saddle assembly includes a vertical support member operatively connecting the polishing system to the saddle assembly and wherein the vertical support member enables vertical and rotational movement of the polishing system with respect to the saddle assembly.
6. A progressive cavity pump rotor polishing system as in claim 5 wherein the vertical support member includes a threaded screw, nut and drive motor for operative control of the vertical movement of the polishing system with respect to the frame.
7. A progressive cavity pump rotor polishing system as in any one of claims 1-wherein the polishing system includes a belt sander.
8. A progressive cavity pump rotor polishing system as in any one of claims 1-wherein the polishing system includes a polishing wheel.
9. A progressive cavity pump rotor polishing system as in any one of claims 3-wherein the wheel and bearing system includes at least four wheel pairs for engagement with the double rail wherein each wheel pair respectively engage with an upper surface and lower surface of one rail and wherein the wheel pairs are horizontally displaced with respect to one another to provide vertical, horizontal and torsional stability to the saddle system relative to the double rail.
10. A progressive cavity pump rotor polishing system as in any one of claims 1-further comprising a control system on the saddle assembly for operative control of:
a) the polishing system;
b) the headstock assembly; and c) the horizontal movement of the polishing system along the frame.
a) the polishing system;
b) the headstock assembly; and c) the horizontal movement of the polishing system along the frame.
11. A progressive cavity pump rotor polishing system as in claim 10 wherein the control system includes start, stop and speed control of the polishing system.
12. A progressive cavity pump rotor polishing system as in any one of claims 10 or 11 wherein the control system includes start, stop and speed control of the headstock assembly.
13. A progressive cavity pump rotor polishing system as in any one of claims wherein the control system includes start, stop, directional and speed control of the horizontal movement of the polishing system along the frame.
14. A progressive cavity pump rotor polishing system as in any one of claims wherein the polishing system includes a variable frequency drive motor and the control system includes a display for providing a pressure reading of the relative force being applied to a rotor during polishing.
15. A progressive cavity pump rotor polishing system as in any one claims 1-14 further comprising a lower support rail enabling selective positioning of the tailstock assembly at a selected distance from the headstock assembly.
16. A progressive cavity pump rotor polishing system as in claim 15 wherein the lower support rail includes rollers rotationally supporting a PCP rotor on the lower rail.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2669870A CA2669870A1 (en) | 2009-06-19 | 2009-06-19 | Rotor polishing system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2669870A CA2669870A1 (en) | 2009-06-19 | 2009-06-19 | Rotor polishing system |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2669870A1 true CA2669870A1 (en) | 2010-12-19 |
Family
ID=43379061
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2669870A Abandoned CA2669870A1 (en) | 2009-06-19 | 2009-06-19 | Rotor polishing system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2669870A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105538090A (en) * | 2015-12-04 | 2016-05-04 | 四川燚成钢结构有限公司 | Steel component polishing tool convenient to connect and fix |
| CN114337141A (en) * | 2021-12-30 | 2022-04-12 | 淮安苏马电机科技有限公司 | Motor rotor, motor, and production equipment and process of motor rotor |
| US11298791B2 (en) | 2015-09-28 | 2022-04-12 | Saint-Gobain Abrasives, Inc. | Method and system for removing material from a workpiece |
-
2009
- 2009-06-19 CA CA2669870A patent/CA2669870A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11298791B2 (en) | 2015-09-28 | 2022-04-12 | Saint-Gobain Abrasives, Inc. | Method and system for removing material from a workpiece |
| CN105538090A (en) * | 2015-12-04 | 2016-05-04 | 四川燚成钢结构有限公司 | Steel component polishing tool convenient to connect and fix |
| CN114337141A (en) * | 2021-12-30 | 2022-04-12 | 淮安苏马电机科技有限公司 | Motor rotor, motor, and production equipment and process of motor rotor |
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