ME 452: Machine Design II

Project 1 - Fall 2009

Deliverable Due: Monday, September 14, 2009

Final Report Due: Friday, October 2, 2009
(Before 4:30 pm in the design offices, room 300 ME)
This project is to be completed by each student individually.

Background
Crude oil is often found within sandy layers of porous material deep in the earth.
Once discovered, a hole is bored to the oil-filled layer and a casing inserted into the hole.
Then a pump is used to lift the crude oil out for processing into more useful petroleum-
based products, such as gasoline, oil, diesel fuel, etc. For many wells, the machine of
choice for pumping out the crude oil is the pump jack, also called the nodding donkey,
pumping unit, or horse-head pump. A typical layout of the pump is shown below in
Figure 1.

Figure 1. Schematic Layout of the Pump Unit

(from http://www.aoghs.org/pdf/September.pdf)
 The machine is powered by an electric motor, which drives a gear box through a
belt drive system. This belt and gear reduction greatly increases the torque and decreases
the speed, so that the crank arm of the pump unit (labeled counter balance above) turns
very slowly (usually about 30 revolutions per minute or less). The crank drives the
walking beam through two parallel connecting links, causing it to oscillate. The
oscillation of the walking beam causes the horse head to move up and down, which
drives the pump up and down in the well, much like a hand water pump. There are two
one-way valves in the pump which causes the oil to be pumped up the pipe and out of the
well. Figure 2 below shows the one-way valves in the pump.

Sucker rod Stroke

Oil
Oil
Moving ball
valve moves
Seal with sucker
rod

Well casing
Fixed ball
valve

Figure 2. One way valves in the pump which cause the oil to be pulled up the pipe

For a history of pumping units, see http://www.aoghs.org/pdf/September.pdf. For

more information on oil pumps, see http://en.wikipedia.org/wiki/Pumpjack. For a nice
animation see http://en.wikipedia.org/wiki/File:Pump_jack_animation.gif. To see some
old used machinery for sale (used pumpjacks, gear boxes, etc.) go to
http://www.lafoyequipment.com/pumping_units.htm.
 Problem Statement
The goal of this project is the design and analysis of the walking beam, the two
connecting links (called the pitman arm in Figure 1 above), and the two crank arms. To
do this, you will need to model the kinematics of the pumping unit. You will also need to
model the sucker rod and estimate the loads it places on the horse-head, so that you can
estimate the loads in the links. From these loads you can determine suitable dimensions
and material choices to meet the given yield and fatigue factors of safety. Finally, you
will also need to size the counterweights to minimize the peak torque demands on the
gear-box. (This will be useful information for the second project this semester, which
will include the design of the gear-box).
Solution Approach
Fatigue is caused by time-varying stresses and strains in the material. These stresses can
initiate at a crack, usually at a local surface imperfection such as a machining mark or notch in
the geometry (a bolt hole, for example). Thus, the stress concentration effects are very important
in fatigue. As the stresses are cycled, even at levels below the yield point of the material, the
crack can propagate through the material reducing its cross-sectional area. Eventually, the area
of material left to hold the loads decreases sufficiently to push the local stresses beyond the yield
or even ultimate strength of the material, in which case the part breaks.
The usual steps for fatigue analysis are exactly the 7 steps of stress analysis covered in
previous courses, and reviewed at the beginning of this course. The key added component here
is the fact that the stresses in the links of the pump unit vary with time, so that fatigue failure
modes must be considered in addition to yield failures. The following steps are suggestions for
completing this project.
1. Model the kinematics of the pump unit to obtain the position solution of the linkage.
(Plot 3 and 4 versus crank angle)
2. Model the pumping loads to determine the load fluctuations in the sucker rod, where it
connects to the horse head. (Plot cable tension versus crank angle)
3. Determine the loads on the links as a function of position from steps (1) and (2) above.
(Plot connecting rod tension and crank torque versus crank angle)
4. Determine the weight of the counter-weight shown on link 2 so that the peak torque
requirement from the gearbox is minimized. Use this counterweight value and the
resulting link loads in the rest of the analysis. (Report counter weight result)
TURN IN DELIVERABLE: Results of steps 1-4 above. Plots and counter weight
results only, no discussion needed. Discussion will be included in the final report.
This is just a progress check to make sure your numbers are good.
---------- DUE Monday September 14, 2009, by 4:30 pm in room 300 ME. ----------
5. Determine potential critical planes in the cranks, connecting links, and walking beam.
6. Determine how the internal loads vary with time on the critical planes.
7. Find the critical points on each critical plane, including stress concentration effects.
8. Calculate the fatigue and yield factors of safety at each critical point.
9. Determine appropriate sizes and materials for the parts to meet the given factor of
safety requirements. Be sure to check buckling if necessary.
FINAL REPORT DUE Friday October 2, 2009, by 4:30 pm in room ME 300
 Machine Data and Assumptions

Pump Unit Geometry

x
y
Rocking Beam
Link Lengths:
4 O2A = 1.0 ft
B AB = 4.0 ft
O4 O4B = 4.0 ft
Connecting Link 3 O2Q = 4.0 ft
Crank with counter-weight, O4Q = 3.873 ft
cg2 Horse Head cg2O2 = 1.5 ft
rotates 10 rpm cw A (Circular arc
2 about O4
Motor O2 Radius is 4.0 ft) Cable
Q
Gear-box

Well
Head

Note: There are TWO link 2s and TWO link 3s, one on each side of the gear box.
Assume they share the loads equally.

Sucker Rod Loading

Sucker rod diameter = 1.0 in (solid rod)

Weight density of sucker rod (steel) = 0.285 lb/cu-in
Weight of moving ball valve = 50 lb
Weight density of oil = 0.0314 lb/cu-in
Inside diameter of well casing = 4.0 in
Depth of well = 1000 ft. (oil is being lifted 1000 ft)
Neglect friction, and flow losses
Determine if inertia terms are negligible
Neglect pressure drops across the ball valves
Oil pressure at discharge of well (at the well head) is atmospheric
Rocking Beam Design

For the beam concept shown below,

Select an appropriate standard size with minimum factors of safety of 3 for all yield and
fatigue calculations. Choose its length, L4.

Locate 8 bolt holes in the bottom of the beam for fastening the bearings (one location for
the ground pivot, one for the connection to link 3).

Size and locate the 2 bolt holes in the end of the beam for fastening the horse head.
Assume the two horse-head bolts take all of the loading between the horse head and the
beam in double shear. Assume no load sharing due to friction in the joint.
2 holes for bolts on
end of beam to fasten
horse head American Standard I-Beam
Locate and size
appropriately Side view End View

L4

4.0 ft

6 in 6 in Holes centered
Holes for 3/4 Bolts laterally in
4 at each location flanges
on bottom of beam

Connecting Link 3

For Link 3, choose material, and size d, t3, L3, and w3 appropriately for buckling, yield
and fatigue factors of safety of at least 3. Assume equal load sharing on both sides of the
gear-box (there are two link 3s).

Hole diameter, d

w3

4.0 ft t3
L3
Crank Link 2

For the crank link 2, determine the weight and geometry needed in the counter weight to
locate its cg 1.5 feet from the ground pivot, and to minimize the peak torque loading on
the gear-box. Also, choose material, and size L2, t2, and w2 appropriately for buckling,
yield, and fatigue factors of safety of at least 3. Assume equal load sharing on each of the
two crank links, one on each side of the gear-box.

Dimension to achieve
appropriate counter- This hole diameter to
weight properties be sized in project 2.
For now, size it to
Pin, with diameter, d, match link 3.
to match link 3,
Sticking up out of page
height t3.

w2

1.0 ft t2
L2 t3

General Assumptions and Data

Life is to be 10 years of continuous service.

All factors of safety are to be at least 3.0

Speeds are slow so that viscous and inertial loads may be negligible verify this.

Weights of links (except counter-weight) may be negligible relative to other loads

verify this.
 Report

1. Final design solution (one page). Show the design geometry (neat hand drawings are
sufficient) and material choices. Discuss as needed to make it clear. Show sufficient detail
that our shop could make the parts.

2. Brief Solution Approach (1 to 2 pages)

Overall summary of the solution approach

3. Calculation Results (5 to 10 pages)

Kinematic results
Sucker rod loading results
Force analysis results
Counter weight results
Critical plane analysis
Critical point selection
Stress concentrations
Material choices (life calculations)
Final factors of safety

4. Appendices.
Appendix A:
Include free-body diagrams, equation derivations
Include sample hand calculations to explain your work.
Appendix B:
Include matlab code, or sample spreadsheet pages.

At your discretion, you may combine sections 2 and 3 together if you think that is clearer. The
grade sheet on the next page will be used by the teaching assistants to grade your report.
 ME 452 Machine Design II
Grade sheet for Final Report - Project 1, Fall 2009

(_____/10 points) Final Design Solution

(_____/10 points) Solution Approach: (One or Two pages)

(_____/50 points) Calculation Results: (5 to 10 pages)

Kinematic results
Sucker rod loading results
Force analysis results
Counter weight results
Critical plane analysis
Critical point selection
Stress concentrations
Material choices (life calculations)
Final factors of safety

(_____/15 points) Appendices:

Appendix A: Supporting information for the Solution Approach section above. (20 points)
Include free-body diagrams, equation derivations, to identify the state of stress at the critical plane.
Include sample hand calculations to explain your work.

Appendix B: Include computer programs and samples of spread-sheet pages as appropriate

(_____/15 points) Format:

Clear, well organized writing; Clear plots, tables, figures; Clear appendix material. Appropriate and informative titles
and legends on all plots and tables.