Tong manipulator system

Abstract

A tong manipulator system includes a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage. A first rotational positioning subsystem includes a first positioning arm, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis. A second rotational positioning subsystem includes a second positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis. A tong assembly is connected to the second positioning arm. The tong assembly includes a lower clamp and an upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate to make up or break down connections in the pipe.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 719,566, filed Nov. 12, 2024, the entirety of which is hereby incorporated herein by reference for all purposes.BACKGROUND

[0002] A tong assembly can be used to breakout or makeup connections on drill pipe, casing, and tubing.SUMMARY

[0003] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.

[0004] A tong manipulator system includes a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage. A first rotational positioning subsystem includes a first positioning arm, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis. A second rotational positioning subsystem includes a second positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis. A tong assembly is connected to the second positioning arm. The tong assembly includes a lower clamp and an upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate to make up or break down connections in the pipe.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 shows a first view of a tong manipulator system according to an example of the present disclosure.

[0006] FIG. 2 shows a top view of the tong manipulator system of FIG. 1.

[0007] FIG. 3 shows a bottom view of the tong manipulator system of FIG. 1.

[0008] FIG. 4 shows a second view of the tong manipulator system of FIG. 1.

[0009] FIG. 5 shows a section view of the tong manipulator system of FIG. 1.

[0010] FIG. 6 schematically depicts an example control system configured to control functions of a tong manipulator system.

[0011] FIG. 7 schematically shows an example computing system.DETAILED DESCRIPTIONFIG. 1 shows a first view of a tong manipulator system 100 for a tong assembly according to an example of the present disclosure. FIG. 2 shows a top view of the tong manipulator system of FIG. 1. FIG. 3 shows a bottom view of the tong manipulator system of FIG. 1. FIG. 4 shows a second view of the tong manipulator system of FIG. 1. FIG. 5 shows a section view of the tong manipulator system of FIG. 1. FIG. 6 schematically depicts an example control system configured to control functions of the tong manipulator system of FIG. 1. One or more aspects of the control system of FIG. 7 may be implemented as computing system 700 described with respect to FIG. 7.

[0013] Manually actuated and / or controlled features of existing tong assemblies can have various disadvantages and / or limitations. As an example, a tong assembly can have a weight of approximately 1200 pounds, which can present challenges for human operators to manipulate. Tong manipulator system 100 offers the potential to address the various disadvantages and / or limitations of tong assemblies that have previously relied upon manually actuated and / or controlled features.

[0014] One example of a tong manipulator system includes one or more of the following features: (1) hydraulically actuated (e.g., hydraulic power may be provided by a rig hydraulic power unit), (2) a hydraulically actuated lower clamp that grips the pipe, (3) an upper clamp and rotary assembly that rotates the pipe against the lower clamp to make up and / or take apart pipe joints (e.g., the pipe joints can be a tapered buttress thread style) in which clamping and / or rotation is accomplished via a hydraulic motor that can be manually actuated via a hydraulic spool valve assembly by the operator, (4) hydraulic valves to actuate the upper and lower clamps, (5) a spring assembly that separates the upper and lower clamps (e.g., to allow for axial make up and / or take apart) wherein when a joint is screwed together it collapses axially, which requires some relative motion between the upper and lower clamps, (6) a torque sensor that includes a pancake-style hydraulic cylinder connected to a pressure gauge, wherein the torque sensor is connected to the upper clamp and will indicate (e.g., by hydraulic pressure) how much torque is applied to the upper clamp relative to the lower clamp, and which is used to confirm how much torque is applied to the pipe joint when it is screwed together, (7) a manual operated positioner, wherein horizontal motion is via a jib beam, and vertical positioning is accomplished via a spring style mechanism that supports the vertical weight / position of the tong assembly.

[0015] Tong manipulator system 100 includes a vertical positioning assembly for changing the position of aspects of the tong manipulator system relative to a vertical axis. The vertical positioning assembly may include one or more of the following features: (1) hydraulically actuated, (2) provides position feedback mounted in and / or on the hydraulic cylinder, (3) a circular flange mount at the bottom, (4) composite bearings between fixed tower and moving outer carriage, (5) a replaceable keyway that prevents rotation of the outer carriage, (6) support on the outer carriage for a first rotational positioning subsystem (discussed below), (7) hydraulic valves, (8) a hydraulic hose bulkhead, (9) an electrical junction box, (10) an electrical cabling bulkhead, and (11) supports for the hydraulic valves, the hydraulic hose bulkhead, the electrical junction box, and the electrical cabling bulkhead. Example performance characteristics of tong manipulator system 100 for the vertical axis include a speed of 0.14 m / s, a force of 73 kN (cylinder extend), and hydraulic pressure of 150 bar. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on implementation.

[0016] In the example of FIG. 1, tong manipulator system 100 includes a vertical positioning subsystem 102. The vertical positioning system includes a fixed tower 104 and a moveable outer carriage 106. A hydraulic positioning system (described below with respect to FIG. 5) is configured to adjust the position of the moveable outer carriage relative to the fixed tower. In FIG. 1, the vertical positioning subsystem further comprises a replaceable keyway 108 configured to prevent rotation of the moveable outer carriage relative to the fixed tower.

[0017] Tong manipulator system 100 includes a first rotational positioning subsystem for rotating aspects of the tong manipulator system about a first rotational axis. The first rotational positioning system may include one or more of the following features: (1) connected to the bottom of the moveable carriage of the vertical positioning subsystem carriage, (2) a servo motor, (3) a gearbox (e.g., low backlash), (4) a drive gear, (5) a turntable bearing, (6) a turntable bearing mount plate with a splash shield, (7) a first positioning arm (e.g., burned and / or machined from plate steel), (8) hydraulic hoses, (9) electrical cabling, and (10) supports for the hydraulic hoses, the electrical cabling, and components used for a second rotational positioning subsystem (discussed below). Example performance characteristics of tong manipulator system 100 for the first rotational positioning system include a rotary speed of 2 revolutions per minute (rpm) and a torque of 200 Nm. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on the implementation.

[0018] In the example of FIG. 1, tong manipulator system 100 includes a first rotational positioning subsystem 110. The first rotational positioning system includes a first positioning arm 112 rotatably connected to the moveable outer carriage 106 of the vertical positioning subsystem 102. A first servo motor 114 is configured to cause rotation of the first positioning arm 112 about the first rotational axis. In the example of FIG. 1, the first positioning arm 112 is rotatably connected to the moveable outer carriage via a turntable bearing 116.

[0019] Tong manipulator system 100 includes a second rotational positioning subsystem for rotating aspects of the tong manipulator system about a second rotational axis. The second rotational subsystem may include one or more of the following features: (1) components for the second rotational positioning assembly are connected to the top of the first rotational positioning assembly, (2) a servo motor, (3) a gearbox (e.g., low backlash), (4) a support bearing, (5) a second positioning arm (e.g., burned and / or machined from plate steel), (6) a pipe proximity sensor array, (7) an electrical junction box, (8) a lower tong clamp, (9) an upper tong rotary clamp, (10) a torque frame (e.g., between upper and lower tongs), (11) a torque sensor, (12) an electrical junction box and cabling, (13) hydraulic hoses, and (14) supports for the lower tong clamp, the upper tong rotary clamp, the torque frame (e.g., between upper and lower clamps), the torque sensor, the electrical junction box and cabling, and the hydraulic hoses. Example performance characteristics of tong manipulator system 100 for the second rotational positioning system include a rotary speed of 5 rpm and a torque of 200 Nm. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on implementation.

[0020] In the example of FIG. 1, tong manipulator system 100 includes a second rotational positioning subsystem 118. The second rotational positioning subsystem includes a second positioning arm 120 rotatably connected to the first positioning arm 112. A second servo motor 122 is configured to cause rotation of the second positioning arm about the second rotational axis.

[0021] In the example of FIG. 1, tong manipulator system 100 includes a tong assembly 124 connected to the second positioning arm 120. The tong assembly includes a lower clamp 126 configured to grip a pipe. The tong assembly additionally includes an upper clamp 128 configured to grip the pipe. The upper clamp includes a rotary assembly 130 configured to rotate relative to the lower clamp to make up or break down connections in the pipe. In some examples, the lower clamp and the upper clamp are hydraulically actuated. In some examples, the tong manipulator system further comprises a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp. In FIG. 1, tong manipulator system 100 includes a hydraulic motor 132 configured to rotate the rotary assembly. Furthermore, in FIG. 1, the tong assembly further includes a spring assembly 134 positioned between the upper clamp and the lower clamp to facilitate axial movement of the upper clamp relative to the lower clamp.

[0022] In some examples, the tong manipulator system may include a pipe proximity sensor array configured to detect proximity of the pipe. The pipe proximity sensor array may include one or more of the following features: (1) a spring mounted hardware bracket (e.g., replaceable for different sizes of drilling pipe), (2) a vertical position proximity sensor, (3) one or more horizontal position proximity sensors, and (4) a pipe presence proximity sensor. The pipe proximity sensor array can be used to sense the actual drilling pipe location and to make position corrections (e.g., relatively fine / small position corrections) using the servo system if the pipe is out of position. The pipe proximity sensor array can also be used to sense that a pipe is actually in place.

[0023] In at least some examples, the tong manipulator system may include a torque sensor. As one example, the torque sensor can take the form of a pancake-style cylinder with pressure transducer and / or a load cell.

[0024] In some examples, the tong manipulator system may include rotary position sensors used to ensure that the tong assembly is in the correct position before motion is initiated relative to the first and second rotational axes.

[0025] FIGS. 2-5 provide additional views of tong manipulator system 100. FIG. 2 provides an upper view of the tong manipulator system, and illustrates one example rotational range of motion of the tong manipulator system between a jack and a mouse hole. FIG. 3 provides a bottom view of the tong manipulator system. FIG. 4 provides a second view of tong manipulator system. As shown, each of the first and second servo motors is coupled to a respective low-backlash gearbox, labeled in FIG. 4 as gearboxes 136A and 136B. FIG. 5 provides a section view of tong manipulator system 100 along section A shown in FIG. 4. In some examples, movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower. FIG. 5 depicts composite bearings 138A and 138B between the moveable outer carriage and the fixed tower. Additionally, FIG. 5 depicts a hydraulic positioning system 140 configured to adjust the position of the moveable outer carriage relative to the fixed tower.

[0026] The tong manipulator system 100 can include a control system. As non-limiting examples, the control system may include one or more of: a motor starter panel that includes Class I, Div 2 electrical classification per NFPA 79; a main circuit breaker (e.g., 460 / 3 / 60 power supplied by others); one or more servo amplifiers; a programmable logic controller (PLC) controller; PLC input / output (I / O); intrinsic safe barriers for proximity sensors; a terminal strip; and conduit seal assemblies. The control system can further include a control panel that includes Class 1, Div 2 electrical classification per NFPA 79, and a HMI (touch screen human interface device), as an example.

[0027] The control panel and / or control system can provide the following settings: Position 1 location (X, Y, Z), Position 2 location (X, Y, Z), Park location (X, Y, Z), speed settings for axis motions, and acceleration settings for axis motions. The control panel and / or control system can provide the following diagnostic information: fault annunciation, system voltage, and servo temperature. The control panel and / or control system can provide the following status information: motion (stopped, moving, in-position), servo status (operational, ready, running, temperature, current, torque), and position sensor feedback. The control panel and / or control system can provide a manual / automatic selector, a manual motion axis select (axis, direction). The control panel and / or control system can include user-operable pushbuttons and / or actuators that provide E-stop, Keyswitch OFF.ON.MCR SET, Power ON pilot light, Position 1 select (illuminated), Position 2 select (illuminated), Park Position (illuminated), Move initiate (e.g., dual buttons, both of which may be pushed simultaneously and continuously to move the machine, in some examples) (illuminated), Tighten (illuminated), and / or Loosen (illuminated), as examples.

[0028] This is schematically illustrated in FIG. 6, depicting an example control system 600 that may be used to control one or more functions of tong manipulator system 100. In the example of FIG. 6, the control system includes at least a motor starter panel 602, a main circuit breaker 604, one or more servo amplifiers 606, a PLC 608, and a control panel 610 comprising a touch-screen HMI 612.

[0029] The touch-screen HMI may in some cases be used to display various information relating to the status and / or behavior of the tong manipulator system. In FIG. 6, touch-screen HMI 612 is used to display status information 614 and diagnostic information 616. The status information may include one or more of motion status, servo status, and position sensor feedback, as examples. The diagnostic information may include one or more of fault annunciation, system voltage, and servo temperature.

[0030] In some examples, the control panel includes one or more user-operable controls. In FIG. 6, control panel 610 includes one or more user-operable controls 618. The user-operable controls may include one or more of: controls for automatically moving the tong assembly to one or more respective predetermined positions, controls for initiating manual movement of the tong assembly, a tighten control (e.g., for gripping a pipe), and a loosen control (e.g., for releasing the pipe).

[0031] In at least some examples, a test fixture may be provided for tong manipulator system 100 to assemble, test, and train operators on the system prior to installation.

[0032] In at least some examples, the control system can include or take the form of a computing system of one or more computing devices and / or other electronic components. FIG. 7 schematically depicts an example computing system 700, which may be included in control system 600, and / or used to implement one or more of the above-described subcomponents of control system 600. Computing system 700 includes a logic machine 702, a data storage machine 704, and an input / output subsystem 706. The data storage machine 704 has instructions stored thereon executable by the logic machine 702 to implement any of the control methods or processes described herein.

[0033] The logic machine 702 includes one or more physical logic devices configured to execute instructions. For example, the logic machine 702 may be configured to execute instructions that are part of one or more programs, routines, libraries, objects, components, data structures, or other logical constructs. Such instructions may be implemented to perform a task, implement a data type, transform the state of one or more components, achieve a technical effect, or otherwise arrive at a desired result.

[0034] The logic machine 702 of computing system 700 may include one or more processor devices configured to execute software instructions. Additionally or alternatively, the logic machine 702 may include one or more hardware or firmware logic machines configured to execute hardware or firmware instructions. Processors of the logic machine may be single-core or multi-core, and the instructions executed thereon may be configured for sequential, parallel, and / or distributed processing.

[0035] The data storage machine 704 of computing system 700 includes one or more physical storage devices configured to hold instructions executable by the logic machine 702 to implement the methods and processes described herein. When such methods and processes are implemented, the state of the storage machine may be transformed—e.g., to hold different data. The storage machine may include removable and / or built-in devices, including computer memory devices and / or other forms of computer data storage.

[0036] Aspects of the logic machine 702 and data storage machine 704 may be integrated together into one or more hardware-logic components. Such hardware-logic components may include field-programmable gate arrays (FPGAs), program- and application-specific integrated circuits (PASIC / ASICs), program- and application-specific standard products (PSSP / ASSPs), system-on-a-chip (SOC), and complex programmable logic devices (CPLDs), for example.

[0037] Input / output subsystem 706 includes one or more input devices and / or one or more input interfaces that are operatively coupled to one or more peripheral input devices. Such input devices can enable a user (e.g., a human operator) to provide a user input to control operation of the tong manipulator system disclosed herein. Additionally, input / output subsystem 706 includes one or more output devices and / or one or more output interfaces that are operatively coupled to one or more peripheral output devices. Such output devices can enable the computing system to generate an output that can be perceived by a user, enabling the user to receive feedback of an operational state of the tong manipulator system disclosed herein. Input / output subsystem 706 can include a network interface in at least some examples that operatively couples the computing system to a communications network, enabling the computing system to communicate with one or more remote devices.

[0038] One example of an output device of input / output subsystem 706 is a display subsystem that may be used to present a visual representation of data held by the data storage machine 704. This visual representation may take the form of a graphical user interface (GUI). As the herein described methods and processes change the data held by the storage machine, and thus transform the state of the storage machine, the state of the display subsystem may likewise be transformed to visually represent changes in the underlying data. The display subsystem may include one or more display devices utilizing virtually any type of technology. In some examples, the display subsystem can take the form of a touch-screen that also serves as an input device of input / output subsystem 706. Such display devices may be combined with the logic machine and / or storage machine in a shared enclosure, or such display devices may be peripheral display devices.

[0039] Further, the disclosure comprises configurations according to the following examples.Example 1

[0040] A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; and a tong assembly connected to the second positioning arm, the tong assembly comprising: a lower clamp configured to grip a pipe; and an upper clamp configured to grip the pipe, and the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe.Example 2

[0041] The tong manipulator system of Example 1, wherein the lower clamp and the upper clamp are hydraulically actuated.Example 3

[0042] The tong manipulator system of Example 1, further comprising a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp.Example 4

[0043] The tong manipulator system of Example 1, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.Example 5

[0044] The tong manipulator system of Example 1, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.Example 6

[0045] The tong manipulator system of Example 1, wherein the first positioning arm is rotatably connected to the moveable outer carriage via a turntable bearing.Example 7

[0046] The tong manipulator system of Example 1, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.Example 8

[0047] The tong manipulator system of Example 1, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.Example 9

[0048] The tong manipulator system of Example 1, further comprising a control system, wherein the control system includes a motor starter panel, a main circuit breaker, one or more servo amplifiers, a programmable logic controller (PLC), and a control panel comprising a touch screen human interface device.Example 10

[0049] The tong manipulator system of Example 9, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.Example 11

[0050] The tong manipulator system of Example 9, wherein the control panel includes a plurality of user-operable controls, including one or more controls for automatically moving the tong assembly to one or more respective predetermined positions, one or more controls for initiating manual movement of the tong assembly, a tighten control, and a loosen control.Example 12

[0051] A computing system of a tong manipulator system, the computing system comprising: a logic machine; and a data storage machine holding instructions executable by the logic machine to: change a position of a tong assembly of the tong manipulator system, the tong assembly including a lower clamp and an upper clamp configured to grip a pipe, and wherein the position of the tong assembly is changed by controlling one or more of: a vertical positioning subsystem of the tong manipulator system, the vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system controllable by the logic machine to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem of the tong manipulator system, the first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor controllable by the logic machine to cause rotation of the first positioning arm about a first rotational axis; and a second rotational positioning subsystem of the tong manipulator system, the second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor controllable by the logic machine to cause rotation of the second positioning arm about a second rotational axis, wherein the tong assembly is connected to the second positioning arm; actuate the lower clamp and the upper clamp of the tong assembly to grip the pipe; and rotate a rotary assembly of the upper clamp relative to the lower clamp to make up or break down connections in the pipe.Example 13

[0052] The computing system of Example 12, wherein the lower clamp and the upper clamp are hydraulically actuated.Example 14

[0053] wherein the tong manipulator system further comprises a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp; and wherein the instructions are further executable by the logic machine to control the hydraulic motor to rotate the rotary assembly of the upper clamp relative to the lower clamp.Example 15

[0054] The computing system of Example 12, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.Example 16

[0055] The computing system of Example 12, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.Example 17

[0056] The computing system of Example 12, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.Example 18

[0057] The computing system of Example 12, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.Example 19

[0058] The computing system of Example 12, further comprising a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.Example 20

[0059] A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; a tong assembly connected to the second positioning arm, the tong assembly comprising: a hydraulically actuated lower clamp configured to grip a pipe; and a hydraulically actuated upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe, wherein a spring assembly positioned between the upper clamp and the lower clamp facilitates axial movement of the upper clamp relative to the lower clamp; and a control system including a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system.Example 21

[0060] A method performed by a computing system with respect to a tong manipulator system, the method comprising: changing a position of a tong assembly of the tong manipulator system, the tong assembly including a lower clamp and an upper clamp configured to grip a pipe, and wherein the position of the tong assembly is changed by controlling one or more of: a vertical positioning subsystem of the tong manipulator system, the vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system controllable to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem of the tong manipulator system, the first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor controllable by the logic machine to cause rotation of the first positioning arm about a first rotational axis; and a second rotational positioning subsystem of the tong manipulator system, the second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor controllable to cause rotation of the second positioning arm about a second rotational axis, wherein the tong assembly is connected to the second positioning arm; actuating the lower clamp and the upper clamp of the tong assembly to grip the pipe; and rotating a rotary assembly of the upper clamp relative to the lower clamp to make up or break down connections in the pipe.

[0061] It will be understood that the configurations and / or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. As such, various acts illustrated and / or described may be performed in the sequence illustrated and / or described, in other sequences, in parallel, or omitted. Likewise, the order of the above-described processes may be changed.

[0062] The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various processes, systems and configurations, and other features, functions, acts, and / or properties disclosed herein, as well as any and all equivalents thereof.

Examples

example 1

[0040]A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; and a tong assembly connected to the second positioning arm, the tong assembly comprising: a lower clamp configured to grip a pipe; and an upper clamp configured to grip the pipe, and the upper clamp including a rotary...

example 2

[0041]The tong manipulator system of Example 1, wherein the lower clamp and the upper clamp are hydraulically actuated.

example 3

[0042]The tong manipulator system of Example 1, further comprising a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 719,566, filed Nov. 12, 2024, the entirety of which is hereby incorporated herein by reference for all purposes.BACKGROUND

[0002] A tong assembly can be used to breakout or makeup connections on drill pipe, casing, and tubing.SUMMARY

[0003] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.

[0004] A tong manipulator system includes a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage. A first rotational positioning subsystem includes a first positioning arm, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis. A second rotational positioning subsystem includes a second positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis. A tong assembly is connected to the second positioning arm. The tong assembly includes a lower clamp and an upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate to make up or break down connections in the pipe.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 shows a first view of a tong manipulator system according to an example of the present disclosure.

[0006] FIG. 2 shows a top view of the tong manipulator system of FIG. 1.

[0007] FIG. 3 shows a bottom view of the tong manipulator system of FIG. 1.

[0008] FIG. 4 shows a second view of the tong manipulator system of FIG. 1.

[0009] FIG. 5 shows a section view of the tong manipulator system of FIG. 1.

[0010] FIG. 6 schematically depicts an example control system configured to control functions of a tong manipulator system.

[0011] FIG. 7 schematically shows an example computing system.DETAILED DESCRIPTIONFIG. 1 shows a first view of a tong manipulator system 100 for a tong assembly according to an example of the present disclosure. FIG. 2 shows a top view of the tong manipulator system of FIG. 1. FIG. 3 shows a bottom view of the tong manipulator system of FIG. 1. FIG. 4 shows a second view of the tong manipulator system of FIG. 1. FIG. 5 shows a section view of the tong manipulator system of FIG. 1. FIG. 6 schematically depicts an example control system configured to control functions of the tong manipulator system of FIG. 1. One or more aspects of the control system of FIG. 7 may be implemented as computing system 700 described with respect to FIG. 7.

[0013] Manually actuated and / or controlled features of existing tong assemblies can have various disadvantages and / or limitations. As an example, a tong assembly can have a weight of approximately 1200 pounds, which can present challenges for human operators to manipulate. Tong manipulator system 100 offers the potential to address the various disadvantages and / or limitations of tong assemblies that have previously relied upon manually actuated and / or controlled features.

[0014] One example of a tong manipulator system includes one or more of the following features: (1) hydraulically actuated (e.g., hydraulic power may be provided by a rig hydraulic power unit), (2) a hydraulically actuated lower clamp that grips the pipe, (3) an upper clamp and rotary assembly that rotates the pipe against the lower clamp to make up and / or take apart pipe joints (e.g., the pipe joints can be a tapered buttress thread style) in which clamping and / or rotation is accomplished via a hydraulic motor that can be manually actuated via a hydraulic spool valve assembly by the operator, (4) hydraulic valves to actuate the upper and lower clamps, (5) a spring assembly that separates the upper and lower clamps (e.g., to allow for axial make up and / or take apart) wherein when a joint is screwed together it collapses axially, which requires some relative motion between the upper and lower clamps, (6) a torque sensor that includes a pancake-style hydraulic cylinder connected to a pressure gauge, wherein the torque sensor is connected to the upper clamp and will indicate (e.g., by hydraulic pressure) how much torque is applied to the upper clamp relative to the lower clamp, and which is used to confirm how much torque is applied to the pipe joint when it is screwed together, (7) a manual operated positioner, wherein horizontal motion is via a jib beam, and vertical positioning is accomplished via a spring style mechanism that supports the vertical weight / position of the tong assembly.

[0015] Tong manipulator system 100 includes a vertical positioning assembly for changing the position of aspects of the tong manipulator system relative to a vertical axis. The vertical positioning assembly may include one or more of the following features: (1) hydraulically actuated, (2) provides position feedback mounted in and / or on the hydraulic cylinder, (3) a circular flange mount at the bottom, (4) composite bearings between fixed tower and moving outer carriage, (5) a replaceable keyway that prevents rotation of the outer carriage, (6) support on the outer carriage for a first rotational positioning subsystem (discussed below), (7) hydraulic valves, (8) a hydraulic hose bulkhead, (9) an electrical junction box, (10) an electrical cabling bulkhead, and (11) supports for the hydraulic valves, the hydraulic hose bulkhead, the electrical junction box, and the electrical cabling bulkhead. Example performance characteristics of tong manipulator system 100 for the vertical axis include a speed of 0.14 m / s, a force of 73 kN (cylinder extend), and hydraulic pressure of 150 bar. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on implementation.

[0016] In the example of FIG. 1, tong manipulator system 100 includes a vertical positioning subsystem 102. The vertical positioning system includes a fixed tower 104 and a moveable outer carriage 106. A hydraulic positioning system (described below with respect to FIG. 5) is configured to adjust the position of the moveable outer carriage relative to the fixed tower. In FIG. 1, the vertical positioning subsystem further comprises a replaceable keyway 108 configured to prevent rotation of the moveable outer carriage relative to the fixed tower.

[0017] Tong manipulator system 100 includes a first rotational positioning subsystem for rotating aspects of the tong manipulator system about a first rotational axis. The first rotational positioning system may include one or more of the following features: (1) connected to the bottom of the moveable carriage of the vertical positioning subsystem carriage, (2) a servo motor, (3) a gearbox (e.g., low backlash), (4) a drive gear, (5) a turntable bearing, (6) a turntable bearing mount plate with a splash shield, (7) a first positioning arm (e.g., burned and / or machined from plate steel), (8) hydraulic hoses, (9) electrical cabling, and (10) supports for the hydraulic hoses, the electrical cabling, and components used for a second rotational positioning subsystem (discussed below). Example performance characteristics of tong manipulator system 100 for the first rotational positioning system include a rotary speed of 2 revolutions per minute (rpm) and a torque of 200 Nm. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on the implementation.

[0018] In the example of FIG. 1, tong manipulator system 100 includes a first rotational positioning subsystem 110. The first rotational positioning system includes a first positioning arm 112 rotatably connected to the moveable outer carriage 106 of the vertical positioning subsystem 102. A first servo motor 114 is configured to cause rotation of the first positioning arm 112 about the first rotational axis. In the example of FIG. 1, the first positioning arm 112 is rotatably connected to the moveable outer carriage via a turntable bearing 116.

[0019] Tong manipulator system 100 includes a second rotational positioning subsystem for rotating aspects of the tong manipulator system about a second rotational axis. The second rotational subsystem may include one or more of the following features: (1) components for the second rotational positioning assembly are connected to the top of the first rotational positioning assembly, (2) a servo motor, (3) a gearbox (e.g., low backlash), (4) a support bearing, (5) a second positioning arm (e.g., burned and / or machined from plate steel), (6) a pipe proximity sensor array, (7) an electrical junction box, (8) a lower tong clamp, (9) an upper tong rotary clamp, (10) a torque frame (e.g., between upper and lower tongs), (11) a torque sensor, (12) an electrical junction box and cabling, (13) hydraulic hoses, and (14) supports for the lower tong clamp, the upper tong rotary clamp, the torque frame (e.g., between upper and lower clamps), the torque sensor, the electrical junction box and cabling, and the hydraulic hoses. Example performance characteristics of tong manipulator system 100 for the second rotational positioning system include a rotary speed of 5 rpm and a torque of 200 Nm. It will be understood that other suitable performance characteristics can be provided by the tong manipulator system, depending on implementation.

[0020] In the example of FIG. 1, tong manipulator system 100 includes a second rotational positioning subsystem 118. The second rotational positioning subsystem includes a second positioning arm 120 rotatably connected to the first positioning arm 112. A second servo motor 122 is configured to cause rotation of the second positioning arm about the second rotational axis.

[0021] In the example of FIG. 1, tong manipulator system 100 includes a tong assembly 124 connected to the second positioning arm 120. The tong assembly includes a lower clamp 126 configured to grip a pipe. The tong assembly additionally includes an upper clamp 128 configured to grip the pipe. The upper clamp includes a rotary assembly 130 configured to rotate relative to the lower clamp to make up or break down connections in the pipe. In some examples, the lower clamp and the upper clamp are hydraulically actuated. In some examples, the tong manipulator system further comprises a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp. In FIG. 1, tong manipulator system 100 includes a hydraulic motor 132 configured to rotate the rotary assembly. Furthermore, in FIG. 1, the tong assembly further includes a spring assembly 134 positioned between the upper clamp and the lower clamp to facilitate axial movement of the upper clamp relative to the lower clamp.

[0022] In some examples, the tong manipulator system may include a pipe proximity sensor array configured to detect proximity of the pipe. The pipe proximity sensor array may include one or more of the following features: (1) a spring mounted hardware bracket (e.g., replaceable for different sizes of drilling pipe), (2) a vertical position proximity sensor, (3) one or more horizontal position proximity sensors, and (4) a pipe presence proximity sensor. The pipe proximity sensor array can be used to sense the actual drilling pipe location and to make position corrections (e.g., relatively fine / small position corrections) using the servo system if the pipe is out of position. The pipe proximity sensor array can also be used to sense that a pipe is actually in place.

[0023] In at least some examples, the tong manipulator system may include a torque sensor. As one example, the torque sensor can take the form of a pancake-style cylinder with pressure transducer and / or a load cell.

[0024] In some examples, the tong manipulator system may include rotary position sensors used to ensure that the tong assembly is in the correct position before motion is initiated relative to the first and second rotational axes.

[0025] FIGS. 2-5 provide additional views of tong manipulator system 100. FIG. 2 provides an upper view of the tong manipulator system, and illustrates one example rotational range of motion of the tong manipulator system between a jack and a mouse hole. FIG. 3 provides a bottom view of the tong manipulator system. FIG. 4 provides a second view of tong manipulator system. As shown, each of the first and second servo motors is coupled to a respective low-backlash gearbox, labeled in FIG. 4 as gearboxes 136A and 136B. FIG. 5 provides a section view of tong manipulator system 100 along section A shown in FIG. 4. In some examples, movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower. FIG. 5 depicts composite bearings 138A and 138B between the moveable outer carriage and the fixed tower. Additionally, FIG. 5 depicts a hydraulic positioning system 140 configured to adjust the position of the moveable outer carriage relative to the fixed tower.

[0026] The tong manipulator system 100 can include a control system. As non-limiting examples, the control system may include one or more of: a motor starter panel that includes Class I, Div 2 electrical classification per NFPA 79; a main circuit breaker (e.g., 460 / 3 / 60 power supplied by others); one or more servo amplifiers; a programmable logic controller (PLC) controller; PLC input / output (I / O); intrinsic safe barriers for proximity sensors; a terminal strip; and conduit seal assemblies. The control system can further include a control panel that includes Class 1, Div 2 electrical classification per NFPA 79, and a HMI (touch screen human interface device), as an example.

[0027] The control panel and / or control system can provide the following settings: Position 1 location (X, Y, Z), Position 2 location (X, Y, Z), Park location (X, Y, Z), speed settings for axis motions, and acceleration settings for axis motions. The control panel and / or control system can provide the following diagnostic information: fault annunciation, system voltage, and servo temperature. The control panel and / or control system can provide the following status information: motion (stopped, moving, in-position), servo status (operational, ready, running, temperature, current, torque), and position sensor feedback. The control panel and / or control system can provide a manual / automatic selector, a manual motion axis select (axis, direction). The control panel and / or control system can include user-operable pushbuttons and / or actuators that provide E-stop, Keyswitch OFF.ON.MCR SET, Power ON pilot light, Position 1 select (illuminated), Position 2 select (illuminated), Park Position (illuminated), Move initiate (e.g., dual buttons, both of which may be pushed simultaneously and continuously to move the machine, in some examples) (illuminated), Tighten (illuminated), and / or Loosen (illuminated), as examples.

[0028] This is schematically illustrated in FIG. 6, depicting an example control system 600 that may be used to control one or more functions of tong manipulator system 100. In the example of FIG. 6, the control system includes at least a motor starter panel 602, a main circuit breaker 604, one or more servo amplifiers 606, a PLC 608, and a control panel 610 comprising a touch-screen HMI 612.

[0029] The touch-screen HMI may in some cases be used to display various information relating to the status and / or behavior of the tong manipulator system. In FIG. 6, touch-screen HMI 612 is used to display status information 614 and diagnostic information 616. The status information may include one or more of motion status, servo status, and position sensor feedback, as examples. The diagnostic information may include one or more of fault annunciation, system voltage, and servo temperature.

[0030] In some examples, the control panel includes one or more user-operable controls. In FIG. 6, control panel 610 includes one or more user-operable controls 618. The user-operable controls may include one or more of: controls for automatically moving the tong assembly to one or more respective predetermined positions, controls for initiating manual movement of the tong assembly, a tighten control (e.g., for gripping a pipe), and a loosen control (e.g., for releasing the pipe).

[0031] In at least some examples, a test fixture may be provided for tong manipulator system 100 to assemble, test, and train operators on the system prior to installation.

[0032] In at least some examples, the control system can include or take the form of a computing system of one or more computing devices and / or other electronic components. FIG. 7 schematically depicts an example computing system 700, which may be included in control system 600, and / or used to implement one or more of the above-described subcomponents of control system 600. Computing system 700 includes a logic machine 702, a data storage machine 704, and an input / output subsystem 706. The data storage machine 704 has instructions stored thereon executable by the logic machine 702 to implement any of the control methods or processes described herein.

[0033] The logic machine 702 includes one or more physical logic devices configured to execute instructions. For example, the logic machine 702 may be configured to execute instructions that are part of one or more programs, routines, libraries, objects, components, data structures, or other logical constructs. Such instructions may be implemented to perform a task, implement a data type, transform the state of one or more components, achieve a technical effect, or otherwise arrive at a desired result.

[0034] The logic machine 702 of computing system 700 may include one or more processor devices configured to execute software instructions. Additionally or alternatively, the logic machine 702 may include one or more hardware or firmware logic machines configured to execute hardware or firmware instructions. Processors of the logic machine may be single-core or multi-core, and the instructions executed thereon may be configured for sequential, parallel, and / or distributed processing.

[0035] The data storage machine 704 of computing system 700 includes one or more physical storage devices configured to hold instructions executable by the logic machine 702 to implement the methods and processes described herein. When such methods and processes are implemented, the state of the storage machine may be transformed—e.g., to hold different data. The storage machine may include removable and / or built-in devices, including computer memory devices and / or other forms of computer data storage.

[0036] Aspects of the logic machine 702 and data storage machine 704 may be integrated together into one or more hardware-logic components. Such hardware-logic components may include field-programmable gate arrays (FPGAs), program- and application-specific integrated circuits (PASIC / ASICs), program- and application-specific standard products (PSSP / ASSPs), system-on-a-chip (SOC), and complex programmable logic devices (CPLDs), for example.

[0037] Input / output subsystem 706 includes one or more input devices and / or one or more input interfaces that are operatively coupled to one or more peripheral input devices. Such input devices can enable a user (e.g., a human operator) to provide a user input to control operation of the tong manipulator system disclosed herein. Additionally, input / output subsystem 706 includes one or more output devices and / or one or more output interfaces that are operatively coupled to one or more peripheral output devices. Such output devices can enable the computing system to generate an output that can be perceived by a user, enabling the user to receive feedback of an operational state of the tong manipulator system disclosed herein. Input / output subsystem 706 can include a network interface in at least some examples that operatively couples the computing system to a communications network, enabling the computing system to communicate with one or more remote devices.

[0038] One example of an output device of input / output subsystem 706 is a display subsystem that may be used to present a visual representation of data held by the data storage machine 704. This visual representation may take the form of a graphical user interface (GUI). As the herein described methods and processes change the data held by the storage machine, and thus transform the state of the storage machine, the state of the display subsystem may likewise be transformed to visually represent changes in the underlying data. The display subsystem may include one or more display devices utilizing virtually any type of technology. In some examples, the display subsystem can take the form of a touch-screen that also serves as an input device of input / output subsystem 706. Such display devices may be combined with the logic machine and / or storage machine in a shared enclosure, or such display devices may be peripheral display devices.

[0039] Further, the disclosure comprises configurations according to the following examples.Example 1

[0040] A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; and a tong assembly connected to the second positioning arm, the tong assembly comprising: a lower clamp configured to grip a pipe; and an upper clamp configured to grip the pipe, and the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe.Example 2

[0041] The tong manipulator system of Example 1, wherein the lower clamp and the upper clamp are hydraulically actuated.Example 3

[0042] The tong manipulator system of Example 1, further comprising a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp.Example 4

[0043] The tong manipulator system of Example 1, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.Example 5

[0044] The tong manipulator system of Example 1, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.Example 6

[0045] The tong manipulator system of Example 1, wherein the first positioning arm is rotatably connected to the moveable outer carriage via a turntable bearing.Example 7

[0046] The tong manipulator system of Example 1, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.Example 8

[0047] The tong manipulator system of Example 1, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.Example 9

[0048] The tong manipulator system of Example 1, further comprising a control system, wherein the control system includes a motor starter panel, a main circuit breaker, one or more servo amplifiers, a programmable logic controller (PLC), and a control panel comprising a touch screen human interface device.Example 10

[0049] The tong manipulator system of Example 9, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.Example 11

[0050] The tong manipulator system of Example 9, wherein the control panel includes a plurality of user-operable controls, including one or more controls for automatically moving the tong assembly to one or more respective predetermined positions, one or more controls for initiating manual movement of the tong assembly, a tighten control, and a loosen control.Example 12

[0051] A computing system of a tong manipulator system, the computing system comprising: a logic machine; and a data storage machine holding instructions executable by the logic machine to: change a position of a tong assembly of the tong manipulator system, the tong assembly including a lower clamp and an upper clamp configured to grip a pipe, and wherein the position of the tong assembly is changed by controlling one or more of: a vertical positioning subsystem of the tong manipulator system, the vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system controllable by the logic machine to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem of the tong manipulator system, the first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor controllable by the logic machine to cause rotation of the first positioning arm about a first rotational axis; and a second rotational positioning subsystem of the tong manipulator system, the second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor controllable by the logic machine to cause rotation of the second positioning arm about a second rotational axis, wherein the tong assembly is connected to the second positioning arm; actuate the lower clamp and the upper clamp of the tong assembly to grip the pipe; and rotate a rotary assembly of the upper clamp relative to the lower clamp to make up or break down connections in the pipe.Example 13

[0052] The computing system of Example 12, wherein the lower clamp and the upper clamp are hydraulically actuated.Example 14

[0053] wherein the tong manipulator system further comprises a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp; and wherein the instructions are further executable by the logic machine to control the hydraulic motor to rotate the rotary assembly of the upper clamp relative to the lower clamp.Example 15

[0054] The computing system of Example 12, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.Example 16

[0055] The computing system of Example 12, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.Example 17

[0056] The computing system of Example 12, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.Example 18

[0057] The computing system of Example 12, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.Example 19

[0058] The computing system of Example 12, further comprising a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.Example 20

[0059] A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; a tong assembly connected to the second positioning arm, the tong assembly comprising: a hydraulically actuated lower clamp configured to grip a pipe; and a hydraulically actuated upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe, wherein a spring assembly positioned between the upper clamp and the lower clamp facilitates axial movement of the upper clamp relative to the lower clamp; and a control system including a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system.Example 21

[0060] A method performed by a computing system with respect to a tong manipulator system, the method comprising: changing a position of a tong assembly of the tong manipulator system, the tong assembly including a lower clamp and an upper clamp configured to grip a pipe, and wherein the position of the tong assembly is changed by controlling one or more of: a vertical positioning subsystem of the tong manipulator system, the vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system controllable to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem of the tong manipulator system, the first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor controllable by the logic machine to cause rotation of the first positioning arm about a first rotational axis; and a second rotational positioning subsystem of the tong manipulator system, the second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor controllable to cause rotation of the second positioning arm about a second rotational axis, wherein the tong assembly is connected to the second positioning arm; actuating the lower clamp and the upper clamp of the tong assembly to grip the pipe; and rotating a rotary assembly of the upper clamp relative to the lower clamp to make up or break down connections in the pipe.

[0061] It will be understood that the configurations and / or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. As such, various acts illustrated and / or described may be performed in the sequence illustrated and / or described, in other sequences, in parallel, or omitted. Likewise, the order of the above-described processes may be changed.

[0062] The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various processes, systems and configurations, and other features, functions, acts, and / or properties disclosed herein, as well as any and all equivalents thereof.

Examples

example 1

[0040]A tong manipulator system, comprising: a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower; a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis; a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; and a tong assembly connected to the second positioning arm, the tong assembly comprising: a lower clamp configured to grip a pipe; and an upper clamp configured to grip the pipe, and the upper clamp including a rotary...

example 2

[0041]The tong manipulator system of Example 1, wherein the lower clamp and the upper clamp are hydraulically actuated.

example 3

[0042]The tong manipulator system of Example 1, further comprising a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp.

Claims

1. A tong manipulator system, comprising:a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower;a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis;a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis; anda tong assembly connected to the second positioning arm, the tong assembly comprising:a lower clamp configured to grip a pipe; andan upper clamp configured to grip the pipe, and the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe.

2. The tong manipulator system of claim 1, wherein the lower clamp and the upper clamp are hydraulically actuated.

3. The tong manipulator system of claim 1, further comprising a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp.

4. The tong manipulator system of claim 1, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.

5. The tong manipulator system of claim 1, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.

6. The tong manipulator system of claim 1, wherein the first positioning arm is rotatably connected to the moveable outer carriage via a turntable bearing.

7. The tong manipulator system of claim 1, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.

8. The tong manipulator system of claim 1, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.

9. The tong manipulator system of claim 1, further comprising a control system, wherein the control system includes a motor starter panel, a main circuit breaker, one or more servo amplifiers, a programmable logic controller (PLC), and a control panel comprising a touch screen human interface device.

10. The tong manipulator system of claim 9, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.

11. The tong manipulator system of claim 9, wherein the control panel includes a plurality of user-operable controls, including one or more controls for automatically moving the tong assembly to one or more respective predetermined positions, one or more controls for initiating manual movement of the tong assembly, a tighten control, and a loosen control.

12. A computing system of a tong manipulator system, the computing system comprising:a logic machine; anda data storage machine holding instructions executable by the logic machine to:change a position of a tong assembly of the tong manipulator system, the tong assembly including a lower clamp and an upper clamp configured to grip a pipe, and wherein the position of the tong assembly is changed by controlling one or more of:a vertical positioning subsystem of the tong manipulator system, the vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system controllable by the logic machine to adjust a position of the moveable outer carriage relative to the fixed tower;a first rotational positioning subsystem of the tong manipulator system, the first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor controllable by the logic machine to cause rotation of the first positioning arm about a first rotational axis; anda second rotational positioning subsystem of the tong manipulator system, the second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor controllable by the logic machine to cause rotation of the second positioning arm about a second rotational axis, wherein the tong assembly is connected to the second positioning arm;actuate the lower clamp and the upper clamp of the tong assembly to grip the pipe; androtate a rotary assembly of the upper clamp relative to the lower clamp to make up or break down connections in the pipe.

13. The computing system of claim 12, wherein the lower clamp and the upper clamp are hydraulically actuated.

14. The computing system of claim 12, wherein the tong manipulator system further comprises a hydraulic motor configured to rotate the rotary assembly of the upper clamp relative to the lower clamp; andwherein the instructions are further executable by the logic machine to control the hydraulic motor to rotate the rotary assembly of the upper clamp relative to the lower clamp.

15. The computing system of claim 12, wherein the tong assembly further comprises a spring assembly positioned between the upper clamp and the lower clamp, wherein the spring assembly facilitates axial movement of the upper clamp relative to the lower clamp.

16. The computing system of claim 12, wherein each of the first and second servo motors is coupled to a respective low-backlash gearbox.

17. The computing system of claim 12, wherein movement of the moveable outer carriage relative to the fixed tower is facilitated by one or more composite bearings between the moveable outer carriage and the fixed tower.

18. The computing system of claim 12, wherein the vertical positioning subsystem further comprises a replaceable keyway configured to prevent rotation of the moveable outer carriage relative to the fixed tower.

19. The computing system of claim 12, further comprising a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system, the status information including one or more of motion status, servo status, and position sensor feedback, and the diagnostic information including one or more of fault annunciation, system voltage, and servo temperature.

20. A tong manipulator system, comprising:a vertical positioning subsystem comprising a fixed tower, a moveable outer carriage, and a hydraulic positioning system configured to adjust a position of the moveable outer carriage relative to the fixed tower;a first rotational positioning subsystem including a first positioning arm rotatably connected to the moveable outer carriage of the vertical positioning subsystem, and a first servo motor configured to cause rotation of the first positioning arm about a first rotational axis;a second rotational positioning subsystem including a second positioning arm rotatably connected to the first positioning arm, and a second servo motor configured to cause rotation of the second positioning arm about a second rotational axis;a tong assembly connected to the second positioning arm, the tong assembly comprising:a hydraulically actuated lower clamp configured to grip a pipe; anda hydraulically actuated upper clamp configured to grip the pipe, the upper clamp including a rotary assembly configured to rotate relative to the lower clamp to make up or break down connections in the pipe, wherein a spring assembly positioned between the upper clamp and the lower clamp facilitates axial movement of the upper clamp relative to the lower clamp; anda control system including a touch screen human interface device, wherein the touch screen human interface device is configured to display status information and diagnostic information for the tong manipulator system.

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