Automated Drill Pipe Handling System With Robotic Lifting Arm
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Solution Overview
Problem
Current manual systems for handling drill pipes at drill sites are prone to misconnection and pose safety risks due to operator involvement, necessitating an automated solution for efficient and safe pipe handling.
Innovation Solution
An automated system for handling drill pipes that includes a pipe lifting mechanism with hydraulic actuators, a control arm with pivoting and rotating capabilities, and a controller to manage the movement of pipes between storage racks and on-hole positions, allowing for fully automated operation and adaptation to multiple rows without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation is used for transporting and reorienting pipe, then ease of operation is maintained, but safety risks and misconnection potential increase
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system featuring a programmable arm, sensors, and control mechanisms that can autonomously grasp, transport, and position drill pipes, eliminating human exposure to hazardous environments while maintaining operational reliability
Solution Approach 2:
The system incorporates self-positioning capabilities through sensors and feedback mechanisms that allow the robotic arm to automatically detect pipe locations, adjust its movements, and place pipes accurately without continuous human intervention or guidance
2Reliability
If manual handling is used, then operational flexibility is maintained, but misconnection risks increase
Solution Approach 1:
The patent incorporates sensors and detection mechanisms that provide real-time feedback to the control system, enabling the robotic arm to verify pipe positions, orientations, and connection statuses, thereby ensuring accurate connections while managing system complexity through automated monitoring and adjustment
3Reliability
If automated operation is implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The patent divides the automated pipe handling system into modular functional components including a robotic arm module, sensing module, control module, and pipe storage module, allowing the complex automated system to be managed through independent, interchangeable units that can be maintained and replaced separately
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system enhances safety by reducing operator exposure to hazards and improves efficiency by minimizing misconnection risks through precise and automated pipe handling and storage management.
Implementation Method 1
a lifting device including a lifting actuator to raise a stack of drill pipe positioned in one of the storage rows
Data Source
AI summary
A system includes a rack with rows for storing drill pipe, and a moveable structure having a control support coupled to an upper portion and a lifting device coupled to a lower portion. The moveable structure travels along a guide for positioning adjacent any of the rows. The control support includes a pivoting actuator, a rotating actuator, an extension arm having a drill pipe capture actuator, and an extension actuator. The lifting device includes a lifting actuator that raises a stack of drill pipe. The system further includes a controller that interprets a control support state including actuator positions and a position index value, and records a position description including the control support state corresponding to the position index value. The controller interprets a position request signal and provides actuator control signals in response to the position request signal and the position description.