Automatic Multi-Speed Gear and Clutch for Time-Critical Ram Shearing
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Solution Overview
Problem
Existing pressure control equipment struggles to shear certain types of tubular products in oil and gas wells within the allotted time, particularly when shearing is required in limited time frames like 30-45 seconds, due to increased difficulty in shearing these products.
Innovation Solution
A system and methodology that employs an automatic, multi-speed technique using a roller screw mechanism with a motor and clutch system to shift between high-speed, low-force and low-speed, high-force modes, enabling rapid engagement and increased force for shearing tubular products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-speed reduction gear system is used, then the device complexity is low, but the productivity is insufficient to shear tubular products within the allotted time
Solution Approach 1:
The patent implements a dynamic multi-speed reduction gear system that automatically shifts between different gear ratios based on operational requirements. The system transitions from a single fixed ratio to multiple variable ratios, enabling the ram to operate at high speed during travel and engage at optimal force ratios when contacting the tubular product, thereby resolving the contradiction between speed and complexity.
Solution Approach 2:
The system changes the gear ratio parameter dynamically during operation. By incorporating multiple gear sets that can be selectively engaged, the system adjusts the reduction ratio to match different operational phases - high ratio for approach and engagement, lower ratio for power transmission during shearing, thus improving productivity without requiring a completely complex redesign.
2Force
If a high-force mode is engaged immediately, then the shearing force is sufficient, but the advancement speed becomes too slow to meet time requirements
Solution Approach 1:
The system dynamically adjusts the force-speed characteristic by switching between different gear ratios. During the approach phase, a gear ratio that allows higher speed is engaged. Upon engagement with the tubular product, the system automatically shifts to a gear ratio that provides higher force, thus resolving the contradiction between maintaining high speed and providing sufficient shearing force.
Solution Approach 2:
The system employs periodic switching between different operational modes (high-speed approach mode and high-force shearing mode) based on the operational phase. This periodic action allows the system to optimize for speed during travel and for force during engagement, meeting both time and strength requirements.
3Loss of time
If the ram advances rapidly to the tubular product, then the time for shearing is reduced, but the force applied during contact becomes insufficient to shear the product
Solution Approach 1:
The system performs preliminary high-speed advancement to reach the tubular product quickly, minimizing the time loss. Upon contact, the gear system automatically shifts to provide higher force, ensuring that the shearing action is both timely and effective. This preliminary action followed by force enhancement resolves the contradiction between speed and force.
Solution Approach 2:
The system changes the force parameter by engaging different gear ratios at different operational stages. The rapid advancement uses a gear ratio optimized for speed, while the contact phase triggers a shift to a gear ratio optimized for force transmission, thus reducing time loss without compromising shearing capability.
4Productivity
If a multi-speed gear system is implemented, then the productivity and force capability are enhanced, but the device complexity increases
Solution Approach 1:
The multi-speed gear system incorporates automatic shifting mechanisms that self-regulate based on operational conditions. The clutch system automatically engages or disengages specific gear ratios without external control, allowing the system to self-optimize its performance. This self-service capability enhances productivity while keeping the control complexity manageable.
Solution Approach 2:
The gear system is designed to perform multiple functions through a single integrated mechanism. The same clutch and gear assembly handles both the high-speed approach phase and the high-force shearing phase, as well as providing force multiplication during contact. This multi-functionality improves productivity without proportionally increasing complexity, as one system handles multiple operational requirements.
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
Enables efficient shearing of a variety of tubular products by automatically transitioning from rapid advancement to a higher force mode, ensuring timely and effective shearing operations in well applications.
Implementation Method 1
a force enhancement system having a roller screw oriented to exert a linear force
Implementation Method 2
a clutch system to shift between high-speed, low-force and low-speed, high-force modes
Data Source
AI summary
A technique facilitates application of increased force in various well applications while limiting the overall time period of the operation by automatically utilizing two modes of operation. In some well applications, the technique automatically applies increased force to facilitate shearing of a tubular product in a timely manner. By way of example, the system may be utilized to rapidly advance rams to the point of contact with the tubular product extending through well equipment, e.g. through a blowout preventer (BOP), and then to automatically shift to a slower advance but higher force mode. The higher force mode facilitates shearing of a variety of tubular products in a variety of well applications.