Combined Multi-Coupler for Rapid Top Drive Tool Changes
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Solution Overview
Problem
The process of changing tools attached to a top drive during drilling operations is time-consuming and dangerous, requiring safer, faster, and more reliable connections that can convey load, data, signals, power, and bi-directional torque between the tool string and the top drive.
Innovation Solution
A combined multi-coupler system with a housing featuring a bayonet profile and tapered load shoulders, a locking plate, and couplers that enable quick connection and disconnection, transferring axial and torsional loads, as well as electrical, hydraulic, and pneumatic signals between the top drive and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional tool attachment methods are used, then the connection can convey load and torque, but the tool changing process is time-consuming and dangerous
Solution Approach 1:
The coupling mechanism is divided into separate components: a coupling plate with notches on the top drive side, and corresponding interlock keys on the tool side. This segmentation allows for modular assembly and quick engagement/disengagement of tools without requiring complex manual operations or prolonged exposure to hazardous environments.
Solution Approach 2:
The coupling plate is pre-positioned on the top drive with notches already formed, and the interlock keys are pre-aligned with these notches. This preliminary preparation enables rapid tool attachment by simply engaging the pre-aligned components, eliminating the need for time-consuming alignment and securing operations during tool changes.
2Reliability
If traditional connection methods are used, then the connection can transfer torque and load, but personnel safety is compromised due to working at heights
Solution Approach 1:
The coupling mechanism is designed to self-align and self-secure through the interaction of notches and interlock keys. The geometric fit of these components automatically ensures proper alignment and secure engagement, eliminating the need for complex manual alignment procedures and reducing the time personnel must spend in hazardous positions during tool changes.
Solution Approach 2:
The coupling plate is pre-positioned on the top drive with notches already formed, and the interlock keys are pre-aligned with these notches. This preliminary preparation enables rapid tool attachment by simply engaging the pre-aligned components, eliminating the need for time-consuming alignment and securing operations during tool changes.
3Adaptability or versatility
If a simple coupling mechanism is used, then the device complexity is reduced, but the ability to convey multiple signals and loads is compromised
Solution Approach 1:
The coupling plate and interlock key mechanism serves multiple functions simultaneously: it transfers mechanical torque and axial loads through the notched engagement, while also providing alignment features and secure locking. This multi-functional design achieves versatile signal and load transmission without requiring separate dedicated components for each function, thereby maintaining simplicity while enhancing capability.
Data Source
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Figure 2B
AI summary
Embodiments of the present disclosure provide combined multi-coupler assembly for quickly connecting a top drive to a tool. The combined multi-coupler assembly includes a drive stem and a tool dock that may be coupled to each other. When the drive stem and the tool dock are connected, axial loads, torsional loads, and hydraulic, pneumatic, electrical, optical, or other types of communications may be transferred between the drive stem and the tool dock.