Drill Floor Robot Arm With Tool Change for Hazardous Rig Tasks
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Solution Overview
Problem
The drill floor on a drilling rig is a hazardous area due to the presence of moving, heavy-duty equipment that poses a risk of injury to personnel performing tasks such as stabbing connections and handling BHA jewelry, mud buckets, and other operations.
Innovation Solution
A robotic system with a base on a track, a robot arm, and end effector tools is used to perform operations on the drill rig floor, controlled by a robot controller to minimize personnel presence in hazardous areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If personnel are present on the drill floor to perform tasks, then operational capability is maintained, but safety risk increases due to exposure to moving heavy-duty equipment
Solution Approach 1:
The patent replaces human operators with an automated robotic system that includes a robot controller, robot arm, and end effector tools. The robot controller receives commands and translates them into coordinated movements of the robot arm and tools to perform drilling operations, thereby eliminating the need for personnel to be physically present in hazardous zones while maintaining full operational capability
Solution Approach 2:
The patent introduces a remote control system as an intermediary between the operator and the drilling equipment. The operator controls the robotic system from a safe location, and the robot controller acts as a mediator that translates control signals into precise mechanical actions by the robot arm and end effector tools, allowing operational capability to be maintained without direct personnel presence on the drill floor
2Reliability
If automated robotic systems are deployed to reduce personnel presence, then safety is improved, but system complexity increases
Solution Approach 1:
The patent designs a multi-functional robotic system where a single robot controller can manage various end effector tools (such as drilling tools, cutting tools, and handling tools) and perform multiple drilling operations. The robot arm is designed with sufficient degrees of freedom to execute diverse tasks, reducing the need for multiple specialized systems and thereby managing overall complexity while maintaining safety
Solution Approach 2:
The patent incorporates autonomous capabilities into the robotic system, including automated tool selection and changeover, self-positioning using sensors and feedback mechanisms, and automated control algorithms that enable the system to perform complex drilling operations with minimal human intervention. This self-service capability reduces the complexity of manual control systems while enhancing safety
Data Source
AI summary
A system for performing operations on a work center disposed on a drill rig floor includes a robotic system having a base disposed on a track for movement thereon, a robot arm supported on the base, and one or more end effector tools selectively attachable to an end of the robot arm. A control system has a robot controller in communication with the robotic system. The robot controller is configured to command the robotic system to enter a mode for performing a selected operation, command the robot arm to engage one of the one or more end effector tools related to the selected operation from a tool storage, command the robotic system to move along the track to a position adjacent to the work center, and command the robotic system to perform the selected operation at the work center using the robot arm and the engaged end effector tool.