Drill Pipe Pose Estimation Using Multi-Sensor Fusion
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Solution Overview
Problem
Human intervention in tripping operations for drill pipes introduces inefficiencies and variability, as precise placement of iron roughnecks is challenging due to the harsh drilling environment and small margin of error.
Innovation Solution
A system comprising a processor coupled with a time of flight (TOF) camera, LIDAR sensor, and optical camera, which generates pose and orientation estimates of the drill pipe's tool joint, enabling automated and accurate positioning of the roughneck for efficient tripping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human intervention is used in tripping operations, then operational flexibility is maintained, but efficiency is reduced and variability is introduced
Solution Approach 1:
The system enables self-service automation where the iron roughneck automatically positions itself and performs tripping operations based on sensor data and processor control, eliminating the need for human operators to manually control each movement and decision in the tripping process
Solution Approach 2:
The patent replaces manual mechanical operations with an automated system comprising sensors (optical camera, TOF camera, LIDAR), a processor for analyzing data and generating control signals, and an automated iron roughneck that executes positioning and tripping operations without human intervention
2Manufacturing precision
If precise placement of iron roughneck is required, then tripping accuracy is improved, but the margin of error becomes extremely small and difficult to achieve
Solution Approach 1:
The patent introduces multiple sensor intermediaries (optical camera, time-of-flight camera, LIDAR sensor) that act as mediators between the control system and the drill pipe, enabling precise measurement of stick-up height and orientation without requiring direct human measurement or estimation
Solution Approach 2:
The system transitions from traditional single-dimensional or manual measurement methods to multi-dimensional spatial measurement using TOF and LIDAR sensors that capture three-dimensional position and orientation data, providing comprehensive spatial information for precise roughneck placement
3Measurement precision
If multiple sensors are used to detect drill pipe parameters, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent implements multi-functionality where a single integrated system performs multiple measurement functions: the optical camera captures visual information, the TOF camera measures distance and depth, and the LIDAR sensor provides precise spatial mapping, with all sensors coordinated by a single processor that generates unified control signals for the iron roughneck
Solution Approach 2:
The system merges multiple sensing technologies (optical, time-of-flight, LIDAR) into a single integrated measurement and control system, combining their respective strengths to achieve comprehensive and accurate detection of drill pipe parameters while centralized processing reduces overall system complexity
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 system enhances efficiency and reduces variability by providing precise stick-up height and orientation data for the drill pipe, allowing for automated and repeatable placement of the roughneck, optimizing the tripping process.
Implementation Method 1
a time of flight (TOF) camera... The processor can receive from the TOF camera a TOF signal representative of a first coordinate associated with a stick-up height of a tool joint
Implementation Method 2
a light detection and ranging (LIDAR) sensor... The processor can receive from the LIDAR sensor a LIDAR signal representative of a second coordinate associated with the stick-up height of the tool joint
Data Source
AI summary
A processor is operably coupled to a time of flight (TOF) camera, a light detection and ranging (LIDAR) sensor, and an optical camera. The processor can receive a TOF signal representative of a first coordinate associated with a stick-up height of a tool joint of a pipe of a drill string during a tripping operation on a rig drill floor, and a pitch and a roll of the tool joint. The processor can receive a LIDAR signal representative of a second coordinate associated with the stick-up height, and the pitch of the tool joint. The processor can receive an optical camera signal representative of a third coordinate associated with the stick-up height of the tool joint and the roll of the tool joint. The processor can generate a pose estimate and an orientation estimate based on the signals.