Drill Pipe Speed Sensor for Connection Status Detection

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Solution Overview

Problem

Current technologies in the oil and gas industry lack sensors to effectively determine the status of drill pipe connections, leading to potential damage from shouldered or cross-threaded connections during the connection or disconnection process.

Innovation Solution

A drill pipe speed sensor system that includes a roller head assembly with an incremental encoder and a pivot assembly, capable of measuring the rotational speed and direction of drill pipes, and is adaptable to various outer diameters without component modification, allowing for real-time status determination of drill pipe connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a drill pipe speed sensor is implemented to determine connection status, then connection status determination accuracy is improved, but device complexity increases

Engineering Contradiction:

Improveconnection status determination accuracyVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical connection status detection methods with a speed sensor-based measurement system. The incremental encoder converts rotational speed measurements into digital signals that indicate connection status, substituting mechanical observation with precise electronic measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The roller acts as an intermediary between the rotating drill pipe and the incremental encoder. It transfers the rotational motion of the drill pipe to the encoder without direct mechanical coupling, enabling accurate speed measurement while isolating the encoder from harsh mechanical environments.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the sensor is designed to accommodate various outer diameters, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improvecompatibility with various outer diametersVSAvoidsensor system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mounting structure incorporates movable and adjustable components that allow the sensor to dynamically adapt to different drill pipe outer diameters. The roller position and encoder orientation can be adjusted to maintain proper alignment regardless of the pipe diameter, enabling universal compatibility without requiring multiple specialized sensors.

Inventive Principle:

Principle #15Dynamics

3Productivity

If real-time measurement is implemented to prevent damage, then productivity is improved, but use of energy increases

Engineering Contradiction:

Improveconnection status determination speedVSAvoidsensor operation energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The incremental encoder continuously measures rotational speed during drill pipe operation, providing real-time connection status information without interrupting the drilling process. This continuous measurement enables immediate detection of connection issues, allowing operators to take corrective action before damage occurs, thereby improving productivity through preventive monitoring.

Inventive Principle:

Principle #20Continuity of useful action

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 faster and more accurate determination of drill pipe connection status, preventing damage by identifying shouldered or cross-threaded conditions, and is compatible with a range of drill pipe diameters.

Implementation Method 1

The drill pipe speed sensor includes a roller head assembly including an incremental encoder

Methodology Applied

Scientific EffectIncremental encoding:

Implementation Method 2

The biasing member contacts the mounting members and extends between the mounting members... The biasing member is configured to move the roller head assembly in a forward or rearward direction

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12139977B2Pipe speed sensor

Publication Date: 2024.11.12 NAT OILWELL VARCO LP

AI summary

A drill pipe speed sensor includes a roller head assembly including an incremental encoder, a roller to contact a drill pipe, and first and second rotating members. The first rotating member is coupled to the roller, the second rotating member is coupled to the incremental encoder, and the first rotating member is coupled to the second rotating member. The sensor also includes a pivot assembly having mounting plates, pivotal arms, first and second mounting members, and a biasing member. The first and second mounting members extend between the mounting plates, which are parallel to each other. The biasing member contacts the mounting members and extends between the mounting members, and the biasing member is parallel to the mounting plates. The pivotal arms extend from the mounting plates to the roller head assembly and pivot relative to the mounting plates, and the first mounting member is coupled to two pivotal arms.