Dual-Member Pipe Coupling via Alternating Spindle Rotation
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Solution Overview
Problem
Existing horizontal boring machines face challenges in efficiently coupling and disconnecting dual-pipe drill strings, particularly in rocky conditions, due to misalignment and improper threading of pipe sections, which can lead to stress on threads and inefficiencies in drilling operations.
Innovation Solution
An automatic dual-pipe makeup/breakout system that includes a spindle with an inner and outer spindle, a carriage with float sensors and processors to monitor and adjust rotation and thrust, enabling alternating clockwise and counterclockwise rotation of the inner spindle to align and couple pipe sections, and coordinating thrust and rotation of the outer spindle for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual coupling methods are used for dual-pipe drill strings, then operational flexibility is maintained, but misalignment and improper threading occur leading to stress on threads and inefficiencies
Solution Approach 1:
The system uses float sensors to automatically detect carriage position and control rotation direction without human intervention. The carriage self-adjusts its float position to trigger the appropriate rotation sequence, eliminating manual alignment operations while maintaining precision coupling of dual-pipe sections.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated control system that uses float sensors, processors, and coordinated rotation mechanisms. This substitution eliminates human error in alignment while managing operational complexity through systematic automation sequences.
2Reliability
If automated rotation control is implemented, then coupling precision is improved, but system complexity increases
Solution Approach 1:
The system employs float sensors that continuously monitor carriage position and provide feedback to the processor. Based on this feedback, the processor automatically adjusts rotation direction and timing, ensuring precise coupling while managing control complexity through closed-loop feedback mechanisms.
Solution Approach 2:
The control system dynamically adjusts rotation sequences based on real-time float position detection. The system transitions between different rotation states (clockwise, counterclockwise, alternating) depending on the carriage's float position, providing adaptive control that improves reliability without requiring overly complex fixed-program control.
3Strength
If float-based automatic control is used, then threading stress is reduced, but detection and measurement difficulty increases
Solution Approach 1:
The float sensor acts as an intermediary that converts the physical float position of the carriage into detectable electrical signals. This intermediary mechanism simplifies the detection process by providing a clear, measurable indicator of carriage position that directly controls the rotation sequence, thereby protecting threads while managing detection complexity.
Data Source
AI summary
A system and method of making up and breaking out a dual-member drill string. The system comprises a spindle, a spindle carriage and a drive frame. The drive frame provides thrust to the spindle, while the spindle carriage provides rotation. The spindle has an outer spindle and an inner spindle, and is adapted to connect to a pipe section having an outer pipe section and an inner pipe section. Inner joints are geometrically shaped, while outer joints are threaded. When making up dual member drill string, the spindle is advanced, with the outer spindle rotating, and the inner spindle rotating in alternating directions, or “dithering.” A float sensor and a processor are used in tandem to cooperatively couple the inner spindle with the inner pipe sections and the outer spindle with the outer pipe sections.