Floating Sled Sensor for Drill Rod Decoupling Detection
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Solution Overview
Problem
Conventional drill rod handling systems lack an efficient and reliable method for decoupling rods from a drill string, particularly in detecting the complete disconnection of threaded ends, leading to manual intervention and potential misalignment or damage during handling and storage.
Innovation Solution
A rod handling apparatus with a gripper unit featuring a sled in an axially 'floating' configuration, equipped with sensors and bias components, monitors the axial movement of the sled relative to the frame to precisely detect the decoupling of threaded connections, allowing for controlled and efficient disconnection and transport of drill rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional gripper systems are used to disconnect drill rods, then the system structure remains simple, but the ability to precisely detect complete disconnection of threaded ends is insufficient, leading to manual intervention requirements
Solution Approach 1:
The patent replaces conventional mechanical detection methods with a sensor-based detection system. Sensors mounted on the sled detect the axial position and movement of the drill rod during disconnection, providing precise electronic detection of complete separation without requiring complex mechanical linkages or manual verification.
Solution Approach 2:
The sled acts as an intermediary component between the gripper frame and the drill rod. It provides a controlled interface that allows the rod to be held and then released, while the sensors on the sled mediate the detection of the disconnection event by monitoring axial position changes during the threading and unthreading process.
2Productivity
If manual intervention is used for rod disconnection detection, then the system structure remains simple, but productivity decreases due to regular manual intervention requirements
Solution Approach 1:
The system performs self-service through automated detection. The sensors on the sled automatically detect when a rod is completely disconnected by monitoring axial position changes, and the control system automatically triggers the next operation without requiring manual intervention, enabling continuous automated operation.
Solution Approach 2:
The detection system provides real-time feedback to the control system. When sensors detect a change in axial position indicating complete rod separation, this feedback signal automatically triggers the next drilling operation, creating a closed-loop automated control system that eliminates manual intervention and maintains continuous productivity.
3Reliability
If drill rods are handled without precise detection of complete disconnection, then handling speed may be maintained, but misalignment or damage can occur during transport and storage
Solution Approach 1:
The system performs preliminary detection of rod disconnection status before initiating transport operations. The sensors detect the complete separation of threaded ends in advance, allowing the control system to prepare for the next operation and ensuring the rod is fully disconnected and ready for safe handling, preventing misalignment or damage during transport.
Data Source
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AI summary
Method and apparatus for disconnecting an end rod (115) from a drill string (100) coupled together by a threaded connection (604,605). Rod handling apparatus (102) comprises a gripper unit (106) having a 'floating' sled (206) with a sensor unit (208) configured to monitor relative axial position of the sled relative to a frame (205) of the gripper unit to determine a decoupling of the threaded connection and a separation of an end rod from the drill string.