Gripperhead Pipe Detection Using Inductive Sensors
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Solution Overview
Problem
Existing systems for manipulating and detecting tubulars in oil and gas drilling operations are inefficient and prone to errors, particularly in handling densely stacked pipes, as they lack the ability to accurately measure pipe diameter and ensure secure gripping, leading to costly mistakes like crushed pipes or pipes slipping out of the gripper.
Innovation Solution
A modular gripperhead system equipped with sensors, such as inductive sensors, that can locate pipe position, measure size, and ensure secure gripping by applying the appropriate compression force, allowing for quick setup and teardown, and easy module replacement, thereby reducing downtime and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional grippers are used to handle densely stacked pipes, then the gripping operation can be performed, but the ability to accurately measure pipe diameter and verify secure gripping is lost, leading to crushed pipes or pipes slipping out
Solution Approach 1:
The patent replaces mechanical measurement methods with magnetic field-based sensors (inductive sensors) to detect pipe diameter and verify gripping status. This substitution enables precise measurement without adding complex mechanical measurement components to the gripper system.
Solution Approach 2:
The patent introduces sensors as an intermediary between the gripper and the pipe, allowing the gripper to detect pipe characteristics and gripping status indirectly through sensor signals. This intermediary enables measurement capability without directly modifying the gripper's mechanical structure.
2Productivity
If stands are stacked densely in the fingerboard to increase storage capacity, then space utilization is improved, but the difficulty to select and secure a stand from the stack increases
Solution Approach 1:
The patent employs sensors that provide real-time feedback about pipe position, diameter, and gripping status. This feedback mechanism allows the system to automatically adjust and select pipes from dense stacks by detecting their characteristics and confirming secure gripping, thereby maintaining ease of operation despite increased storage density.
Solution Approach 2:
The sensor-equipped gripper enables the system to automatically identify and select pipes from the stack based on their own detection capabilities. The gripper itself performs the selection function by detecting pipe characteristics and determining which pipe to grasp, eliminating the need for external intervention in the selection process.
3Productivity
If manual manipulation of tubulars is used to avoid complex equipment, then device complexity is reduced, but operational efficiency and safety decrease due to dangerous and inefficient operations
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated gripper system equipped with sensors. The sensors provide detection capabilities that enable automated control, improving efficiency and safety while the modular design keeps the added complexity manageable through standardized components.
Solution Approach 2:
The sensor-equipped gripper system performs self-monitoring and self-adjustment during tubular manipulation. The system automatically detects pipe characteristics and adjusts gripping force accordingly, enabling efficient automated operation without requiring complex external control mechanisms for each manipulation task.
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 modular gripperhead system enhances operational efficiency by accurately handling tubulars, reducing errors and downtime, and allowing for rapid adaptation to different pipe sizes and conditions, thus improving overall drilling rig productivity.
Implementation Method 1
A sensor, such as an inductive sensor, is disposed on the grabber assembly and configured to determine a position of the cylindrical tubular pipe within the chamber
Data Source
AI summary
The systems, devices, and methods described herein relate to tubular detection on a gripperhead system for a drilling rig. The gripperhead system includes a grabber and a gripper each having first and second grabber arm and pistons connected to the first and second arms. Each arm may also include an inwardly facing gripping surface forming at least a portion of a chamber sized to receive a portion of a cylindrical tubular. One or more sensors may be disposed on the gripperhead system, including proximity sensors disposed on the arms, inductive sensors disposed within the pistons, and ultrasonic sensors disposed on other features of gripperhead system. The one or more sensors may be configured to determine the position of the tubular in relation to the arms, measure the size of the tubular, measure the compression force of the grabber, and ensure that the tubular is secured within the grabber.