Sensor-Guided Hose Alignment for Fracturing Manifold Connection
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Solution Overview
Problem
The connection of high-pressure hoses to manifold skids in oil and gas field fracturing operations is labor-intensive, time-consuming, and poses safety risks due to the weight and bulk of the hoses, requiring multiple workers to lift and maneuver heavy hoses for connection.
Innovation Solution
A hose quick connection device with a hose holding and moving mechanism, sensing devices, and a controller that generates motion commands to automatically align and connect the hose to the manifold interface, reducing the need for manual labor and enhancing safety by allowing a single operator to perform the task.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-pressure hard pipe is used to connect fracturing equipment to manifold skid, then connection strength and pressure resistance are improved, but device weight and installation complexity increase significantly
Solution Approach 1:
The patent changes the physical state and material properties from rigid hard pipe to flexible high-pressure hose, transforming the connection method while maintaining pressure resistance capabilities. This allows the system to achieve sufficient strength without the excessive weight of hard pipe components.
Solution Approach 2:
The connection system is divided into modular components including hose assemblies with quick-connect couplings, allowing separate handling and connection of individual segments rather than moving entire hard pipe assemblies. This segmentation reduces the weight that must be manually handled while maintaining connection integrity.
2Stress or pressure
If high-pressure hard pipe is used for manifold connection, then pressure resistance is improved, but installation time and labor requirements increase
Solution Approach 1:
Hose assemblies are pre-assembled with quick-connect couplings and proper length before arrival at the well site. This preliminary preparation eliminates on-site assembly time and allows for rapid connection to the manifold skid, significantly reducing installation time while maintaining pressure resistance through factory-quality connections.
Solution Approach 2:
The patent replaces the mechanical assembly process of hard pipe connections (requiring multiple workers to strike union joints) with a simplified coupling mechanism that can be connected by a single operator through a straightforward insertion and locking action, dramatically reducing both time and labor requirements.
3Adaptability or versatility
If long high-pressure hose (3 meters or more) is used to connect fracturing equipment to manifold skid, then flexibility and reach are improved, but hose weight and handling difficulty increase
Solution Approach 1:
The patent employs dynamically adjustable hose lengths and a mobile cart-based holding mechanism that can be positioned optimally near the fracturing equipment. This allows the use of shorter hose segments when possible, reducing weight, while maintaining the flexibility and reach needed for various well site configurations through repositioning of the holding cart.
Solution Approach 2:
A mobile cart-based hose holding mechanism serves as an intermediary support system, bearing the weight of the hose and providing a stable dispensing point. This eliminates the need for workers to manually support and maneuver the full weight of long hoses, reducing handling difficulty while preserving hose flexibility and reach capabilities.
4Ease of operation
If manual handling of heavy high-pressure hose is performed by multiple workers, then connection capability is achieved, but safety risks and labor intensity increase
Solution Approach 1:
The patent replaces manual human handling with an automated hose laying mechanism mounted on a mobile cart. This mechanical system automatically feeds, positions, and connects the hose to the manifold skid, eliminating the need for multiple workers to manually lift and maneuver heavy hoses, thereby significantly improving safety while maintaining connection capability.
Solution Approach 2:
The hose holding and laying mechanism is designed to automatically perform the connection task without requiring human physical intervention for hose handling. The system self-manages the hose dispensing, positioning, and connection processes, reducing labor intensity and safety risks associated with manual handling of heavy high-pressure hoses.
Data Source
AI summary
The present disclosure relates to a hose quick connection device for a fracturing equipment, comprising: a hose holding and moving mechanism for holding a hose and moving the hose between an initial position and a target position, wherein at the target position, an end of the hose is aligned with a manifold interface; and a controller configured to: receive first orientation information indicating the orientation of the hose from the first sensing device and receive second orientation information indicating the orientation of the manifold interface from the second sensing device; generate a desired motion command for moving the hose to the target position, based on the first orientation information and the second orientation information; and control the hose holding and moving mechanism to execute the desired motion command to move the hose to the target position. The present disclosure further relates to a fracturing equipment comprising the hose quick connection device.