Injector Head Chain Synchronization via Feedback Control
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Solution Overview
Problem
The existing conveyor apparatuses for continuous elongate devices (CEDs) like coiled tubing in oil and gas exploration suffer from unsynchronized belt drive chains, leading to wear and fatigue due to differential rotation speeds and angles of engagement, resulting in friction loss and potential damage to the tubing.
Innovation Solution
The implementation of a system that measures the position of chain blocks and adjusts them to maintain synchronization through sensors and actuators, ensuring both chains rotate at the same speed and engage the tubing uniformly, using counter-force members and rollers to align the tubing centerline with the injector centerline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If independent belt drive chains are used without synchronization, then device complexity is reduced, but wear and fatigue of the continuous tubing increases due to unsynchronized engagement
Solution Approach 1:
Position sensors detect the relative positions of chain blocks on opposite chains and provide feedback signals to actuators, which adjust the chain block positions to maintain synchronization. This closed-loop feedback system ensures continuous tubing engagement occurs at identical positions on both chains, preventing differential wear and fatigue while maintaining operational reliability.
Solution Approach 2:
The patent replaces complex mechanical synchronization mechanisms (such as gear linkages or cam systems) with a combination of position sensors and actuators that use electronic control and feedback. This substitution reduces mechanical complexity while achieving more precise and reliable synchronization of the belt drive chains.
2Reliability
If synchronized belt drive chains are implemented with sensors and actuators, then tubing wear is reduced, but device complexity increases
Solution Approach 1:
Position sensors continuously monitor the relative positions of chain blocks and provide real-time feedback to the control system. This feedback enables automatic adjustment of chain block positions through actuators, ensuring synchronized engagement with the continuous tubing and significantly reducing wear and fatigue on the tubing.
Solution Approach 2:
The synchronization system is designed to automatically detect and correct position deviations between chain blocks without requiring external intervention. The sensors and actuators work together in a self-regulating manner to maintain proper synchronization, reducing the need for manual adjustment and complex external control mechanisms.
3Ease of operation
If chain blocks engage tubing at different positions, then ease of operation is maintained, but friction loss and energy efficiency deteriorate
Solution Approach 1:
Position sensors detect deviations in chain block positions and provide feedback to actuators that adjust the positions to ensure synchronized engagement. This maintains optimal friction conditions between the chains and tubing, minimizing energy loss while preserving ease of operation.
Solution Approach 2:
The system dynamically adjusts the position parameters of chain blocks to maintain synchronization with the continuous tubing. By changing the positional parameters based on real-time feedback, the system optimizes friction conditions and energy efficiency without compromising operational ease.
Data Source
AI summary
The invention relates to an injector head (2) comprising; a pair of oppositely located, cooperatively movable, segmented continuous belt drive chains (21; 22), said each belt drive chain (21, 22) running over a respective pair of drive sprockets (25a, 25b) and tension sprockets (26a, 26b), wherein a tubing receiving section (7′) is defined between the belt drive chains (21, 22). The tubing receiving section (7′) having a tubing section centerline (46) extending through the center of the tubing receiving section (7′). The injector head (2) having an injector centerline (45) extending through the centerline of the injector head (2), said injector centerline (45) and said tubing section centerline (46) being substantially aligned in the longitudinal direction in an initial position, a pair of elongate counter-force members (32a, 32b) is positioned at each side of the tubing receiving section (7′). The injector head (2) has at least one actuator (35) adapted to move at least one of said elongate counter-force elongate member (32a, 32b) in order to bring the tubing section centerline (46) out of alignment with said injector centerline (45).