Coiled Tubing Injector Motor Speed Equalization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Coiled tubing injector heads face challenges in maintaining equal drive motor speeds, leading to potential pipe slippage due to uneven motor operation, which existing systems fail to address effectively without additional timing motors or gears.
Innovation Solution
A system and method utilizing hydraulic control lines, valves, and sensors to regulate pressure on swash plates of independent drive motors, ensuring both motors operate at substantially matching speeds through a programmable logic controller, eliminating the need for auxiliary timing motors or gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If independent drive motors are used for each drive chain, then the injector head can operate with simpler mechanical structure, but the motor speeds become uneven causing pipe slippage
Solution Approach 1:
Speed sensors are installed on each independent drive motor to continuously monitor motor speeds. The sensor signals are fed to a digital computer that compares the speeds and automatically actuates control valves to adjust hydraulic pressure, creating a closed-loop feedback system that maintains equal motor speeds and prevents pipe slippage
Solution Approach 2:
The patent replaces traditional mechanical timing mechanisms (such as timing gears or auxiliary timing motors) with an electro-hydraulic control system. Digital computers and control valves regulate hydraulic pressure to each drive motor, substituting complex mechanical synchronization with electronic control and hydraulic actuation
2Reliability
If auxiliary timing motors or gears are added to synchronize motor speeds, then pipe slippage is prevented, but device complexity increases
Solution Approach 1:
The patent eliminates auxiliary timing motors and timing gears by replacing them with an electronic control system. Digital computers receive speed sensor inputs and control hydraulic valves that independently regulate each drive motor's speed, substituting mechanical synchronization components with electronic-hydraulic control mechanisms
Solution Approach 2:
Hydraulic control lines connect the digital computer-controlled valves to the hydraulic fluid supply of each drive motor. By regulating hydraulic pressure through these control lines, the system achieves precise motor speed control without mechanical timing devices, using hydraulic actuation instead of mechanical gearing
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
This solution effectively equalizes drive motor speeds, reducing the likelihood of pipe slippage by dynamically adjusting hydraulic pressure, thereby enhancing operational stability and efficiency without requiring additional components like timing motors or gears.
Implementation Method 1
Each sensor is configured to output to a digital computer a signal representative of a motor speed, and at least one valve associated with a hydraulic control line is operable to regulate pressure in the hydraulic control line and thereby increase or decrease the speed of the corresponding motor
Data Source
AI summary
A system for controlling a coiled tubing injector head includes a hydraulic control line in fluid communication with each drive motor, a valve associated with one or both hydraulic control lines, and a sensor associated with each drive motor. Each sensor is configured to output to a digital computer a signal representative of a motor speed, and at least one valve associated with a hydraulic control line is operable to regulate pressure in the hydraulic control line and thereby increase or decrease the speed of the corresponding motor until both speed sensors report substantially matching motor speeds.