Magnetostrictive Torque Measurement in Top Drive Systems
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Solution Overview
Problem
There is a need for an accurate method to measure torque in top drive systems used in drilling operations to ensure proper engagement and prevent overloading of drill strings, drill heads, and drill bits.
Innovation Solution
A top drive system equipped with a torque measurement device (TMD) that includes a sensing member configured to measure the magnetostrictive effect and an evaluation unit to calculate the magnitude of the torque reaction force, allowing for precise torque measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional torque measurement methods are used, then the device complexity is reduced, but the measurement precision is insufficient to accurately measure torque for ensuring proper engagement and preventing overloading
Solution Approach 1:
The patent replaces traditional mechanical torque measurement methods with a magnetostrictive sensing system. The sensing member utilizes magnetostrictive effects to detect torque, converting mechanical stress into magnetic field changes that can be measured electronically. This substitution enables more precise torque measurement while reducing mechanical complexity through non-contact sensing.
Solution Approach 2:
The patent changes the measurement parameter from direct mechanical deflection to magnetostrictive effect detection. By measuring changes in magnetic properties of the sensing member under torque load, the system achieves higher measurement precision. The evaluation unit processes these magnetic parameter changes to calculate torque magnitude, enabling accurate measurement without complex mechanical linkages.
2Reliability
If no torque measurement device is installed, then the device complexity is low, but the reliability is compromised due to inability to detect improper engagement or overloading conditions
Solution Approach 1:
The patent implements a feedback mechanism where the sensing member continuously monitors torque conditions and the evaluation unit processes this information to detect improper engagement or overloading. The system provides real-time feedback on torque magnitude, enabling immediate detection of abnormal conditions and allowing for corrective action before damage occurs, thereby enhancing operational reliability.
Solution Approach 2:
The patent replaces complex mechanical safety devices with an electronic sensing and evaluation system. The magnetostrictive sensing member combined with the evaluation unit provides reliable torque monitoring without the mechanical complexity of traditional safety devices. This electronic approach enhances reliability through precise measurement and programmable detection thresholds.
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 solution provides accurate and reliable torque measurement, enhancing the safety and efficiency of drilling operations by preventing overloading and ensuring proper engagement between the top drive and drill string.
Implementation Method 1
the sensing member is configured to measure a magnetostrictive effect
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
A top drive system for use with a tool (102)for handling tubulars on a drilling rig includes a motor unit (100); a coupling unit that transfers torque to the tool; a torque measurement device TMD (200) coupled to at least one of the motor unit, the tool, or the coupling unit, wherein the TMD includes a sensing member coupled to an evaluation unit, wherein the sensing member is configured to measure a change in electrical resistance and the evaluation unit is configured to calculate a magnitude of the torque based on the measured change in electrical resistance.