Modular Power Tong Gear Train for High Torque in Tight Rig Space
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Solution Overview
Problem
Conventional power tongs used in the oil and gas industry are limited by their size, weight, and cost due to the need for large, expensive gear trains to achieve high torque capacity, which restricts their use on drilling rigs due to space constraints and requires frequent replacement of damaged gear sections.
Innovation Solution
A modular power tong assembly with a transmission box housing multiple drive gears, idler gears encircling the rotary gear, and cam roller assemblies that reduce size, weight, and cost while increasing torque capacity, featuring a make and break mechanism with a rotating cylinder and swing arm system for safe operation, and modular jaw assemblies with cam shoe inserts for adjustable gripping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional gear trains are used to achieve high torque capacity, then torque strength is improved, but weight and size increase significantly
Solution Approach 1:
The power tong is divided into modular components including a head assembly, body assembly, and interchangeable jaw assemblies. The gear train is segmented into a head gear assembly that can be independently replaced. This modularity allows optimization of each component's weight and strength characteristics, reducing overall weight while maintaining torque capacity through selective replacement of worn segments rather than entire assemblies.
Solution Approach 2:
The patent employs composite construction methods where the head assembly incorporates reinforced structures with optimized material distribution. The body assembly uses composite materials that provide high strength-to-weight ratio, allowing the gear train to achieve required torque capacity without excessive weight. This composite approach enables concentrated reinforcement only where structural integrity is critical for torque transmission.
2Strength
If conventional gear trains are used to achieve high torque capacity, then torque strength is improved, but device size and footprint increase
Solution Approach 1:
The jaw assemblies are designed to nest within the body assembly when not in use, and the head assembly can be stored within or attached to the body. This nesting arrangement minimizes the footprint on the drilling rig floor while maintaining full torque capacity when deployed. The modular components can be stacked or arranged compactly when not actively engaged in operations.
Solution Approach 2:
The power tong incorporates movable and adjustable components including interchangeable jaw assemblies that can be quickly swapped, and a head assembly that can be replaced without moving the entire device. This dynamic configurability allows the same base unit to adapt to different torque requirements and tubular sizes, eliminating the need for multiple fixed-size devices and reducing overall footprint.
3Strength
If large gear trains are used to achieve high torque capacity, then torque strength is improved, but cost increases
Solution Approach 1:
The gear train is segmented into a head gear assembly that can be independently manufactured and replaced. This allows standardization of gear components that can be produced more efficiently through specialized manufacturing processes. Worn or damaged gear sections can be replaced without replacing the entire power tong, significantly reducing maintenance costs and extending the overall device lifecycle.
Solution Approach 2:
The head assembly and jaw assemblies are designed as universal components that can be interchanged across different power tong models or configurations. This universality allows a single set of expensive gear components to serve multiple functions and applications, reducing the need for duplicate expensive components and lowering overall manufacturing and maintenance costs.
4Reliability
If conventional jaw designs are used, then gripping capability is adequate, but adaptability to different tubular sizes is limited
Solution Approach 1:
The jaw assembly is segmented into interchangeable components including different sized jaw dies and positioning elements. This allows selection of specific jaw configurations matched to particular tubular sizes and weights, maintaining optimal gripping capability across a wide range of applications. Each jaw assembly can be independently replaced or adjusted without affecting other components.
Solution Approach 2:
The jaw assemblies incorporate adjustable positioning mechanisms and interchangeable components that allow dynamic adaptation to different tubular dimensions. The ability to quickly swap jaw configurations enables the same base assembly to reliably grip various tubular sizes, from small production tubing to large casing, maintaining optimal gripping force and contact geometry for each application.
Data Source
AI summary
A power tong assembly has a transmission box having a plurality of speeds. A gear train completely encircles a rotary gear by including idler gears, fluid lines and actuating mechanisms within a tong door, which itself can be remotely operated. Cam roller assemblies can be inversely mounted into cage plates and a support race can be mounted into an opening, thereby eliminating the need to cut a groove in a rotary gear. Filler blocks can be inserted adjacent to gears to catch and redirect slung grease from gears back to said gears, while dampening noise and reducing the misuse of grease, thereby increasing effectiveness of lubrication. A make and break actuator assembly can be housed on the power tong body such that it is completely covered from external damage except when momentarily activated. A symmetric rotary gear, rotary gear inserts, cam shoe inserts and over-travel cam stops are provided.