Multi-Station Torque Wrench for Parallel Flange Bolt Tightening
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Solution Overview
Problem
The manual process of tightening or loosening multiple bolts in large structures, such as rig risers, is time-consuming and prone to human error, fatigue, and safety issues, particularly in deepwater drilling operations where efficiency and precision are critical.
Innovation Solution
A robotic torque wrench system with multiple torque stations that can simultaneously engage and rotate bolts during high-torque and low-torque phases, utilizing a hydraulically actuated riser spider and a control panel for remote operation, allowing for simultaneous tightening or loosening of multiple bolts without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual torque wrenches are used to tighten bolts, then operational flexibility is maintained, but the process is time-consuming and prone to human error
Solution Approach 1:
The patent replaces manual mechanical torque wrench operation with an automated robotic system that uses computer-controlled mechanisms to apply torque. The robotic torque wrench system eliminates human intervention in the torque application process, thereby increasing speed while maintaining or improving precision through automated control systems and sensors that monitor torque application in real-time.
Solution Approach 2:
The robotic system performs the torque application task autonomously without requiring human operators to manually position and operate torque wrenches on each bolt. The system self-manages the sequence of operations, positioning, torque application, and verification, thereby improving both productivity and reliability through consistent automated execution.
2Productivity
If multiple operators use two torque wrenches simultaneously, then some parallel processing is achieved, but coordination complexity and potential for error increase
Solution Approach 1:
The patent merges multiple torque application functions into a single integrated robotic system. Instead of having multiple operators coordinate separate torque wrenches, the robotic system combines positioning, torque application, and monitoring functions into one automated unit that can service multiple bolts in sequence or parallel without human coordination complexity.
Solution Approach 2:
The robotic torque wrench system is designed with universal capabilities to perform multiple functions: positioning itself on different bolts, applying precise torque, monitoring the process, and adapting to various bolt configurations. This multi-functionality replaces the need for multiple specialized operators and tools, simplifying the overall system while maintaining parallel processing capability.
3Ease of operation
If operators manually position and remove torque wrenches between bolts, then adaptability to different bolt locations is achieved, but continuous operation is interrupted
Solution Approach 1:
The robotic system employs dynamic positioning capabilities that allow it to automatically move between different bolt locations without manual intervention. The system can adjust its position, orientation, and approach angle adaptively to access bolts in various locations, maintaining ease of operation while eliminating the time loss associated with manual wrench repositioning and removal.
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
Significantly reduces the time required for installing or removing riser sections, enhances operational efficiency, and improves safety by automating the process, ensuring precise torque application across all bolts, thus reducing the risk of human error and fatigue-related mistakes.
Implementation Method 1
utilizing a hydraulically actuated riser spider
Data Source
AI summary
An improved multi-bolt and nut torque wrench for installing and removing bolts or nuts from flanged joints or the like which includes a plurality of torque stations having a plurality of high torque wrenches for engaging the heads of the bolts or nuts during a high torque phase of removal or installation; a plurality of low-torque motors operatively engaged with the wrenches for rotating the bolts or nuts during the low torque phase of removal or installation; a source of hydraulic fluid for driving the low-torque motors during the low-torque phase, and driving the high-torque wrenches during the high torque phase; and a mechanism for switching between the two phases depending on the torque needed.