Optical Drill Pipe Sensor for Bend Radius and Torque Monitoring
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Solution Overview
Problem
Horizontal directional drilling systems face limitations in monitoring bend radius and torque forces exerted on drill pipes, leading to potential damage from exceeding these limitations during underground utility installations.
Innovation Solution
A system comprising a light source and optical sensing device within the drill pipe to emit and detect a light beam, with a processor determining the forces exerted by processing the detection signal, allowing for real-time measurement of bend radius and torque forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional drilling systems are used without optical monitoring, then the system is simpler and cheaper, but the ability to monitor bend radius and torque forces is insufficient
Solution Approach 1:
The patent replaces traditional mechanical sensing systems with an optical measurement system. A light source emits light through the drill pipe wall, and optical sensors detect light transmission changes caused by pipe bending and torque. This substitution enables precise measurement of bend radius and torque forces without complex mechanical contact sensors inside the pipe.
Solution Approach 2:
The patent introduces light as an intermediary medium to measure mechanical parameters. The light beam passes through the pipe wall and its transmission characteristics change in response to pipe deformation. This intermediary approach allows non-contact measurement of forces and bending without direct mechanical interaction with the pipe interior.
2Reliability
If optical sensing devices are installed within the drill pipe, then real-time force monitoring is enabled, but the device complexity increases
Solution Approach 1:
The patent implements a feedback system where optical sensors continuously monitor light transmission through the drill pipe and provide real-time data to a control system. The system compares measured bend radius and torque forces against predetermined safe operating limits and provides feedback signals when thresholds are approached, enabling operators to adjust drilling parameters to prevent pipe damage.
Solution Approach 2:
The patent replaces complex mechanical force sensors with optical measurement components. By measuring light transmission changes caused by pipe wall deformation, the system determines torque and bending forces without requiring mechanical contact sensors, strain gauges, or other complex mechanical measurement devices inside the pipe.
3Ease of operation
If light transmission method is used to measure forces, then non-contact measurement is achieved, but the measurement precision may be affected by light source stability
Solution Approach 1:
The patent uses a reference light path or reference measurement channel that copies the measurement setup but is isolated from the pipe. By comparing the light transmission through the pipe against this reference, the system compensates for variations in light source intensity and detector sensitivity, maintaining measurement precision despite light source instability.
Solution Approach 2:
The patent employs modulation techniques where the light source is modulated at a specific frequency and the detector is tuned to detect only this frequency. This parameter change approach filters out DC drift and low-frequency noise from light source instability, improving the signal-to-noise ratio and measurement accuracy of the optical force sensing system.
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
Enables accurate monitoring and display of bend radius and torque forces, preventing damage to drill pipes by providing operators with critical feedback on approaching limitations, thus enhancing the safety and efficiency of drilling operations.
Implementation Method 1
a light source supported within the pipe section to emit a light beam within the pipe section, an optical sensing device supported within the pipe section and spaced apart from the light source
Data Source
AI summary
A system and method for monitoring bend radius and torque force exerted on a drill string. A sensor system is supported within a pipe section of the drill string and has a light source supported within the pipe section to emit a light beam within the pipe section. An optical sensing device is supported within the pipe section and spaced apart from the light source. The optical sensing device transmits a detection signal indicative of the position of the light beam on a surface of the optical sensing device to a processor that determines the bend radius and torque force exerted on the pipe section.