Passive Tool Coupling for Robot Drill Rig End Effector Exchange
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Solution Overview
Problem
Conventional pipe handling operations, such as drill pipe handling, are labor-intensive and dangerous, often requiring manual labor and limited by the speed of human operators, and robotic systems lack efficient power-assisted mechanisms for tool engagement and disengagement.
Innovation Solution
A passive coupling mechanism that allows tools to be interchanged on a tool arm through relative rotation, eliminating the need for hydraulic, pressurized air, or electrical power, by using a housing with an engaging lock that secures the connection through rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operations are used for pipe handling, then operators can maneuver drill pipe stands, but the operations are labor-intensive and dangerous
Solution Approach 1:
The coupling mechanism is designed to automatically engage and lock when the tool arm approaches the tool, without requiring manual intervention. The spring-loaded locking arms and cam surfaces automatically interact to secure the connection, making the system self-servicing and eliminating the need for operators to manually handle heavy pipe stands.
2Extent of automation
If robotic systems are used for pipe handling, then labor intensity is reduced, but efficient power-assisted mechanisms for tool engagement are lacking
Solution Approach 1:
The patent removes the complex power-assisted mechanisms (hydraulic, pneumatic, or electrical systems) from the coupling mechanism, extracting only the essential mechanical elements needed for engagement. This simplification makes the mechanism easier to operate while maintaining automated functionality through the robot's natural movement.
Solution Approach 2:
The patent replaces complex powered mechanical systems with a simpler passive mechanical system. Instead of using motors, hydraulics, or pneumatics to actuate the locking mechanism, the design uses the robot's own movement and gravity to drive the engagement process through cam surfaces and spring-loaded arms.
3Ease of operation
If passive coupling mechanism is used, then power assistance is eliminated, but tool engagement speed may be limited
Solution Approach 1:
The spring-loaded locking arms are pre-positioned and under spring tension, ready to immediately engage with the cam surfaces when the tool arm approaches. This preliminary preparation of the locking mechanism ensures rapid engagement without requiring power actuation during the actual coupling process.
Solution Approach 2:
The coupling mechanism uses dynamic cam surfaces that automatically guide the locking arms into the locked position as the tool arm moves into place. The cam geometry converts the robot's linear approach motion into rotational locking motion, enabling fast passive engagement without requiring the robot to slow down or pause for actuation.
Data Source
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AI summary
A system for interchanging end effectors on a robot of a drill rig. The system comprises a robot (50), a coupling mechanism (100), and one or more end effectors (60). The robot (50) comprises a base portion (52) configured for securing to a drill floor of the drill rig, a shoulder portion (54) coupled to the base portion (52), an articulated arm (56) operably coupled to the shoulder portion (54) at a first end and extending to a second end, and a wrist portion (58) arranged on the second end of the articulated arm (56) and being adapted for selectively engaging and disengaging an end effector (60). The coupling mechanism (100) comprises a robot portion (102) and a tool portion (104). The one or more end effectors (60) are arranged at a setting location accessible by the wrist portion (58) of the robot (50) using the coupling mechanism (100). The robot (50) is configured to use the one or more end effectors (60) to perform selected operations on the drill rig and is further configured to use the coupling mechanism (100) to interchange end effectors (60) to use selected end effectors (60) that correspond to the selected operations.