Rib Alignment Jig for Screen Filter Cartridge Assembly

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Solution Overview

Problem

Current sand screens used in downhole operations for controlling sand and debris in fluids are formed through diffusion bonding, which can be complex and inefficient, particularly in creating a robust assembly that effectively filters particles while being mounted to a tubular.

Innovation Solution

A method involving the use of a rib alignment jig to position and resistance weld sleeve members around rib members, forming a screen assembly with a screen cartridge decoupled from the ribs, allowing for efficient assembly and filtration of downhole fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If diffusion bonding is used to form screen layers and ribs, then the screen assembly can be formed, but the manufacturing process becomes complex and inefficient

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidbonding process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces the diffusion bonding process (thermal/chemical mechanism) with a mechanical assembly process using a rib alignment jig. The jig mechanically positions and holds the screen layers and ribs during assembly, eliminating the need for complex diffusion bonding equipment and processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The rib alignment jig serves as an intermediary tool that facilitates the assembly of screen layers and ribs. It provides a standardized interface and positioning mechanism, acting as a mediator between the various components and the assembly process, thereby simplifying manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If ribs are diffusion bonded to screen layers, then structural integrity is achieved, but manufacturing time and efficiency are reduced

Engineering Contradiction:

Improveassembly efficiencyVSAvoidmanufacturing cycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The rib alignment jig is prepared in advance with positioning features and alignment mechanisms. By having the jig ready with pre-configured alignment features, the actual assembly process becomes faster and more efficient, reducing the time required for rib-to-screen-layer attachment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The assembly process is segmented into discrete steps facilitated by the jig: positioning, alignment, and attachment. This segmentation allows for standardized, repeatable operations that increase productivity while reducing overall manufacturing cycle time compared to monolithic diffusion bonding.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If screen layers are bonded together and rolled into a tube, then a functional screen assembly is formed, but the process requires multiple complex steps

Engineering Contradiction:

Improveassembly process simplicityVSAvoidmanufacturing process efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges the positioning, alignment, and attachment functions into a single rib alignment jig system. This consolidation of multiple functions into one tool simplifies the manufacturing process and improves efficiency by eliminating the need for separate operations for each function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rib alignment jig is designed as a universal fixture that can accommodate and align multiple screen layers and ribs simultaneously. This multi-functional tool handles various assembly tasks (positioning, alignment, support) in a single device, simplifying the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This method simplifies the formation of screen assemblies, enhancing their structural integrity and filtration efficiency by ensuring robust bonding of sleeves to rib members and decoupling the screen cartridge from ribs, thus effectively controlling sand and debris in downhole operations.

Implementation Method 1

resistance welding the sleeve to the first end portion of each of the plurality of rib members

Methodology Applied

Scientific EffectResistance welding: Welding

Data Source

PatentUS10458210B2Manufacturing method of rib support for screen/filter cartridge

Publication Date: 2019.10.29 BAKER HUGHES CO

AI summary

A method of forming a screen assembly includes arranging a first end portion of each of a plurality of rib members into a rib alignment jig, positioning a sleeve about the rib alignment jig with an inner surface of the sleeve abutting the first end portion of each of the plurality of rib members, and resistance welding the sleeve to the first end portion of each of the plurality of rib members.