Robotic Pipe Stand Handling With Feedback-Guided Manipulation

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Solution Overview

Problem

Conventional drill pipe handling operations on drilling rigs are labor-intensive, dangerous, and limited by the speed at which human operators can maneuver drill pipe stands between the well center and the setback area, requiring manual handling and laborious processes.

Innovation Solution

A pipe handling system comprising a lifting system and robotic arms with end effectors, coordinated by a controller, that can engage and manipulate drill pipe stands independently, reducing the need for human operators and enhancing efficiency and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If human operators manually handle drill pipe stands, then operational flexibility and adaptability are maintained, but labor intensity increases, safety risks increase, and operational speed is limited

Engineering Contradiction:

Improveautomation of pipe handlingVSAvoidcomplexity of handling system

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The pipe handling system is divided into multiple independent robotic units, each equipped with specialized end effectors for specific tasks. The system segments the handling process into distinct operations (grasping, lifting, positioning, connecting) performed by different robotic components working in coordination, thereby achieving high automation while managing complexity through functional decomposition

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic handling system employs multi-functional end effectors that can perform multiple operations including grasping, lifting, positioning, and connecting drill pipe stands. These universal robotic components can adapt to different handling tasks through programmable control, reducing the need for specialized equipment for each function and managing system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If human operators maneuver drill pipe stands, then manual control and adaptability are maintained, but operational speed is limited by human reaction time and physical capacity

Engineering Contradiction:

Improveoperational speed of pipe handlingVSAvoidease of maneuvering pipe stands

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system replaces manual mechanical manipulation with automated robotic mechanisms equipped with sensors and programmable control. Robotic end effectors with grippers and manipulators perform grasping, lifting, and positioning operations at higher speeds than human operators, while feedback devices provide real-time data for precise control, achieving both high productivity and ease of operation through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic handling system incorporates feedback devices that continuously monitor the position, status, and environmental conditions during pipe handling operations. This real-time feedback enables the controller to adjust robotic movements dynamically, maintaining high operational speed while ensuring precise and easy maneuvering of drill pipe stands through closed-loop control

Inventive Principle:

Principle #23Feedback

3Reliability

If human operators handle drill pipe stands manually, then operational simplicity is maintained, but safety risks increase due to exposure to heavy loads and hazardous environments

Engineering Contradiction:

Improvesafety of handling operationsVSAvoidlevel of automated control

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system replaces human operators with robotic units that perform all manual handling tasks. These robots are equipped with specialized end effectors for grasping and manipulating drill pipe stands, eliminating human exposure to heavy loads and hazardous drilling environments. The automated robotic system maintains high reliability through sensor feedback and programmable safety protocols while achieving complete automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic end effectors serve as intermediaries between the control system and the drill pipe stands. These specialized grippers and manipulators provide a safe interface for handling heavy and hazardous pipe components, isolating human operators from direct contact with dangerous loads while enabling precise control through automated feedback mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11613940B2Devices, systems, and methods for robotic pipe handling

Publication Date: 2023.03.28 NAT OILWELL VARCO LP

AI summary

The present disclosure relates to systems and methods for automated drill pipe handling operations, such as trip in, trip out, and stand building operations. A pipe handling system of the present disclosure may include a lifting system for handling a load of a pipe stand, a pipe handling robot configured for engaging with the pipe stand and manipulating a position of the pipe stand, and a feedback device configured to provide information about a condition of the pipe stand, the lifting system, or the pipe handling robot. In some embodiments, the pipe handling robot may be a first robot configured for engaging with and manipulating a first end of the pipe stand, and the system may include a second pipe handling robot configured for engaging with and manipulating a second end of the pipe stand.