Coordinated Robotic Pipe Handling for Drill Stand Positioning
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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 improved efficiency and safety.
Innovation Solution
A pipe handling system comprising a lifting system and two robots, one on the drill floor and one on the racking board, that can independently and coordinatedly manipulate drill pipe stands, using feedback devices and a controller to manage the movement and positioning of pipe stands without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If human operators manually maneuver drill pipe stands, then operational flexibility and adaptability are maintained, but labor intensity increases and safety risks arise
Solution Approach 1:
The patent replaces human operators with automated robotic systems equipped with sensors, controllers, and actuators. The robotic manipulators perform drill pipe handling operations autonomously, substituting human mechanical actions with automated mechanical systems controlled by electronic sensors and processors, thereby eliminating safety risks associated with human exposure to hazardous environments while maintaining operational flexibility through programmable control.
Solution Approach 2:
The robotic system incorporates self-monitoring sensors and automated control mechanisms that enable the system to detect its own state, adjust its operations, and maintain optimal performance without human intervention. The feedback devices continuously monitor position, force, and operational parameters, allowing the robotic system to self-correct and adapt during drill pipe handling operations.
2Productivity
If human operators manually handle drill pipe stands, then system complexity remains low, but operational speed is limited by human capability
Solution Approach 1:
The patent replaces human-operated mechanical systems with automated robotic systems that use sensors, microprocessors, and automated control algorithms. This substitution enables operational speeds far exceeding human capabilities while the modular robotic architecture and standardized interfaces help manage the inherent complexity through systematic design.
Solution Approach 2:
The robotic system incorporates feedback devices including position sensors, force sensors, and encoders that continuously monitor operational parameters and provide real-time feedback to the control system. This feedback enables high-speed automated operations with precise control, allowing the system to react and adjust faster than human operators while maintaining accuracy through closed-loop control mechanisms.
3Measurement precision
If automated robotic systems are implemented, then operational speed and precision are improved, but system complexity increases
Solution Approach 1:
The patent employs multiple feedback devices including position encoders, force sensors, and vision systems that continuously monitor the robotic manipulators' position and orientation. This multi-sensor feedback system provides real-time data to the control algorithms, enabling high positioning accuracy through closed-loop control that compensates for disturbances and uncertainties, thereby achieving precision comparable to or exceeding human capability despite the increased system complexity.
Solution Approach 2:
The robotic system is divided into modular components including separate manipulators, sensors, controllers, and end-effectors that can be independently designed, tested, and maintained. This segmentation allows complex functions to be broken down into manageable modules, making the overall system complexity more tractable while enabling high precision through coordinated operation of specialized subsystems.
4Productivity
If robotic systems with multiple components are used, then operational efficiency is improved, but ease of operation decreases due to coordination requirements
Solution Approach 1:
The patent integrates multiple robotic manipulators and control functions into a unified automated system managed by a central controller. The coordination complexity is internalized within the system's control architecture, which automatically manages the interaction between multiple components through pre-programmed sequences and real-time coordination algorithms, thereby achieving high operational efficiency without exposing coordination complexity to operators.
Solution Approach 2:
The robotic system incorporates self-coordination capabilities through automated control algorithms that manage the interaction between multiple manipulators and components. The system autonomously handles task allocation, motion coordination, and conflict resolution between components, eliminating the need for human operators to manually coordinate complex multi-component operations while maintaining high operational efficiency.
Data Source
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AI summary
A pipe handling system including a lifting system for handling a load of a pipe stand, a pipe handling robot (116a, 116b) configured for engaging with the pipe stand (110) and manipulating a position of the pipe stand (110), and a feedback device configured to provide information about a condition of the pipe stand, the lifting system, or the pipe handling robot (116a, 116b). In some embodiments, the pipe handling robot (116a) 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 (116b) configured for engaging with and manipulating a second end of the pipe stand (110).