Robotic Pipe Manipulation System for Oil Well Safety
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Solution Overview
Problem
Oil well servicing operations, particularly tripping in and tripping out of pipes, pose significant health and safety risks due to the need for extensive human involvement, leading to hazardous conditions for workers.
Innovation Solution
A robotic system is integrated into oil well service rigs, featuring a base, mast, arm, and end effector with grabbing members, capable of autonomous manipulation and positioning of pipes, reducing human intervention through sensors and actuators for controlled movement and gripping of elongated objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators manually service oil wells using traditional rig systems, then operational control and flexibility are maintained, but worker safety and health risks significantly increase due to exposure to hazardous conditions on raised platforms and during pipe manipulation
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that includes a robotic arm, end effector, and control system. The robotic arm manipulates pipe sections through automated gripping, lifting, and positioning mechanisms, eliminating the need for human workers to physically handle heavy pipes on hazardous platforms. The control system coordinates multiple actuators to perform tripping operations autonomously.
Solution Approach 2:
The robotic system performs self-service through autonomous operation where the control system automatically manages the entire pipe manipulation process without continuous human intervention. The system includes sensors and feedback mechanisms that allow it to monitor its own operation and adjust accordingly, with humans only needing to initiate and supervise the automated sequence.
2Productivity
If traditional manual tripping operations are used, then system complexity remains relatively low, but productivity and operational efficiency are reduced due to manual handling limitations
Solution Approach 1:
The robotic system is divided into distinct functional modules: a base support structure, a multi-joint robotic arm with individual actuators, an end effector with gripping mechanisms, and a centralized control system. Each component performs a specific function and can be independently controlled, allowing for optimized performance of each subsystem while maintaining overall system productivity.
Solution Approach 2:
The robotic arm and end effector are designed as multi-functional units capable of performing various pipe manipulation tasks including gripping, lifting, rotating, and positioning different types of pipe sections. The system can adapt to different operational requirements through programmable control sequences, making it a universal solution for various tripping operations.
3Object-affected harmful factors
If automated robotic systems are deployed, then worker exposure to hazardous conditions is reduced, but device complexity and initial implementation costs increase
Solution Approach 1:
The robotic system acts as an intermediary between human operators and hazardous pipe manipulation tasks. Humans remain in safe control areas while the robotic system physically interacts with pipes in hazardous zones. The end effector serves as the intermediary interface that transfers control from human operators to the automated mechanical system, eliminating direct human exposure to heavy lifting and platform work.
Data Source
AI summary
A robotic system coupled to a racking platform of an oil well service or drilling rig comprising a base coupled to the racking platform at a fixed location, a mast pivotally coupled to the base by a mast pivot joint allowing rotation of the mast about a mast axis, a mast actuator for controllably rotating the mast about the mast pivot joint, an arm coupled to the mast and moveable along a radial direction with respect to the mast axis, an arm actuator for controllably moving the arm along the radial direction, an end effector pivotally coupled to an end of the arm by an end effector pivot joint allowing rotation of the end effector about an end effector axis oriented generally parallel to the mast axis, and an end effector actuator for controllably rotating the end effector about the end effector pivot joint. The end effector comprises at least one grabbing member operable to selectively grab an elongated object under control of a grabbing member actuator.