Rotating Bar Coupling for Top Drive Torque Transfer
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Solution Overview
Problem
Current methods for coupling top drives to tools in drilling operations are time-consuming, dangerous, and lack efficient bi-directional torque transmission, often relying on friction-based solutions that are not reliable for high torque applications and require complex manufacturing processes.
Innovation Solution
A coupling system that includes a first plate with a stabbing member and a second plate with a complementary hollow, a rotatable bar, and a securing mechanism, along with a drive stem and fixation ring system, allowing for secure axial load and bi-directional torque transfer between the top drive and tools, enabling quick and safe tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If friction-based locking methods are used, then ease of manufacture is improved, but torque resistance deteriorates
Solution Approach 1:
The patent replaces friction-based mechanical locking with a positive locking mechanism using a bar that engages with notches in the stabbing member. This mechanical engagement provides high torque resistance through direct contact and geometric interlocking, eliminating reliance on friction between component surfaces.
2Strength
If positive locking methods are used, then torque resistance is improved, but device complexity worsens
Solution Approach 1:
The coupling system is divided into distinct functional components: a stabbing member with notches for torque transfer, a bar for positive locking, and a securing member for retention. This segmentation allows each component to perform its specific function efficiently while maintaining overall system simplicity.
Solution Approach 2:
The bar is positioned within a bore in the second plate, and the securing member is integrated into the same plate structure. This nested arrangement consolidates multiple components into a compact configuration, reducing overall device complexity while maintaining positive locking capability.
3Ease of manufacture
If traditional threaded connections are used, then ease of manufacture is improved, but reliability worsens due to risk of breaking
Solution Approach 1:
The patent replaces traditional threaded connections with a stabbing mechanism featuring a stabbing member with notches that engage positively with the bar. This design eliminates the risk of thread stripping or breaking while maintaining ease of assembly through a straightforward stabbing and locking motion.
4Strength
If complex locking mechanisms are used, then torque resistance is improved, but ease of operation worsens
Solution Approach 1:
The bar is pre-positioned within the bore and the securing member is pre-configured in the second plate. When the stabbing member is inserted, the bar automatically engages with the notches, and the securing member can be quickly activated to lock the connection. This preliminary arrangement eliminates complex multi-step operations.
Solution Approach 2:
The stabbing member's notches are designed to automatically engage with the bar upon insertion, creating a self-locking mechanism. The securing member then simply needs to be activated to maintain the connection, allowing the system to perform much of the locking action automatically without complex manual operations.
Data Source
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AI summary
A method and system for coupling a drive unit to a tool adapter includes joining a first plate to a second plate; stabbing a stabbing member of the first plate into a hollow of the second plate; and rotating a bar of the second plate from an open position to a closed position to secure the stabbing member in the hollow. An embodiment includes positioning the tool adapter below the drive unit; stabbing a coupling head into a coupling recess; moving a fixation ring vertically; and securing bolts of the drive unit in notches of the coupling head.