Rotating Ring Tool Coupler for Bi-Directional Torque Transfer
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Solution Overview
Problem
Current methods for coupling top drives to tools in drilling operations face challenges with bi-directional torque transmission, often resulting in weak connections, high costs, and safety hazards due to limited torque resistance and complexity in manufacturing, as well as issues with cross-threading and component alignment.
Innovation Solution
A tool coupler system featuring a ring coupler with mating features and an actuator that rotates to engage a complementary profile on a central shaft or housing, allowing for bi-directional torque transmission while providing threading compensation and secure connections without the need for extensive component alignment or additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional threading compensation systems (hydraulic cylinders) are used to provide accurate alignment and positioning, then threading compensation is achieved, but component length and vertical clearance increase significantly
Solution Approach 1:
The ring coupler is rotatably mounted within the housing, nesting the rotational alignment mechanism inside the existing component structure. This eliminates the need for external hydraulic cylinders and their associated stroke lengths, achieving threading compensation without increasing overall component length
Solution Approach 2:
The ring coupler rotates dynamically between a first position (disengaged) and a second position (engaged), allowing the connection to transition from unaligned to aligned states. This rotational dynamics replaces the linear extension dynamics of hydraulic cylinders, achieving alignment without increasing component length
2Strength
If high bi-directional torque connections are made with positive locking methods (keys, clutches, cross/through-bolting), then torque resistance is sufficient, but device complexity and manufacturing cost increase
Solution Approach 1:
The ring coupler integrates multiple functions into a single component: it provides rotational alignment, positive locking through mating features, and bi-directional torque transmission. This merges what would traditionally require separate keys, clutches, or cross-bolts into one integrated mechanism, reducing complexity while maintaining high torque resistance
Solution Approach 2:
The ring coupler serves multiple purposes: aligning the threaded connection, providing positive locking, and transmitting bi-directional torque. This multi-functionality replaces multiple specialized components, simplifying the overall connection system while achieving high torque capabilities
3Force
If threaded connections are used for tool string connections, then load transfer is achieved, but bi-directional torque capability is limited and cross-threading risk exists
Solution Approach 1:
The ring coupler features an asymmetric profile with mating features that engage in a specific rotational position. This asymmetry ensures proper alignment and prevents cross-threading, while the engaged position provides positive locking for bi-directional torque capability, enhancing reliability beyond conventional symmetric threaded connections
Data Source
AI summary
Apparatus and methods are provided for coupling a first component to a second component of a tool coupler. A first component includes a ring coupler having mating features and rotatable between first and second positions; an actuator to rotate the ring coupler between the positions; and a second component comprising a profile complementary to the ring coupler. A method includes inserting a central shaft of the first component into a housing of the second component; rotating a ring coupler around the central shaft; and engaging mating features of the ring coupler with a profile. A method also includes clamping a profile using the ring coupler and a second ring coupler. A method also includes moving a second ring coupler vertically relative to the housing to engage a profile.