Shaker Screen Damage Detection Using Computer Vision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shaker screens in drilling operations are often damaged and clogged, requiring time-consuming manual inspection and replacement, with variability in operator judgment leading to inefficiencies and increased costs.
Innovation Solution
An automated computer vision system using high-shutter-speed cameras, light sources, and processors to analyze shaker screen damage, coupled with automated cleaning and adjustment systems, to determine optimal replacement or repair times based on damage percentage and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual visual inspection is used to assess screen damage, then the method is simple to implement, but it is time-consuming and subjective
Solution Approach 1:
The patent replaces manual visual inspection with an automated computer vision system using cameras and image processing algorithms. The system captures images of the shaker screen and automatically analyzes damage through computational methods, eliminating the need for human operators to physically inspect the screen while significantly reducing assessment time and subjectivity
Solution Approach 2:
The system creates digital copies (images) of the shaker screen condition and analyzes these copies rather than requiring direct physical inspection. By working with image data, the system can repeatedly and rapidly assess damage without the time constraints and subjectivity inherent in manual inspection methods
2Device complexity
If manual visual inspection is used to assess screen damage, then the equipment required is minimal, but the process is expensive and subjective
Solution Approach 1:
The patent replaces subjective human judgment with objective computer vision algorithms that systematically analyze screen damage. The automated image processing provides consistent, repeatable measurements free from individual operator bias, significantly improving assessment reliability while the added equipment cost is offset by the elimination of repeated manual inspections
Solution Approach 2:
The system provides continuous feedback about screen condition through automated image analysis, enabling real-time monitoring and objective assessment. This feedback mechanism allows for consistent evaluation criteria to be applied repeatedly, ensuring reliable and reproducible damage assessment that improves operational decision-making
3Productivity
If visual inspection is performed periodically, then operator safety is maintained, but the screening process becomes inefficient
Solution Approach 1:
The patent enables continuous monitoring of screen condition through automated image capture and analysis, eliminating the need for periodic manual inspections. The system operates continuously to track damage accumulation in real-time, allowing for immediate detection when replacement is needed and eliminating delays associated with scheduling and performing periodic manual checks
Solution Approach 2:
The system performs self-monitoring of screen condition through automated image analysis, eliminating the need for operators to manually inspect screens. The computer vision system independently assesses damage and provides recommendations, freeing operators from time-consuming inspection tasks while maintaining continuous awareness of screen status to optimize drilling productivity
Data Source
AI summary
A system for cleaning, repairing, and/or replacing damaged shaker screens is disclosed. The system may comprise a shale shaker with a replaceable shaker screen, at least one camera, and a computer processor. The camera is positioned to capture images of the shale shaker screen and the processor is capable of receiving said images from the camera. The processor is configured to analyze the images and detect damaged regions of the shale shaker screen. The processor is also configured to determine when a screen is damaged above a predefined threshold. Certain embodiments allow for the automatic cleaning, repair, and/or replacement of the shaker screen.