Sliding Tool Coupler for Fast Bi-Directional Top Drive Torque
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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 limited in torque resistance and require additional components, increasing costs and complexity.
Innovation Solution
A top drive system with a drive unit and tool adapter that utilizes sliding coupling members and torque profiles to enable bi-directional torque transmission, along with axial load transfer, through a mechanism that includes a drive stem, retainer, and coupling recesses, allowing for quick and secure connection without the need for high-friction threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction-based thread locking mechanisms are used to achieve bi-directional torque capabilities, then torque resistance is limited, but device complexity and cost increase due to additional components
Solution Approach 1:
The connection system is divided into separate functional elements: a connection member with external threads and a separate locking mechanism with internal threads and locking elements. This segmentation allows the locking elements to engage with threaded portions to provide bi-directional torque capabilities without requiring complex integrated designs, thereby maintaining torque resistance while reducing overall device complexity
Solution Approach 2:
The locking elements act as intermediaries between the connection member and the connection assembly. These locking elements engage with the threaded portions of both components to transfer and secure bi-directional torque, eliminating the need for additional friction-based locking mechanisms or compounds while maintaining strong torque resistance
2Strength
If high bi-directional torque capabilities are achieved through positive locking methods, then torque resistance improves, but manufacturing cost increases due to turning and milling operations
Solution Approach 1:
The connection system separates the torque transfer function into distinct components: the connection member provides external threading for axial load transfer, while the locking mechanism provides internal threading and locking elements for torque transfer. This segmentation allows each component to be manufactured using simpler turning operations rather than complex milling operations, reducing manufacturing costs while maintaining high bi-directional torque capabilities
Solution Approach 2:
The threaded portions serve multiple functions: they provide both axial load transfer and torque transfer capabilities. The locking elements engage with these universal threaded structures to achieve bi-directional torque capabilities without requiring separate specialized features, thereby simplifying manufacturing while maintaining strength
3Force
If traditional threaded connections are used for tool string connections, then axial load transfer is achieved, but bi-directional torque transfer is limited and connection time increases
Solution Approach 1:
The locking elements are pre-positioned within the locking mechanism and the connection member is pre-threaded with external threads. When the connection is made by simply screwing the components together, the locking elements automatically engage with the threaded portions, providing immediate bi-directional torque capabilities without requiring additional manual operations. This preliminary preparation eliminates time-consuming post-connection locking steps while maintaining strong axial load and torque transfer
Data Source
AI summary
A drive unit of a top drive system includes a drive stem having a plurality of ports from an exterior thereof to an interior thereof. A plurality of sliding coupling members is disposed in the ports. A coupling collar encircles the drive stem and has actuation surfaces and recessed surfaces on an interior thereof, wherein the recessed surfaces align with the ports when the coupling collar is in a first position, and the actuation surfaces align with the ports when the coupling collar is in a second position.