Threaded Coupler with Merged Fluid Channels for Top Drive
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Solution Overview
Problem
Conventional top drives require manual and time-consuming connection of supply lines, posing safety risks to rig personnel due to their single-directional threaded connections, which complicates the coupling process with tools in wellbore operations.
Innovation Solution
A coupler system with a longitudinally movable lock member and an actuator, allowing for bidirectional fluid communication and torque transfer between the top drive and tool, facilitated by a combined multi-coupler system that includes a housing, adapter, and locking assembly with elastomeric seals and trapezoidal threads for secure and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional threaded connections are used for top drive to tool coupling, then torque transfer is achieved, but the connection is single-directional and requires manual supply line connection which is time-consuming and dangerous
Solution Approach 1:
The patent combines the coupling mechanism and supply line connection into a single integrated operation. The coupler assembly includes internal channels that align with external channels in the tool, allowing fluid communication to be established automatically during the coupling process without requiring separate manual supply line connections. This merging of functions eliminates the time-consuming and dangerous manual supply line connection step while maintaining torque transfer capability through the threaded connection.
Solution Approach 2:
The coupler assembly serves multiple functions simultaneously: it provides threaded connection for torque transfer, establishes fluid communication through aligned channels, and enables rapid coupling without manual supply line work. The internal channel structure in the coupler and corresponding external channels in the tool create a universal connection interface that handles both mechanical and fluid coupling in one operation.
2Reliability
If manual connection of supply lines is performed, then fluid communication is established, but rig personnel are exposed to safety risks and operational time is increased
Solution Approach 1:
The coupler assembly performs the fluid communication function automatically through its internal channel structure during the coupling operation. The channels are pre-configured within the coupler and align with corresponding channels in the tool, allowing fluid passage to be established self-service style without requiring rig personnel to manually connect supply lines. This eliminates safety risks associated with manual supply line connection while maintaining connection speed.
3Adaptability or versatility
If single-directional threaded connection is used, then torque transfer is simplified, but bidirectional fluid communication and automated coupling cannot be achieved
Solution Approach 1:
The patent employs a nested structure where the coupler assembly contains internal channels that are integrated within the threaded connection structure. The coupler includes an internal channel extending through its body, and the tool includes a corresponding external channel, creating a nested arrangement where fluid communication pathways are embedded within the mechanical coupling structure. This nesting allows bidirectional fluid communication without significantly increasing overall device complexity.
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
A coupler includes a housing having a bore therethrough, a lock member at least partially disposed within the bore of the housing and longitudinally movable relative to the housing between a locked position and an unlocked position, and an actuator at least partially disposed within the housing and configured to move the lock member. In another embodiment, a combined multi-coupler system includes a housing having a bore therethrough, an adapter of a tool dock, and a locking assembly including a lock member at least partially disposed within the bore of the housing and longitudinally movable relative to the housing between a locked position and an unlocked position.