Tong Assembly Mode Detection via Optical Targets

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Solution Overview

Problem

Existing tong assembly systems lack effective methods to detect operational modes due to rotational components interfering with direct wired connections to control systems, preventing accurate feedback on makeup or breakout operations.

Innovation Solution

A sensor system with targets and sensors is implemented, allowing detection of operational modes through optical imaging, ultrasonic, or proximity sensors, coupled with a local and remote controller to analyze and transmit data for mode determination and control adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a make/break switch is mounted to a rotational portion of the tong assembly to enable mode switching, then the tong can shift between makeup and breakout modes, but the rotational movement prevents direct wired connections to the control system, eliminating feedback capability

Engineering Contradiction:

Improvemode switching capabilityVSAvoidfeedback about operational mode

Core Design Contradiction:

Adaptability or versatilityVSLoss of information

Solution Approach 1:

The patent replaces the mechanical wired connection system with an optical sensing system. Optical sensors detect the position of optical targets attached to the mode switch, transmitting operational mode information wirelessly to the control system without requiring physical wired connections that would be disrupted by rotation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical targets as intermediary elements between the mode switch and the optical sensors. These targets serve as mediators that carry positional information from the rotating mode switch to the stationary sensors, enabling indirect information transfer without direct wired connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If direct wired connections are used between the make/break switch and control system, then reliable electrical connection is achieved, but the rotational movement of the switch makes wired connections impossible

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection implementation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent substitutes the mechanical wired connection system with an optical detection system. Optical sensors non-contactingly detect the position of optical targets on the mode switch, providing reliable information transmission without the mechanical constraints of wired connections during rotation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If optical sensors and targets are used to detect mode switch position, then non-contact detection is achieved allowing rotational movement, but additional components are introduced to the system

Engineering Contradiction:

Improverotational compatibilityVSAvoidsensor and target components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent uses optical targets as simple intermediary elements that attach to the mode switch. These targets are straightforward optical features that reflect or emit light to indicate position, providing rotational compatibility while maintaining relatively simple system architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables accurate detection and shifting of operational modes in tong assemblies, ensuring correct makeup or breakout operations by providing real-time feedback and control, overcoming the limitations of direct wired connections.

Implementation Method 1

A first sensor configured to identify the first position of the first target

Methodology Applied

Scientific EffectOptical imaging: Light

Implementation Method 2

A first sensor configured to identify the first position of the first target

Methodology Applied

Scientific EffectUltrasonic detection: Ultrasound

Implementation Method 3

A first sensor configured to identify the first position of the first target

Methodology Applied

Scientific EffectProximity detection: Electromagnetic Induction

Data Source

PatentEP3841274B1Apparatus and methods for determining operational mode of tong assembly

Publication Date: 2023.05.31 WEATHERFORD TECHNOLOGY HOLDINGS LLC

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AI summary

A system for tong assembly operation includes a mode switch for shifting the tong assembly between a first mode of operation and a second mode of operation, the mode switch having a first portion associated with the first mode and a second portion associated with the second mode; a first target coupled to the first portion, the first target movable to a first position corresponding to the first mode of operation; a second target coupled to the second portion, the second target movable to a second position corresponding to the second mode of operation; a first sensor configured to identify the first position of the first target; and a second sensor configured to identify the second position of the second target.