Overhead Counter-Balance Tool Handling System with Control Bar
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tool balancers, particularly those used in off-shore hydraulic tools, face issues with limited extension range, leading to dangerous sudden weight shifts during tensioner failure, and short cable lengths causing jerking motion and cable damage, especially when working with high torque wrenches near buoyant risers.
Innovation Solution
A tool handling system utilizing an overhead counter-balance with complimentary springs and a control bar that eliminates the need for a tensioned spool, allowing for a longer cable length and reducing motion transfer from the tensioner, and positions the tool without contacting the buoyant riser material, thereby preventing cable damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the cable is extended to near its maximum range to increase positioning flexibility, then the extension range is improved, but the force applied to the tool varies and the spool must be positioned just over the operator's head resulting in a short cable length
Solution Approach 1:
The patent employs a dynamic cable tensioning system where the spool can move horizontally along a track, allowing the cable length and tension to be dynamically adjusted based on the tool's position and weight requirements. This resolves the contradiction by enabling both long cable extension and consistent force application through real-time spool repositioning.
Solution Approach 2:
The spool is constrained to move along a horizontal track rather than being fixed in position. This adds a horizontal dimension to the spool's degrees of freedom, allowing it to optimize both cable length and tension independently. The track-guided movement enables the spool to position itself optimally for each operating condition, resolving the force-cable length tradeoff.
2Manufacturing precision
If the cable length is shortened to improve positioning precision, then positioning accuracy is improved, but the cable can make contact with buoyant riser material leading to cable damage
Solution Approach 1:
The patent changes the operational parameters by allowing the spool to move along a horizontal track, which alters the cable's path and geometry. This enables the use of longer cable lengths without compromising positioning accuracy, as the horizontal spool movement provides additional control over the cable's effective length and angle, preventing contact with buoyant riser material.
3Adaptability or versatility
If the spool moves during operation to adjust position, then adaptability is improved, but the tensioner imparts jerking motion to the tool through the short cable
Solution Approach 1:
The horizontal track serves as an intermediary mechanism that decouples the spool's positioning movements from direct transmission to the tool. The track-guided movement allows the spool to adjust position smoothly while the extended cable length acts as a buffer, filtering out jerking motions and providing a more stable tool operation.
4Force
If the tensioner applies force to support the tool weight, then the tool support capability is improved, but failure results in sudden weight shifts causing injury and damage
Solution Approach 1:
The patent implements a track-guided spool system that allows for smoother, more controlled cable tensioning and release. The horizontal movement capability enables gradual adjustment of cable length and tension, preventing sudden weight shifts. Additionally, the system's design allows for better distribution of forces during operation, reducing the risk of catastrophic failure and providing a safer operational envelope.
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
The system effectively supports at least 80-90% of the tool's weight, reduces the risk of injury from sudden weight shifts, and allows safe positioning and operation of tools near buoyant risers by maintaining a stable counter-gravitational force and minimizing cable contact with the riser.
Implementation Method 1
The extension spring(s) are positioned within an extension casing that depends from a block slidably disposed within the counter-balance. The weight of the tool will load the extension spring(s).
Implementation Method 2
One or more compression springs are positioned within the counter-balance. As the block is pulled toward the tool end of the counter-balance, the block will load the compression spring(s).
Implementation Method 3
an overhead counter-balance mounted on pulleys, rails, a pivotable arm, or other conventional means configured to allow horizontal motion of the system
Data Source
AI summary
A tool handling system including an overhead counter-balance and a control bar. The counter-balance uses a series of complementary springs to provide a counter-gravitational force to a suspended tool. When the user wishes to lift the tool from its equilibrium position, the user is assisted by the counter-gravitational force of the springs such that the tool may be lifted with only a small fraction of the force necessary to lift the tool unaided. The control bar will allow users to keep any cable away from a riser or other structure on which the tool is being used.