Tool-Mounted Controller for Hydrocarbon Recovery
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Solution Overview
Problem
Existing hydrocarbon recovery control systems lack sufficient input/output capabilities, leading to inefficient calibration and integration of new tool models, limiting improvements in tongs and other drilling tools due to hardware compatibility issues and insufficient electronic, hydraulic, pneumatic, data, and signal connections.
Innovation Solution
An automated control system with a tool-mounted controller featuring an explosion-proof housing, processor, and circuit board, enabling bi-directional communication and local power generation, which can monitor and actuate tong components for varying torque and angular displacement, and provide clamping and rotation actions, thereby enhancing flexibility and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing control systems are used with new tool models, then hardware compatibility is maintained, but input/output capabilities are insufficient leading to inefficient calibration and integration
Solution Approach 1:
The control system performs automatic calibration of tool sensors and inputs without requiring separate manual calibration procedures. The system pre-configures and validates connections between new tool models and the control architecture, eliminating time-consuming sequential calibration steps and enabling immediate operational readiness upon tool integration.
2Adaptability or versatility
If existing control systems are used with new tool models, then system stability is maintained, but sufficient electronic, hydraulic, pneumatic, data, and signal connections are not provided
Solution Approach 1:
The control system employs a universal controller architecture that integrates multiple control functions (electronic, hydraulic, pneumatic, data, and signal control) into a single multi-functional platform. This universal controller can adapt to various tool models and connection types without requiring separate dedicated control systems for each function, thereby providing comprehensive connection capability while managing system complexity through consolidation.
3Measurement precision
If tool sensors and control system inputs are calibrated separately, then calibration accuracy is maintained, but calibration efficiency is reduced
Solution Approach 1:
The system merges the calibration processes for tool sensors and control system inputs into a single integrated automatic calibration routine. The universal controller coordinates and executes both calibration operations simultaneously or in an optimized sequence, maintaining the precision required for accurate measurements while dramatically improving calibration efficiency by eliminating separate manual procedures.
Data Source
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AI summary
Methods and systems for controlling a set of tools for hydrocarbon recovery are presented. One example system generally includes a first tool (202a) and a first control device (204) mounted on the first tool and configured to operate the first tool. The first control device includes an explosion-proof housing (1102) and a processor (1112) disposed in the housing. The system further includes a second tool (202b) and a second control device (208) mounted on the second tool and configured to operate the second tool. The second control device includes an explosion-proof housing (1102) and a processor (1112) disposed in the housing.