Top Drive Coupling Beam for Drilling Rig
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Solution Overview
Problem
Current drill rig systems face challenges in efficiently coupling top drives to traveling blocks, particularly due to the need for manual and dangerous disconnection processes, which are cumbersome and often require heavy lifting, especially in high-capacity drilling operations where legacy equipment compatibility and angular flexibility are essential.
Innovation Solution
A coupling assembly featuring a movable beam with a non-circular cross-section that spans a gap between two members, allowing for secure engagement and disengagement of a top drive to a traveling block without requiring the removal of pins or hooks, utilizing a force amplifying mechanism and actuation systems for remote operation, ensuring compatibility with API standards and reducing manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional becket connection with pins is used to couple top drives to traveling blocks, then compatibility with legacy equipment is achieved, but the coupling and disconnection process becomes manual, dangerous, and requires heavy lifting operations
Solution Approach 1:
The patent replaces the manual mechanical pin removal system with a powered mechanical system. A beam with a non-circular cross-section engages with a receptacle on the traveling block, and a winch system provides automated mechanical force to pull the beam through the gap, eliminating the need for manual hammering and punching operations.
Solution Approach 2:
The patent introduces a beam as an intermediary component between the top drive and the traveling block. This beam acts as a mediator that transfers the coupling force, allowing the top drive to be connected to the traveling block without direct manual handling of heavy pins or hooks.
2Ease of operation
If manual pin removal and heavy lifting operations are performed for rig up and rig down, then top drives can be disconnected, but operational safety is compromised and significant manual labor is required
Solution Approach 1:
The system performs its own coupling and disconnection operations through automated mechanical means. The winch system, powered by the drill rig's existing power source, automatically pulls the beam through the gap to connect or disconnect the top drive, eliminating the need for manual intervention in dangerous high-stress operations.
Solution Approach 2:
The patent substitutes dangerous manual mechanical operations with a powered mechanical system. Instead of workers manually removing pins and lifting heavy components, a winch-driven beam system performs the coupling and disconnection automatically, significantly improving operational safety.
3Reliability
If a beam with non-circular cross-section is used to prevent rotation, then secure engagement is achieved, but the complexity of the coupling assembly increases
Solution Approach 1:
The patent employs asymmetry by using a beam with a non-circular cross-section (such as rectangular or I-shaped). This asymmetric geometry prevents the beam from rotating within its receptacle, ensuring secure engagement. The asymmetric shape creates a unique fit that eliminates rotational movement while maintaining structural simplicity.
4Ease of operation
If remote actuation systems are implemented for beam operation, then manual labor is reduced, but the device complexity and cost increase
Solution Approach 1:
The patent replaces manual mechanical operations with a powered mechanical system. A winch, driven by the drill rig's existing power source, automatically pulls the beam through the gap to connect or disconnect the top drive. This substitution eliminates the need for manual labor in dangerous operations while utilizing the rig's existing power infrastructure.
Data Source
AI summary
A coupling may be used to couple a top drive to a traveling block in a drilling rig. The coupling comprises a beam that is movable between a retracted configuration in which a becket or bail may be passed behind the beam to a closed configuration in which the beam is linked behind the becket or bail. The beam may include a compound curvature contact area that mates with a corresponding contact area of the becket or bail. The coupling may be remotely actuated.