Top Drive Multi-Coupler for Bidirectional Tool Connection
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Solution Overview
Problem
Conventional top drive systems for wellbore operations require manual connection of supply lines, which is time-consuming and dangerous for rig personnel, and allow only single-direction threaded connections, posing challenges in efficiently coupling top drives to tools.
Innovation Solution
A coupler system with a housing and adapter that includes a window for torsional coupling and a lock ring for longitudinal coupling, allowing bidirectional torque transfer and weight support, along with utility connectors for power and data transfer, facilitating efficient and safe connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection of supply lines is used between top drive and tool, then connection can be made with simple structure, but connection time increases and safety risk increases for rig personnel
Solution Approach 1:
The patent combines multiple coupling functions (mechanical coupling, electrical coupling, hydraulic coupling, pneumatic coupling) into a single integrated coupler system. This merging eliminates the need for separate manual connections of supply lines, thereby reducing connection time and improving safety by automating the coupling process between the top drive and tool.
Solution Approach 2:
The coupler system enables automatic self-coupling through engagement of coupling elements without requiring manual intervention for connecting supply lines. The system serves itself by automatically establishing mechanical, electrical, hydraulic, and pneumatic connections when the coupler engages with the tool, reducing both time and safety risks.
2Adaptability or versatility
If single-direction threaded connection is used between top drive and tool, then connection structure is simple, but torque transfer capability is limited and bidirectional operations cannot be performed
Solution Approach 1:
The coupling connection is segmented into multiple independent functional elements: mechanical coupling elements for torque transfer, electrical coupling elements for power and data, hydraulic coupling elements for fluid transfer, and pneumatic coupling elements. This segmentation allows each element to specialize in its function while collectively providing bidirectional torque transfer and multi-directional operational capability without excessive overall complexity.
Solution Approach 2:
The coupler system is designed as a universal multi-functional interface that can transfer torque bidirectionally, transmit electrical power and data, convey hydraulic fluid, and transport pneumatic pressure. This multi-functionality replaces the limited single-direction threaded connection, enabling versatile operations while the modular design keeps the structure manageable.
3Strength
If conventional threaded connection is used, then only single-direction rotation is allowed, but bidirectional torque transfer and weight support cannot be achieved
Solution Approach 1:
The coupling mechanism incorporates dynamic elements that can adapt to different loading conditions. The mechanical coupling elements are designed to handle bidirectional torque transfer and weight support through movable and adjustable components that respond to operational forces, providing enhanced strength while maintaining a manageable structural complexity through functional adaptability.
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 coupler system enables rapid, safe, and bidirectional coupling of top drives to tools, reducing operational time and enhancing safety by automating the connection process and supporting weight and torque transfer.
Implementation Method 1
the window is configured to receive the tab and torsionally couple the adapter and the housing
Implementation Method 2
the lock ring is configured to longitudinally couple the adapter and the coupler in the locked position
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
In one embodiment, a coupler system for coupling a top drive and a tool, including a drive member of the top drive configured to transfer torque. The drive member having a housing with a bore therethrough and a window formed substantially laterally through the housing. An adapter of the tool is configured to be inserted through the window of the housing. In another embodiment, a method for coupling a top drive to a tool includes moving the tool adjacent to the top drive, the tool including an adapter and the top drive including a housing having a window formed therethrough. The method also includes aligning the adapter with the window and inserting the adapter substantially laterally into the window of the housing, thereby longitudinally and torsionally coupling the top drive and the tool.