Top Drive Tool Coupler With Sliding Members for Bi-Directional Torque
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for coupling top drives to tools in drilling operations are time-consuming, dangerous, and lack efficient bi-directional torque transmission, often relying on friction-based solutions that are not reliable for high torque applications and require additional components, increasing costs.
Innovation Solution
A top drive system with a drive unit and tool adapter that uses sliding coupling members and torque profiles to enable bi-directional torque and load transfer, featuring a drive stem with ports and recesses, and a tool stem sleeve with mating torque profiles, allowing for secure and efficient connection without the need for complex threading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction-based locking methods are used to achieve bi-directional torque capabilities, then torque resistance is provided, but the connection reliability is limited due to friction between component surfaces
Solution Approach 1:
The connection assembly is divided into distinct functional segments: a drive stem with drive gear teeth for torque transmission, a coupling body with coupling gear teeth for engagement, and a separate locking mechanism with locking members. This segmentation allows each component to be optimized for its specific function, with the locking members providing positive mechanical interlocking independent of the friction-based gear engagement.
2Strength
If positive locking methods such as keys, clutches or cross/through-bolting are used to achieve high bi-directional torque capabilities, then torque resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coupling body integrates multiple functions into a single component: it provides the coupling gear teeth for torque transmission, contains the locking members for positive mechanical interlocking, and incorporates sealing elements. This merging eliminates the need for separate keys, clutches, or through-bolts, reducing overall device complexity while maintaining high bi-directional torque capabilities.
Solution Approach 2:
The coupling body serves multiple purposes simultaneously: transmitting torque through gear engagement, providing positive locking through integrated locking members, sealing the connection interface, and guiding axial movement. This multi-functionality reduces the number of separate components needed, simplifying the overall connection structure.
3Force
If threading operations are used to manufacture connections, then load transfer capability is achieved, but manufacturing time and complexity increase due to required turning and milling operations
Solution Approach 1:
The traditional threaded mechanical connection is replaced with a gear-based engagement system. The drive stem and coupling body use meshing gear teeth to transmit torque and maintain connection, eliminating the need for complex threading operations. This substitution simplifies manufacturing while maintaining load transfer capability through the gear engagement.
4Strength
If additional components are added to achieve high bi-directional torque connections, then torque resistance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
Multiple functions are merged into the coupling body: torque transmission through gear teeth, positive locking through integrated locking members, sealing through incorporated seals, and alignment guidance. This consolidation reduces the total number of separate components needed while maintaining high torque resistance capabilities.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Apparatus and methods are for coupling a drive unit to a tool adapter. A drive unit includes a drive stem; a plurality of sliding coupling members; a retainer; a torque profile; a plurality of drive stem ports; a coupling collar; coupling recesses; a plurality of transmission units; and/or first portions of a hydraulic coupling unit. A tool adapter includes a tool stem; a tool stem sleeve; coupling recesses; a torque profile; a plurality of sliding coupling members; and/or second portions of the hydraulic coupling unit. A method of coupling a drive unit to a tool adapter includes positioning the tool adapter below the drive unit; stabbing a drive stem into an interior of a tool stem sleeve; coupling torque between the drive unit and the tool adapter; and coupling load between the drive unit and the tool adapter by engaging a plurality of sliding coupling members.