Top Drive Tool Alignment for Automated Rig-Up Installation
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Solution Overview
Problem
Manual tool exchange on top drives during well operations is time-consuming and hazardous, necessitating automated alignment and installation methods.
Innovation Solution
A modular top drive system with a tool exchange unit that includes a central control unit, tool storage, and alignment assemblies using sensors and cameras for precise positioning and alignment of tools with the top drive unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual tool exchange is performed on top drives, then workers can directly handle and install tools, but the process becomes time-consuming and hazardous due to high-altitude operations
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system equipped with sensors, actuators, and control units. The robot autonomously performs tool exchange tasks that were previously done manually, eliminating the need for workers to perform time-consuming manual handling while maintaining operational efficiency
Solution Approach 2:
The robotic system performs self-positioning and self-alignment using onboard sensors (laser scanners, cameras, proximity sensors) to detect tool locations and adjust its own position automatically. The system serves itself by autonomously navigating, grasping tools, and installing them without continuous human intervention, thereby reducing both time consumption and manual labor requirements
2Ease of operation
If manual tool exchange is performed on top drives, then workers can directly handle and install tools, but the process becomes hazardous due to high-altitude operations
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system equipped with sensors, actuators, and control units. The robot autonomously performs tool exchange tasks that were previously done manually, eliminating the need for workers to perform time-consuming manual handling while maintaining operational efficiency
Solution Approach 2:
The robotic system acts as an intermediary between human operators and the hazardous high-altitude environment. It performs dangerous tasks such as gripping tools, moving them to elevated positions, and installing them on top drives, thereby shielding human workers from exposure to harmful high-altitude conditions while maintaining operational efficiency
3Extent of automation
If automated tool exchange system is implemented, then manual labor and safety risks are reduced, but the device complexity increases due to sensors, cameras, and control systems
Solution Approach 1:
The robotic system is designed as a multi-functional platform that performs diverse operations including navigation, tool detection, grasping, positioning, and installation using integrated sensors and actuators. This universal design consolidates multiple functions into a single system, managing complexity through functional integration rather than separate dedicated systems for each task
Solution Approach 2:
The system employs sensors (laser scanners, cameras, proximity sensors) that continuously provide feedback about tool positions, robot orientation, and environmental conditions. This feedback loop enables the control system to make real-time adjustments, maintaining precision and safety while managing complexity through adaptive control rather than overly complex mechanical designs
4Measurement precision
If automated alignment system with sensors and cameras is used, then positioning precision is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple sensing modalities (laser range finders, cameras, proximity sensors) into an integrated alignment system. By merging these different sensor types into a unified positioning and alignment subsystem, the system achieves high measurement precision through multi-sensor fusion while managing complexity through integrated architecture rather than separate independent systems
Data Source
Figure 1A
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Figure 1C
AI summary
A modular top drive system for construction of a wellbore includes an alignment assembly configured to align a tool with a top drive unit to facilitate automatic tool installation during rig up.