Top Drive Tool Coupler With Stationary Data Uplink

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Solution Overview

Problem

Existing connections between top drives and tools in drilling operations are time-consuming, dangerous, and inefficient, particularly in transferring bi-directional torque and data, with limitations in torque resistance and risk of cross-threading, which complicates high-pressure and high-flow applications.

Innovation Solution

A tool coupler system that includes a receiver assembly and a tool adapter with ring couplers and actuators, enabling bi-directional torque and load transfer, along with a stationary data uplink for wireless communication, facilitating efficient data transfer and reducing the need for complex alignment and turning operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional threaded connections are used to attach tools to the top drive, then the connection can transfer axial load, but it cannot reliably transfer bi-directional torque and requires complex locking mechanisms

Engineering Contradiction:

Improvetorque transfer capabilityVSAvoidconnection structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The connection system is divided into separate functional components: a receptacle with internal splines for torque transfer, a tool adapter with external splines, and independent locking mechanisms. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process compared to integrated threaded connections with multiple locking elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional threaded mechanical connections with a spline-based engagement system combined with hydraulic or pneumatic actuators for locking. This substitution eliminates the need for complex thread forms, multiple locking nuts, and manual tightening operations, allowing for faster and more reliable bi-directional torque transfer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If threading compensation systems are added to provide accurate alignment, then cross-threading risk is reduced, but component length and weight increase significantly

Engineering Contradiction:

Improvealignment accuracyVSAvoidcomponent length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The receptacle and tool adapter are designed with pre-configured spline orientations and engagement features that automatically align when brought together. This preliminary configuration eliminates the need for adjustable threading compensation mechanisms, as the splines naturally guide correct alignment during the connection process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spline interface acts as an intermediary element between the receptacle and tool adapter, providing both alignment guidance and torque transfer functionality. This intermediary structure replaces lengthy threading compensation systems by embedding the alignment function within the compact spline geometry itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If manual tool changing procedures are used, then personnel can perform adjustments, but the process is time-consuming and dangerous due to work at heights

Engineering Contradiction:

Improvetool changing flexibilityVSAvoidtool changing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The connection system incorporates self-aligning spline features and automated locking mechanisms that perform the connection function without manual intervention. The design allows the components to guide themselves into proper alignment and secure the connection through actuated locks, eliminating the need for personnel to manually adjust or tighten connections at height.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Hydraulic or pneumatic actuators provide accelerated and powerful locking action, rapidly securing the tool adapter to the receptacle. This accelerated connection process reduces tool changing time from minutes to seconds while eliminating manual safety risks.

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

Data Source

PatentUS11441412B2Tool coupler with data and signal transfer methods for top drive

Publication Date: 2022.09.13 WEATHERFORD TECHNOLOGY HOLDINGS LLC

AI summary

Equipment and methods for coupling a top drive to one or more tools to facilitate data and/or signal transfer therebetween include a receiver assembly connectable to a top drive; a tool adapter connectable to a tool string, wherein a coupling between the receiver assembly and the tool adapter transfers at least one of torque and load therebetween; and a stationary data uplink comprising at least one of: a data swivel coupled to the receiver assembly; a wireless module coupled to the tool adapter; and a wireless transceiver coupled to the tool adapter. Equipment and methods include coupling a receiver assembly to a tool adapter to transfer at least one of torque and load therebetween, the tool adapter being connected to the tool string; collecting data at one or more points proximal the tool string; and communicating the data to a stationary computer while rotating the tool adapter.