Top Drive Tool Coupler for Fast Bi-Directional Torque Transfer
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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 provide limited torque resistance and require additional costly components.
Innovation Solution
A top drive system that bypasses threaded connections for bi-directional torque transfer using a drive unit and tool adapter configuration, including a torque sleeve and spindle unit, which enables automatic connection and power/data communication, providing high axial load integrity and resistance to bending, flow rates, and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded connections are used to couple top drive to tools, then mechanical connection is established, but the connection is time-consuming and dangerous requiring personnel to work at heights
Solution Approach 1:
The coupling system is pre-configured with drive stems, torque sleeves, and tool adapters that automatically engage when brought together. The preliminary arrangement of components allows for rapid connection without manual intervention during the coupling process, eliminating the time-consuming threaded connection procedure while maintaining secure mechanical attachment
Solution Approach 2:
The coupling mechanism performs self-alignment and self-connection through the interaction of drive stems with tool adapters. The system automatically establishes mechanical, electrical, and hydraulic connections without requiring personnel to manually assemble or tighten components, thereby reducing both time and safety risks
2Strength
If friction-based locking mechanisms are used for bi-directional torque, then torque resistance is provided, but the torque resistance is limited and additional costly components are required
Solution Approach 1:
The invention extracts the torque transmission function from the threaded connection and places it in a dedicated torque sleeve that engages with gear profiles. This separation allows the threaded connection to be simplified while the torque sleeve provides specialized bi-directional torque capability through positive mechanical engagement rather than friction
Solution Approach 2:
The torque sleeve acts as an intermediary component between the drive stem and tool adapter, providing specialized torque transmission capability. It engages with gear profiles on both the drive stem and tool adapter, creating a positive mechanical lock that transmits bi-directional torque without requiring complex additional locking mechanisms
3Strength
If high bi-directional torque capabilities are achieved through positive locking methods, then torque resistance is improved, but manufacturing cost increases due to turning and milling operations
Solution Approach 1:
The torque sleeve serves multiple functions: it provides bi-directional torque transmission, acts as a mechanical lock, and engages with standard gear profiles that can be manufactured with conventional turning operations. By consolidating these functions into a single component with standardized features, the invention achieves high torque capability without requiring expensive multi-step manufacturing processes
4Adaptability or versatility
If traditional threaded connections are used, then mechanical connection is established, but electrical, optical, hydraulic, and pneumatic connections are not efficiently integrated
Solution Approach 1:
The coupling system merges mechanical, electrical, optical, hydraulic, and pneumatic connections into a single integrated coupling action. When the drive stem and tool adapter are brought together, all connection types are simultaneously established through the unified coupling mechanism, eliminating the need for separate connection procedures for each utility type
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A top drive system (100), comprising: a drive stem (380) having first friction surfaces (387) and a load coupling, wherein the load coupling is a threaded coupling (386); a swivel (321) disposed about the drive stem (380); a transmission unit (390) having: second friction surfaces (397) parallel to the first friction surfaces (387); and shoulders (394) proximate a bottom of the transmission unit (390); a transmission selector (393) movable to an "on" position or an "off" position, wherein the drive stem (380) moves synchronously with the transmission unit (390) when the transmission selector is in the "on" position; and a swivel selector (392) movable to an "on" position or an "off" position, wherein the transmission (390) unit moves synchronously with the swivel (321) when the swivel selector is in the "on" position.