Top Drive Tool Coupler With Sliding Members and Torque Profiles
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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 components, increasing costs and complexity.
Innovation Solution
A top drive system with a drive unit and tool adapter that utilizes sliding coupling members and torque profiles to enable bi-directional torque transmission, along with axial load transfer, through a mechanism that includes a drive stem, retainer, and coupling recesses, allowing for quick and secure connection without the need for high-friction threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction-based locking methods (thread locking mechanisms, hydraulic locking rings, set screws) are used to achieve bi-directional torque capabilities, then torque resistance is provided, but the connection strength is limited and additional components are required
Solution Approach 1:
The patent combines the torque transmission and locking functions into a single integrated spline connection system. The splines on the drive stem and corresponding spline recesses in the tool adapter serve dual purposes: transmitting torque bi-directionally and providing mechanical interlocking for secure connection, eliminating the need for separate locking mechanisms
Solution Approach 2:
The spline connection is designed to perform multiple functions simultaneously: it transmits torque in both directions, provides mechanical interlocking, and enables quick connection and disconnection. This multi-functional design replaces what would traditionally require multiple separate components for each function
2Strength
If positive locking methods (keys, clutches, cross/through-bolting) are used to achieve high bi-directional torque capabilities, then torque resistance is significantly improved, but manufacturing cost and device complexity increase due to additional components and operations
Solution Approach 1:
The patent merges the torque transmission function with the connection structure itself. The splines are directly formed on the drive stem and tool adapter, combining what would traditionally be separate torque transmission elements and locking mechanisms into a unified, cost-effective design that requires only turning operations
3Force
If traditional threaded connections are used for coupling, then load transfer is achieved, but torque transmission is limited and bi-directional torque capabilities require complex additional components
Solution Approach 1:
The patent segments the connection functions into distinct elements: the threaded connection handles axial load transfer, while the orthogonal spline connection handles torque transmission. This functional segmentation allows each connection type to be optimized for its specific purpose without requiring complex combinations for dual functionality
Data Source
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.