Triple-Shoulder Torque Connector for High-Capacity Tubular Joints
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Solution Overview
Problem
Conventional downhole tubular connectors lack sufficient torque capacity and often require costly precision machining, making it difficult to achieve necessary strength without increasing the connector's size.
Innovation Solution
The design incorporates a pin component with three torque shoulders that contact corresponding surfaces on a box component, utilizing a sacrificial material between some of these contacts to enhance torque capacity without precision machining, and a threaded collar for additional torque, allowing for increased strength without size increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional connectors are designed to increase torque capacity, then the connector size must increase, but this is not desirable for downhole applications
Solution Approach 1:
The connector is divided into multiple torque transmission elements: thread contacts, shouldered contacts, and settable element contacts. Each segment contributes to the total torque capacity, allowing high strength without increasing overall connector size. The segmentation distributes torque across multiple contact points rather than relying on a single large interface.
Solution Approach 2:
The invention utilizes the radial dimension by incorporating shouldered contacts that engage in the radial direction perpendicular to the axial thread engagement. This multi-dimensional torque transmission (axial threads + radial shoulders + settable elements) increases torque capacity without proportionally increasing connector outer diameter.
2Strength
If precision machining is used to achieve sufficient torque capacity, then manufacturing cost increases and production accuracy problems arise
Solution Approach 1:
The settable element acts as a sacrificial component that deforms or fails in a controlled manner to indicate proper torque application. This disposable element simplifies manufacturing by eliminating the need for ultra-precise machining of the torque transmission surfaces, as the settable element compensates for manufacturing tolerances.
Solution Approach 2:
The settable element changes its physical state (deforms or fractures) at a predetermined torque threshold, providing a built-in torque indicator. This parameter change approach replaces complex precision measurement and control systems with a simple visual or mechanical indicator, reducing manufacturing complexity.
3Strength
If conventional threaded connectors are used, then torque capacity is insufficient, but adding more torque elements increases device complexity
Solution Approach 1:
Multiple torque transmission mechanisms (threaded engagement, shouldered contacts, and settable elements) are merged into a single integrated connector assembly. All elements engage simultaneously or sequentially within the same coupling interface, providing enhanced torque capacity without requiring multiple separate components or complex assembly procedures.
Solution Approach 2:
The connector design provides multiple functions within a single device: torque transmission through threads, additional torque through shouldered contacts, and torque indication through the settable element. This multi-functionality increases torque capacity while maintaining relatively simple overall structure, as all functions are integrated into one connector assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly enhances the torque capacity of the connectors, providing improved durability and reliability without the need for precise manufacturing, thus addressing the limitations of conventional connectors.
Implementation Method 1
the sacrificial material deforms in a direction non-parallel to the direction of insertion
Implementation Method 2
One of the torque shoulders of the pin component comprises a collar that is threadably coupled to the pin component
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A tubular string comprises a plurality of torque connectors connecting a plurality of tubular members. At least one torque connector of the plurality of torque connectors comprises a pin component threadably connected to the box component. The pin comprises a three torque shoulders corresponding to three surfaces of the box component. In at least one embodiment, a sacrificial material is deposited between one of the torque shoulders and one of the surfaces to provide additional torque capacity to the torque connector. Additional apparatus, methods, and systems are disclosed.