Tubular String Make-Up Using Image Processing Alignment Control
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Solution Overview
Problem
Current methods for making up threaded connections in tubular strings for subterranean wells are prone to human error and inefficiency, leading to potential leaks or unthreading issues.
Innovation Solution
The implementation of an image processing system using cameras and an image processor to automatically control the threading process by detecting alignment marks and terminating the rotation when a proper connection is achieved, reducing human intervention and ensuring accurate thread engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used to make up threaded connections in tubular strings, then human operators can perform the threading operation, but human error and inefficiency occur leading to potential leaks or unthreading issues
Solution Approach 1:
The patent replaces manual mechanical operations with an automated image processing system. Cameras capture images of alignment marks on tubulars, image processing algorithms automatically determine threading status, and the system controls the make-up operation without human intervention, eliminating human error while maintaining operational speed
Solution Approach 2:
The system enables the threading operation to self-regulate through automatic image capture, processing, and control. The alignment marks on the tubulars serve as self-indicating features that the image processing system reads to automatically determine when proper threading is achieved, making the process self-controlling and eliminating reliance on human judgment
2Reliability
If automated image processing is implemented to control threading, then human error is reduced and connection reliability improves, but device complexity increases due to cameras and image processing equipment
Solution Approach 1:
The patent introduces alignment marks as intermediary visual features on the tubulars that serve as mediators between the physical threading state and the image processing system. These simple visual markers enable the complex automated system to easily detect threading status without requiring complex sensors or measurement devices
Solution Approach 2:
The system uses optical copies (images) of the alignment marks on the tubulars to determine threading status. Instead of directly measuring physical dimensions or forces, the image processing system analyzes visual copies of the marks, simplifying the measurement process while maintaining high precision and reliability
Data Source
AI summary
A method of making-up tubular string components can include inputting to an image processor image data output from at least one camera, the image processor in response detecting positions of a tubular and a mark on another tubular, threading the tubulars with each other while inputting position data from the image processor to a controller, and the controller terminating the threading in response to the position of the mark relative to the position of the first tubular being within a predetermined range. Another method of making-up tubular string components can include, in response to inputting image data to an image processor, the image processor detecting longitudinal positions of two tubulars, threading the tubulars with each other, and a controller terminating the threading in response to the longitudinal position of one tubular relative to the longitudinal position of the other tubular being within a predetermined range.