Vertical Wireline BHA Assembly Using Robots Under Suspended Loads
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Solution Overview
Problem
Conventional methods for assembling and disassembling wireline bottom hole assemblies (BHAs) are labor-intensive, time-consuming, and pose safety risks due to the need for manual handling of powerful perforating guns under suspended loads, with existing automation solutions failing to provide adequate solutions.
Innovation Solution
An automated system and process using robots within a mobile or permanent structure to vertically assemble and disassemble BHAs, ensuring safety by containing detonations and eliminating the need for workers to work under suspended loads, with robots capable of retrieving and delivering BHA components and performing assembly and disassembly tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional manual assembly methods are used, then workers can directly handle and assemble BHA components, but labor intensity increases and safety risks arise from working under suspended loads
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system that uses mechanical arms, sensors, and control systems to assemble BHA components. The robotic system eliminates direct human contact with heavy components and suspended loads, thereby maintaining operational capability while significantly improving safety.
Solution Approach 2:
The patent introduces a robotic system as an intermediary between human operators and the BHA components. This intermediary performs all hazardous manual tasks including handling perforating guns and working under suspended loads, while human operators monitor and control the system from a safe distance.
2Ease of manufacture
If conventional horizontal assembly on ground is used, then assembly can be performed with basic equipment, but the process becomes labor intensive and time consuming
Solution Approach 1:
The patent transitions the assembly process from horizontal ground-based assembly to vertical assembly within a structured enclosure. This dimensional change allows for more efficient component stacking, better utilization of gravitational force, and improved access for the robotic system, thereby increasing assembly speed and productivity.
Solution Approach 2:
The patent employs a dynamic robotic system with multiple degrees of freedom that can adapt its movements and positioning during assembly. The robotic arms can dynamically adjust their positions, speeds, and forces to optimize the assembly process, thereby improving productivity compared to static conventional methods.
3Device complexity
If manual assembly with hand dollies and stands is used, then equipment requirements remain simple, but the process becomes expensive and time consuming
Solution Approach 1:
The patent employs a multi-functional robotic system that can perform multiple assembly tasks including component handling, positioning, connection, and verification. This universal system replaces multiple specialized manual tools and processes, reducing overall equipment complexity while dramatically decreasing assembly time.
Solution Approach 2:
The robotic system incorporates self-positioning, self-alignment, and self-verification capabilities that eliminate the need for manual measurement and adjustment. The system automatically detects component positions, adjusts alignment, and verifies connections, thereby reducing assembly time without requiring complex external equipment.
4Manufacturing precision
If workers manually thread and torque components, then assembly precision can be controlled, but the process becomes labor intensive and slow
Solution Approach 1:
The patent replaces manual threading and torquing operations with automated robotic mechanisms equipped with precision drives and torque control systems. These robotic systems can apply precise rotational forces and control tightening sequences automatically, maintaining connection precision while increasing assembly speed.
Solution Approach 2:
The patent incorporates sensors and feedback mechanisms that monitor torque application, thread engagement, and connection status in real-time. This feedback system allows the robotic system to adjust its operations dynamically to maintain precision requirements while optimizing assembly speed through automated control.
Data Source
AI summary
An automated system and process for vertically assembling and disassembling a wireline bottom hole assembly (BHA) comprises one or more robots, and a structure comprising a receiver assembly. The receiver assembly comprises a conduit adapted to permit respective bottom hole assembly sections to be moved between an interior and an exterior of the structure. The robots are structured to retrieve bottom hole assembly components from bins and assemble bottom hole assembly sections that make up a bottom hole assembly. The robots move each section to the receiver assembly to connect the section to a partial assemblage comprising a wireline and respective subassemblies. After use of the BHA, the robots disassemble sections of the BHA and move the components to used component bins and/or to a dispensing shoot leading to a waste container. The system has modules adapted to provide information regarding the status of components and the BHA.