Virtual Encoder for Drilling Top Drive Reliability

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Solution Overview

Problem

Current drilling technologies face reliability issues due to top drive runaway caused by loss of encoder feedback, leading to equipment breakdowns, injuries, and potential fires, with a need for a sensorless and encoderless solution for improved drilling reliability in wellbores.

Innovation Solution

A position and velocity measuring tool that eliminates the need for hardware encoder feedback by using a software-based system to communicate with a top drive, providing a virtual encoder and enabling continuous operation through a variable frequency drive connected to an electric motor, with data storage and processing for remote monitoring and control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If hardware encoder feedback is used for position and velocity measurement, then measurement precision is improved, but reliability deteriorates due to encoder failure causing top drive runaway

Engineering Contradiction:

Improveposition and velocity measurement precisionVSAvoidtop drive operation reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent creates a virtual encoder that copies the functionality of a hardware encoder through software algorithms. The virtual encoder calculates position and velocity by processing data from existing sensors (accelerometers, gyroscopes, motor current sensors) rather than relying on a single hardware encoder component. This software-based copy provides the same measurement precision while eliminating the reliability issues of physical encoders.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical hardware encoder system with an electronic/software-based virtual encoder system. Instead of using physical encoders that read mechanical positions, the system uses software algorithms running on the top drive's processor to calculate position and velocity from electrical and sensor data. This substitution eliminates mechanical failure points while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If hardware encoder feedback is used, then position control accuracy is improved, but device complexity increases due to additional hardware components

Engineering Contradiction:

Improveposition control accuracyVSAvoidencoder system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The virtual encoder system uses existing multi-functional components (motor controllers, sensor systems, processors) already present in the top drive to perform encoder functions. Rather than adding dedicated encoder hardware, the system makes the existing control electronics perform dual functions: motor control and position/velocity measurement. This reduces device complexity while maintaining position control accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a software-based virtual encoder that copies encoder functionality without requiring physical encoder hardware. The virtual encoder uses algorithms to simulate encoder output based on data from existing sensors and motor control systems, thereby achieving position control accuracy without increasing hardware complexity.

Inventive Principle:

Principle #26Copying

3Reliability

If sensorless control is implemented, then reliability is improved by eliminating encoder failure, but measurement precision deteriorates without encoder feedback

Engineering Contradiction:

Improvetop drive operation reliabilityVSAvoidposition and velocity measurement precision

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent introduces intermediate sensor systems (accelerometers, gyroscopes, motor current sensors) as mediators between the sensorless control approach and precise measurement requirements. These intermediate sensors provide auxiliary data that the virtual encoder algorithms process to achieve encoder-level measurement precision without using a traditional hardware encoder, thus maintaining both reliability and precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the direct hardware encoder feedback mechanism with an electronic/software-based virtual encoder system that uses multiple indirect measurement sources. Instead of relying on a single direct encoder reading, the system substitutes mechanical encoder feedback with electronic signal processing from multiple sensors, achieving comparable precision while eliminating encoder failure risks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8843220B1Position and velocity measurement tool for standard and directional drilling

Publication Date: 2014.09.23 REMBACH PAUL F

AI summary

A position and velocity measuring tool for use on a top drive of a drilling rig having a variable frequency drive connected to an electric motor and power supply. The position and velocity measuring tool further has a processor connected to the variable frequency drive and a data storage and computer instructions for presenting an operator directional drilling steering system dashboard with numerous visual components which creates and uses a virtual encoder eliminating a failure point of a mechanical encoder.