Virtual Integration Testing With 3D Scans for As-Built Compatibility
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Solution Overview
Problem
Assembling and testing integrated drilling and production systems is time-consuming and expensive, and the tools used for testing are often unavailable for operational systems.
Innovation Solution
A virtual integration test system that uses scanning devices to measure dimensions of as-built components, performs motion and deformation mechanics simulations, and determines interface and integration compatibility, reducing the need for physical testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical integration testing is performed on drilling and production systems, then system integration compatibility is verified, but testing time and costs increase significantly
Solution Approach 1:
The patent creates a virtual copy of the drilling and production system using scanned 3D models of actual components. This virtual model allows integration testing to be performed in simulation rather than with physical hardware, verifying interface compatibility and system integration without the time and cost constraints of physical assembly and disassembly.
2Reliability
If physical integration testing is performed on drilling and production systems, then system integration compatibility is verified, but equipment availability for operational use decreases
Solution Approach 1:
By using virtual copies of the system components created through 3D scanning, the patent enables testing to occur in a digital environment while the physical equipment remains available for operational drilling and production activities. The virtual model captures all geometric and interface characteristics needed for compatibility verification without requiring physical assembly.
3Reliability
If physical integration testing is performed on drilling and production systems, then system integration compatibility is verified, but testing costs increase
Solution Approach 1:
The patent replaces expensive physical integration testing with a virtual simulation using 3D scanned models. This eliminates costs associated with physical assembly, specialized test equipment, and the opportunity cost of equipment unavailability, while maintaining verification of interface compatibility and system integration through digital simulation.
4Manufacturing precision
If detailed dimensional measurements are taken of as-built components, then manufacturing variations are captured, but measurement and processing complexity increases
Solution Approach 1:
The patent replaces complex manual measurement systems with automated 3D scanning technology. The scanning devices automatically capture comprehensive dimensional data of as-built components, including all manufacturing variations and tolerances, without requiring manual measurement of each feature. This automated approach reduces processing complexity while maintaining or improving measurement accuracy.
Data Source
AI summary
A virtual integration test system includes a computer configured to receive data indicative of measured dimensions of as-built components. The computer is also configured to perform a motion mechanics simulation on at least two deformation-uncritical components of the as-built components and perform a deformation mechanics simulation on at least one deformation-critical component of the as-built components. The motion mechanics simulation and the deformation mechanics simulation are performed concurrently within a simulation environment. In addition, the computer is configured to determine interface and integration compatibility of the as-built components based on the motion mechanics simulation and the deformation mechanics simulation, and to output an output signal indicative of the interface and integration compatibility of the as-built components.