Weight Sensor Device for Cable Tension Monitoring
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Solution Overview
Problem
Existing cable tension measurement technologies, such as in-line load cell devices with strain gages, are expensive, prone to premature failure in harsh drilling conditions, and require extensive downtime for replacement.
Innovation Solution
A weight sensor device with a housing featuring intersecting load pin and insert receptacles, cable nests, and a clamping mechanism that measures cable tension by deflecting the cable and using a load pin to transmit a force proportional to the load, allowing for quick and inexpensive repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gages are used in in-line load cell devices to measure cable tension, then measurement accuracy is achieved, but manufacturing cost increases and reliability decreases due to susceptibility to physical conditions and premature failure
Solution Approach 1:
The patent replaces expensive, fragile strain gages with a simple load pin that can be easily and inexpensively replaced. The load pin is a robust, straightforward component that does not rely on sensitive electrical measurements, making it both more reliable in harsh drilling conditions and much cheaper to manufacture and replace.
Solution Approach 2:
The patent substitutes the electrical strain gage measurement system with a purely mechanical load pin system. The load pin mechanically transmits cable tension force to a lever arm, which then actuates a linkage mechanism to indicate the load. This mechanical substitution eliminates the reliability issues associated with electrical components in harsh environments.
2Strength
If strain gages are integral to the in-line load cell device, then structural integrity is maintained, but ease of repair deteriorates as failure requires extensive repair or replacement of the entire load cell
Solution Approach 1:
The patent divides the load measuring system into separate, modular components: the load pin, the lever arm, and the linkage mechanism. This segmentation allows the load pin to be independently replaced without affecting the other components. The receptacle design facilitates easy removal and installation of the load pin, dramatically simplifying maintenance and reducing downtime.
Solution Approach 2:
The patent enables easy discarding of the worn or failed load pin and replacement with a new one. The simple receptacle design allows the load pin to be quickly removed and replaced without requiring extensive disassembly or specialized tools, making the replacement process as simple as changing a light bulb.
3Measurement precision
If in-line load cell devices are used for cable tension measurement, then accurate measurement is achieved, but loss of time increases due to significant downtime required for load cell replacement
Solution Approach 1:
By segmenting the load measuring function into a separate, easily replaceable load pin component, the patent enables rapid maintenance. The load pin can be changed in minutes without requiring removal or replacement of the entire load cell assembly, dramatically reducing operational downtime while maintaining measurement accuracy.
Solution Approach 2:
The simple receptacle design with its straightforward load pin insertion and removal mechanism enables maintenance personnel to perform replacements quickly without requiring specialized tools, extensive training, or complex procedures. The system is designed for easy self-service maintenance.
4Adaptability or versatility
If weight sensors are exposed to harsh drilling conditions including dirt, debris, oils, lubricants, and high pressure steam, then operational capability is maintained, but reliability decreases due to premature failure
Solution Approach 1:
The patent replaces sensitive, harsh-condition-vulnerable strain gages with a simple, robust load pin that can withstand harsh drilling environments. While the load pin may eventually wear, its simple construction makes it far more resistant to the effects of dirt, debris, oils, and steam compared to electrical strain gages, and it can be quickly replaced when needed.
Solution Approach 2:
By replacing electrical strain gages with a purely mechanical load pin system, the patent eliminates components that are particularly vulnerable to harsh drilling conditions. The mechanical load pin has no electrical connections or sensitive elements that could be degraded by exposure to oils, lubricants, steam, or contaminants.
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
The device accurately measures cable tension under harsh conditions, reduces downtime and maintenance costs, and can be easily repaired, providing a cost-effective solution for monitoring cable loads in drilling operations.
Implementation Method 1
measures cable tension by deflecting the cable and using a load pin to transmit a force proportional to the load
Data Source
AI summary
The present invention relates to a weight sensor device. The weight sensor device comprises a housing, which includes a receptacle for a load pin and an insert. A cable nest is secured to each end of the housing. In exemplary embodiments, a load pin is engaged in the housing and secures an insert. A cable clamping mechanism may be attached to the insert. In accordance with various exemplary embodiments, the housing itself is non-load sensing.