Wrench Clamp Alignment Sensing for Tubular Connection Make-Up
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Solution Overview
Problem
Wrenches used for making and breaking tubular connections often experience angular misalignment, leading to collisions that cause damage, operational delays, and increased costs, which are difficult to address accurately, quickly, and inexpensively.
Innovation Solution
A wrench system with a positioning subsystem featuring sensor tracks and position sensors that continuously monitor and automatically correct for angular misalignment between clamp assemblies, using hydraulic or electric sensors to adjust the clamp positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual alignment methods are used, then operational simplicity is maintained, but measurement precision and alignment accuracy deteriorate
Solution Approach 1:
The patent replaces manual visual alignment methods with an automated positioning subsystem that uses sensors (optical, magnetic, or capacitive) to detect the angular position of the tubular relative to the wrench axis. This substitution of mechanical/manual alignment with sensor-based detection resolves the contradiction by providing precise measurement without requiring complex manual procedures
Solution Approach 2:
The positioning subsystem automatically detects and reports angular misalignment without requiring operator intervention for measurement. The system self-monitors the alignment status and provides real-time feedback, eliminating the need for complex manual measurement procedures while maintaining high precision
2Productivity
If alignment correction is performed manually, then device complexity is minimized, but productivity and response time deteriorate
Solution Approach 1:
The positioning subsystem continuously monitors the angular position of the tubular and provides real-time feedback to the control system. When misalignment is detected, the system automatically activates correction mechanisms (rotating the wrench body or adjusting the tubular position) until proper alignment is achieved. This closed-loop feedback system resolves the contradiction by enabling rapid automatic correction while maintaining manageable system complexity through modular design
Solution Approach 2:
The system dynamically adjusts the alignment correction process based on real-time sensor data. The correction mechanism can rotate the wrench body or adjust tubular positioning at variable speeds depending on the magnitude of misalignment, optimizing both speed and precision without requiring overly complex fixed-speed mechanisms
3Reliability
If angular misalignment is not monitored, then device complexity is reduced, but reliability and collision prevention deteriorate
Solution Approach 1:
The positioning subsystem proactively monitors angular alignment before tubular insertion or connection operations commence. By detecting potential misalignment conditions in advance, the system can alert operators or automatically correct the alignment before collisions occur, resolving the contradiction by providing reliable collision prevention through relatively simple advance monitoring
Solution Approach 2:
The positioning subsystem acts as an intermediary between the operator and the tubular-wrench interaction. It continuously measures angular position and provides intermediate feedback that enables preventive action, reducing the need for complex direct collision avoidance mechanisms while maintaining high reliability
Data Source
AI summary
Wrench systems, methods, and related apparatus are used for determining angular misalignment in wrenches that make up and/or break out tubular connections. The systems, methods, and related apparatus are used to continuously monitor for angular misalignment and automatically correct for angular misalignment. A wrench system includes a first clamp assembly, a second clamp assembly, and a positioning subsystem. The positioning subsystem includes one or more sensor tracks mounted to the first clamp assembly, and one or more position sensors mounted to the second clamp assembly. The one or more position sensors are configured to interface with the one or more sensor tracks to measure an angular position of the second clamp assembly relative to the first clamp assembly.