Intelligent top drive for drilling rigs

Abstract

A top-drive system and a drilling rig. The top-drive system includes a sheave configured to receive a drilling line, a frame coupled with the sheave and configured to transmit a weight of a tubular string suspended therefrom to the sheave, a controller, and a sensor in communication with the controller. The sensor is configured to directly measure one or more physical parameters of a drilling operation and provide data representing the one or more physical parameters to the controller.

What is claimed is: 
     
         1 . A top-drive system, comprising:
 a sheave configured to receive a drilling line;   a frame coupled with the sheave and configured to transmit a weight of a tubular string suspended therefrom to the sheave;   a controller; and   a sensor in communication with the controller, wherein the sensor is configured to measure one or more physical parameters of a drilling operation and provide data representing the one or more physical parameters to the controller.   
     
     
         2 . The system of  claim 1 , further comprising:
 a motor;   a motor shaft driven by the motor;   a first gear coupled with the motor shaft and configured to rotate therewith;   a second gear engaging the first gear, such that rotation of the first gear causes the second gear to rotate;   a top-drive shaft coupled with the second gear and the tubular string, wherein rotation of the second gear causes the top-drive shaft to rotate, and wherein rotation of the top-drive shaft causes the tubular string to rotate; and   a thrust bearing coupled with the frame and the top-drive shaft, wherein the thrust bearing transmits a load on the top-drive shaft to the frame, wherein the sensor is configured to measure the load transmitted by the thrust bearing.   
     
     
         3 . The system of  claim 2 , wherein the sensor comprises one or more of a strain gauge positioned on the frame, a linear variable differential transducer coupled to a loaded part of the frame and a non-loaded part of the frame, or a load cell disposed between the thrust bearing and the frame. 
     
     
         4 . The system of  claim 2 , wherein the sensor comprises one or more accelerometers positioned on the frame to detect an effect of a variation of the load applied on the top-drive shaft. 
     
     
         5 . The system of  claim 1 , further comprising:
 a motor;   a motor shaft driven by the motor;   a first gear coupled with the motor shaft and configured to rotate therewith;   a second gear engaging the first gear, such that rotation of the first gear causes the second gear to rotate;   a top-drive shaft coupled with the second gear and the tubular string, wherein rotation of the second gear causes the top-drive shaft to rotate, and wherein rotation of the top-drive shaft causes the tubular string to rotate; and   a torque sensor to measure the torque transmitted by the motor.   
     
     
         6 . The system of  claim 5 , further comprising one or more shaft supports through which the motor shaft is received, wherein the sensor comprises a strain gauge positioned on the one or more shaft supports, to measure a strain on the one or more shaft supports caused by a torque load transmitted from the second gear to the first gear. 
     
     
         7 . The system of  claim 5 , further comprising a second sensor comprising an accelerometer to measure a fluctuation of torque, rotational vibration, or both. 
     
     
         8 . The system of  claim 5 , wherein the sensor is configured to measure a temperature of the motor or a vibration of the motor. 
     
     
         9 . The system of  claim 1 , further comprising:
 a first antenna coupled with the frame or a top-drive shaft extending into the frame; and   a second antenna coupled with the tubular string, wherein the second antenna communicates with the first antenna, and the first antenna communicates with the controller.   
     
     
         10 . A drilling rig, comprising:
 a rig control system configured to calculate drilling parameters; and   a top drive configured to be controlled by the rig control system according to the drilling parameters, the top drive comprising:
 a sheave configured to receive a drilling line; 
 a frame coupled with the sheave and configured to transmit a weight of a tubular string suspended therefrom to the sheave; 
 a controller disposed in communication with the rig control system; and 
 a sensor in communication with the controller, wherein the sensor is configured to measure one or more physical parameters of a drilling operation and provide data representing the one or more physical parameters to the controller. 
   
     
     
         11 . The drilling rig of  claim 10 , wherein the controller is configured to transmit raw data, processed data, or a combination thereof with the rig control system. 
     
     
         12 . The drilling rig of  claim 10 , wherein the top drive further comprises:
 a motor;   a motor shaft driven by the motor;   a first gear coupled with the motor shaft and configured to rotate therewith;   a second gear engaging the first gear, such that rotation of the first gear causes the second gear to rotate; and   a top-drive shaft coupled with the second gear and the tubular string, wherein rotation of the second gear causes the top-drive shaft to rotate, and wherein rotation of the top-drive shaft causes the tubular string to rotate,   wherein the sensor comprises a first sensor and a second sensor is configured to detect a passage of a tooth of the second gear, wherein the first and second sensors are spaced apart by a distance that is different from a distance by which adjacent teeth of the second gear are spaced.