Combined multi-coupler for top drive

The present disclosure generally relates to methods and apparatus for coupling a top drive to a tool for use in a wellbore.

A wellbore is formed to access hydrocarbon bearing formations, e.g. crude oil and/or natural gas, by the use of drilling. Drilling is accomplished by utilizing a drill bit that is mounted on the end of a tubular string, such as a drill string. To drill within the wellbore to a predetermined depth, the drill string is often rotated by a top drive or rotary table on a surface platform or rig, and/or by a downhole motor mounted towards the lower end of the drill string. After drilling to a predetermined depth, the drill string and drill bit are removed, and a section of casing is lowered into the wellbore. An annulus is thus formed between the string of casing and the formation. The casing string is temporarily hung from the surface of the well. The casing string is cemented into the wellbore by circulating cement into the annulus defined between the outer wall of the casing and the borehole. The combination of cement and casing strengthens the wellbore and facilitates the isolation of certain areas of the formation behind the casing for the production of hydrocarbons.

Top drives are equipped with a motor for rotating the drill string. The quill of the top drive is typically threaded for connection to an upper end of the drill pipe in order to transmit torque to the drill string. Conventional top drives also threadedly connect to tools for use in the wellbore. An operator on the rig may be required to connect supply lines, such as hydraulic, pneumatic, data, and/or power lines, between conventional top drives and the tool to complete the connection. The threaded connection between top conventional top drives and tools allows only for rotation in a single direction. Manual connection of supply lines can be time-consuming and dangerous to rig personnel. Therefore, there is a need for improved apparatus and methods for connecting top drives to tools.

The present disclosure generally relates to methods and apparatus for coupling a top drive to a tool for use in a wellbore.

In one embodiment, a coupling system for a top drive and a tool includes a housing of the top drive having a bore therethrough, an adapter of the tool, a latch member at least partially disposed within the housing and radially movable between an extended position and a retracted position, wherein the latch member is configured to longitudinally couple the housing to the adapter, and a lock member at least partially disposed within the housing and longitudinally movable relative to the housing, wherein the lock member is configured to move the latch member between the extended and the retracted positions.

In one embodiment, a coupling system for a top drive includes a housing having a bore therethrough, a latch member at least partially disposed within the housing and radially movable between an extended position and a retracted position, wherein the latch member is configured to longitudinally couple the housing to a tool, and a lock member longitudinally movable relative to the housing and configured to move the latch member between the extended and the retracted positions.

In another embodiment, a coupling system for coupling a top drive to a tool includes a housing having a bore therethrough, a sleeve disposed on an outer surface of the housing, a latch member disposed on an outer surface of the sleeve, wherein the latch member is configured to longitudinally couple the housing to the tool, and a tool dock integrally formed with the tool and configured to receive the latch member.

In another embodiment, a coupling system for coupling a top drive includes a housing having a bore therethrough, a latch member at least partially disposed through a wall of the housing and rotatable relative to the housing, wherein the latch member is configured to longitudinally couple the housing to a tool, and an actuator disposed on an outer surface of the housing and configured to rotate the latch member.

In another embodiment, a method of coupling a top drive and a tool includes moving a top drive adjacent a tool, the top drive including a housing, a lock member at least partially disposed within the housing, and a latch member at least partially disposed within the housing and the tool including an adapter. The method further includes inserting the adapter into the housing, shifting the lock member longitudinally relative to the housing, and moving the latch member radially between an extended position and a retracted position to couple the top drive and the tool.

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 illustrates an isometric view of a combined multi-coupler system according to a first embodiment.

FIG. 2 illustrates a partial cross-sectional view of the combined multi-coupler system according to the first embodiment.

FIGS. 3A and 3B illustrate operation of the combined multi-coupler system according to the first embodiment.

FIG. 4 illustrates an isometric view of a combined multi-coupler system according to a second embodiment.

FIG. 5 illustrates a cross-sectional view of the combined multi-coupler system according to a second embodiment.

FIG. 6 illustrates a tool dock according to the second embodiment.

FIGS. 7A and 7B illustrate operation of the combined multi-coupler system according to the second embodiment.

FIG. 8 illustrates an isometric view of a combined multi-coupler system according to a third embodiment.

FIG. 9 illustrates a cross-sectional view of the combined multi-coupler system according to the third embodiment.

FIGS. 10A-10C illustrate operation of the combined multi-coupler system according to the third embodiment.

FIG. 11 illustrates an isometric view of the combined multi-coupler system according to a fourth embodiment.

FIG. 12 illustrates a cross-sectional view of the combined multi-coupler system according to the fourth embodiment.

FIGS. 13 and 14 illustrate operation of an actuator assembly of the fourth embodiment.

FIGS. 15A and 15B illustrate operation of the combined multi-coupler system according to the fourth embodiment.

FIG. 16 illustrates an isometric view of the combined multi-coupler system according to a fifth embodiment.

FIG. 17 illustrates a cross-sectional view of the combined multi-coupler system according to the fifth embodiment.

FIGS. 18 and 19 illustrate operation of the combined multi-coupler system according to a sixth embodiment.

FIGS. 1 and 2 illustrate a combined multi-coupler system (CMC) 100 , according to a first embodiment. The CMC 100 includes a drive member 110 , a tool dock 120 , and latch assembly 130 . The drive member 110 may be integrally formed with the top drive. The drive member 110 may include a housing 111 . The housing 111 may be tubular having a bore therethrough. The housing 111 may include a connector section, a torque transfer section, and a cone section. The connector section may be disposed at an upper longitudinal end of the housing 111 . An upper longitudinal end of the connector section may be integrally formed with the top drive. The connector section may be tubular having a bore therethrough. The torque transfer section may be disposed beneath the connector section and include drive keys 112 . Drive keys 112 may be formed on an outer surface of the housing 111 . The drive keys 112 may be trapezoidal in shape. The drive keys 112 may have a recess formed therein for receiving adapter keys 122 of the tool dock 120 . An actuator assembly, such as piston and cylinder 113 , may be disposed on the outer surface of the housing 111 . A port 114 may be formed through a wall of the housing 111 adjacent the actuator assembly. A U-shaped groove may be formed through the drive keys 112 and around the port 114 . The cone section may be disposed beneath the torque transfer section. A plurality of ports 115 may be formed through a wall of the housing 111 . The ports 115 may be disposed through the housing 111 below the drive keys 112 .

The tool dock 120 may include the adapter 121 . The adapter 121 may be integrally formed with the tool dock 120 . The adapter 121 may be tubular having a bore therethrough. The adapter 121 may be configured to receive the cone section of the housing 111 therein. The adapter 121 may have adapter keys 122 formed at a longitudinal end thereof. The adapter keys 122 may be trapezoidal in shape. Recesses in the adapter keys 122 may be configured to receive the drive keys 112 . The drive keys 112 may engage the adapter keys 122 and transfer torque between the top drive and the tool dock 120 . A plurality of recesses 123 may be formed in an inner surface of the adapter 121 . The recesses 123 may be partially formed through a wall of the adapter 121 . The recesses 123 may be configured to align with the ports 115 of the housing 111 . The adapter keys 122 may assist in aligning the ports 115 with the recesses 123 . A seal 137 may be disposed at a lower longitudinal end of the adapter. The seal 137 may be disposed in a groove of the adapter 121 . The seal 137 may prevent fluids from entering any gap between the adapter 121 and the drive member housing 111 .

The latch assembly 130 may include a latch member, such as connection pins 131 , and a lock member, such as shift wedge 132 . Connection pins 131 may be cylindrical in shape. A first set of connection pins 131 may be spaced ninety degrees apart around the circumference of the shift wedge 132 . A second set of connection pins 131 may be located around the circumference of the shift wedge 132 beneath the first set. Ports 115 and recesses 123 may be configured to receive the connection pins 131 . Connection pins 131 may have a channel 134 formed therethrough. The connection pins 131 may have a tapered groove formed along an outer surface thereof. Corresponding tapered surfaces 135 may be formed on the shift wedge 132 . The connection pins 131 may be radially movable between a retracted position, shown in FIGS. 2 and 3A , and an extended position, shown in FIG. 3B . The recesses 123 may be configured to receive the connection pins 131 in the extended position. The connection pins 131 may be at least partially disposed in the recesses 123 in the extended position. The shift wedge 132 may be tubular having a bore therethrough. The shift wedge 132 may be disposed in the bore of the housing 111 . Seals 133 may be disposed at opposite longitudinal ends of the shift wedge 132 . The piston and cylinder assembly 113 may be at least partially disposed through the port 114 . Piston and cylinder assembly 113 may be connected to the shift wedge 132 through the port 114 . The shift wedge 132 may be longitudinally movable relative to the housing 111 and the adapter 121 . The shift wedge 132 may be longitudinally movable within the bore of the housing 111 . The piston and cylinder assembly 113 may be configured to longitudinally move the shift wedge 132 within the bore of the housing 111 . The shift wedge 132 may include tapered surfaces 135 . The tapered surfaces 135 may correspond to the tapered grooves formed in the connection pins 131 . The tapered surfaces 135 and tapered grooves may function as a tongue-and-groove connection. The connection pins 131 may be configured to move longitudinally relative to the shift wedge 132 and along the tapered surfaces 135 . The tapered surfaces 135 may be configured to engage and extend the connection pins 131 through the ports 115 and into the recesses 123 of the adapter 121 . A projection 136 may extend from the tapered surfaces 135 . The projection 136 may be circular. The channel 134 may be configured to receive the projection 136 . The projection 136 may be configured to move through the channel 134 .

Alternatively, the drive keys 112 and adapter keys 122 may be omitted and the connection pins 131 may provide the longitudinal and the torsional coupling between the drive member 110 and the tool dock 120 . The connection pins 131 support the axial load of the tool dock 120 and attached tool and transfer torque between the drive member 110 and the tool dock 120 .

FIGS. 3A and 3B illustrate operation of the CMC 100 . The CMC 100 is operable to torsionally and longitudinally couple the top drive to the tool. First, the housing 111 is inserted into the bore of the adapter 121 . The tool dock 120 may be raised or the drive member 110 lowered to begin the process. As the housing 111 is inserted into the bore of the adapter 121 , the drive keys 112 assist in aligning the connection pins 133 with the recesses 123 . Recesses in the drive keys 112 receive the adapter keys 122 . Likewise, the recesses in the adapter keys 122 receive the drive keys 112 . As shown in FIG. 3A , the housing 111 has been inserted into the bore of the adapter 121 . The engaged drive keys 112 and adapter keys 122 transfer torque between the tool and the top drive. Next, the piston and cylinder assembly 113 is actuated to longitudinally move the shift wedge 132 within the bore of the housing 111 . The connection pins 133 are restrained from longitudinal movement relative to the housing 111 by walls of the holes 115 . The channel 134 and projection 136 permit longitudinal movement of the shift wedge 132 relative to the connection pins 131 . The projection 136 moves through the channel 134 as the shift wedge 132 longitudinally moves relative to the housing 111 . As the shift wedge 132 longitudinally moves towards a lower end of the housing 111 , the connection pins 131 slide along the tapered surfaces 135 to the extended position, shown in FIG. 3B . In the extended position, the connection pins 133 are received in the recesses 123 of the adapter 121 . Reception of the connection pins 131 in the recesses 123 longitudinally couples the drive member 110 to the tool dock 120 . In addition, the reception of the connection pins 131 may torsionally couple the drive member 110 to the tool dock 120 and compensate for the axial load hanging beneath the tool dock 120 . Reception of the connection pins 131 in the recesses 123 rotationally couples the top drive to the tool bidirectionally. The shift wedge 132 retains the connection pins 131 in the extended position.

In order to decouple the top drive and the tool, the piston and cylinder assembly 113 is actuated to longitudinally move the shift wedge 132 towards the upper end of the housing 111 . The connection pins 131 slide along the tapered surfaces 135 to the retracted position, shown in FIG. 3A . Movement of the connection pins 131 out of the recesses 123 longitudinally decouples the drive member 110 and the tool dock 120 . The drive member 110 is then lifted or the tool dock 120 lowered to disengage the drive keys 112 and the adapter keys 122 , thereby rotationally decoupling the drive member 110 and the tool dock 120 .

FIGS. 4 and 5 illustrate a CMC system 200 , according to a second embodiment. The CMC 200 may include a drive member 210 , a tool dock 220 , and a latch assembly 230 . The drive member 210 may include a housing 211 . The housing 211 may have a bore therethrough. The housing 211 may be integrally formed with the top drive. The housing 211 may include one or more sections 211 a,b . An upper tubular section 211 a of the housing 211 may be integrally formed with the top drive at an upper longitudinal end thereof. The tubular section 211 a may include a coupling, such as a threaded coupling, formed at a lower longitudinal end thereof for connection to a lower housing section 211 b . Alternatively, the housing 211 may be a single piece. The lower housing section 211 b may have a bore therethrough. The lower housing section 211 b may be configured to receive an adapter 221 of the tool dock 220 . The lower housing section 211 b may have a flange 212 formed at an upper longitudinal end thereof. The flange 212 may be integrally formed with the housing section 211 b . A recess may be disposed between an outer surface of the housing section 211 b and the flange 212 . A port 213 ( FIG. 7A ) may be formed through a wall of the housing section 211 b . The port 213 may be disposed through a wall adjacent the recess. Splines may be formed along an inner surface of the housing section 211 b . The splines may extend radially inward from the inner surface of the housing section 211 b . The splines may assist in alignment during insertion of the adapter 221 of the tool dock 220 .

The latch assembly 230 may include a piston 231 and cylinder 232 assembly, a bracket 233 , a lock member, such as thrust sleeve 234 , a first biasing member, such as main spring 235 , and a latch member, such as pin 236 . The bracket 233 may be an annular ring. The bracket 233 may be disposed on an outer surface of the housing 211 . The bracket 233 may be supported by the flange 212 of the housing 211 . The cylinder 232 may be connected to the bracket. A fluid line may be connected to the cylinder 232 to operate the piston 231 and cylinder 232 assembly. A longitudinal end of the piston 231 may be disposed in the cylinder 232 and longitudinally movable relative thereto. A longitudinal end of the piston opposite the cylinder 232 may be connected to the thrust sleeve 234 . The piston 231 and cylinder 232 assembly may be configured to longitudinally move the thrust sleeve 234 relative to the housing 211 . The thrust sleeve 234 may be an annular ring. The thrust sleeve 234 may be disposed on an outer surface of the housing 211 . The thrust sleeve 234 may be at least partially disposed in the recess between the flange 212 and the housing section 211 b . The thrust sleeve 234 may be longitudinally movable relative to the housing 211 between an extended position, shown in FIG. 7A , and a retracted position, shown in FIG. 7B . The main spring 235 may be disposed in the recess between the flange 212 and the housing section 211 b . The main spring 235 may be an annular ring. The main spring 235 may be an elastomer, such as rubber. The main spring 235 may be supported by an upper longitudinal end of the thrust sleeve 234 . The main spring 235 may be longitudinally constrained in the recess between the thrust sleeve 234 and the flange 212 . The thrust sleeve 234 may be configured to compress the main spring 235 . The main spring 235 may be configured to radially expand within the recess when subjected to longitudinal compression by the thrust sleeve 234 . The main spring 235 may be configured to engage the pin 236 during radial expansion. The thrust sleeve 234 may be configured to engage the main spring 235 . The pin 236 may be at least partially disposed in the recess between the flange 212 and the housing section 211 b . The pin 236 may be radially movable between a retracted position, shown in FIG. 7A , and an extended position, shown in FIG. 7B . The thrust sleeve 234 may be configured to retain the pin 236 in the extended position. The pin 236 may have a lip configured to prevent the pin from falling into the bore of the housing section 211 b . A biasing member, such as circular spring 237 ( FIG. 7A ), may be disposed around the pin 236 . The circular spring 237 may be disposed between the shoulder of the pin and the outer surface of the housing section 211 b . The circular spring 237 may be disposed in a recess of the housing section 211 b . The circular spring 237 may be an elastomer. The circular spring 237 may bias the pin 236 towards the retracted position.

FIG. 6 illustrates the tool dock 220 of the CMC 200 . The tool dock 220 includes an adapter 221 . The adapter 221 may be tubular having a bore therethrough. Splines 222 may be formed along an outer surface of the adapter 221 . Splines 222 may be configured to engage corresponding splines on the inner surface of the housing section 211 b . The adapter 221 may include quick connection pins 223 disposed at a longitudinal end thereof. The quick connection pins 223 may stab into receivers formed in an inner surface of the housing section 211 a . The quick connection pins 223 may be configured to transfer power, data, electronics, hydraulics, and/or pneumatics between the top drive and the tool. A lip 224 may be formed at a longitudinal end of the adapter 221 . An annular recess may be formed between the lip 224 and the splines 222 of the adapter 221 .

FIGS. 7A and 7B illustrate operation of the CMC 200 . The CMC 200 is operable to torsionally and longitudinally couple the top drive to the tool. First, the adapter 221 is inserted into the bore of the housing 211 . The tool dock 220 may be raised or the drive member 210 lowered to begin the process. The splines on the adapter 221 and housing section 211 b facilitate alignment. In addition, the splines on the adapter 221 and the housing section 211 b torsionally couple the housing 211 of the drive member 210 and the adapter 221 the tool dock 220 . Reception of the splines of the adapter within the recesses between the splines on the housing section 211 b rotationally couples the top drive to the tool bidirectionally. As shown in FIG. 7A , the adapter 221 has been inserted into the housing section 211 b . Recesses on the adapter 221 are in alignment with the pin 236 . Next, the piston and cylinder assembly is actuated to longitudinally move the thrust sleeve 234 . The thrust sleeve 234 moves longitudinally upwards relative to the housing 211 . Movement of the thrust sleeve 234 longitudinally compresses the main spring 235 between the flange 212 and an outer surface of the thrust sleeve 234 . As a result, the main spring 235 expands radially inward toward the housing section 211 b and the pin 236 . The main spring 235 expands radially to engage the pin 236 and push the pin 236 into the extended position. The main spring 235 engages and pushes the pin 236 inwards through the port 213 formed in the housing 211 . The pin 236 acts against the biasing force of the circular spring 237 and at least a portion of the pin 236 moves into the recess formed in the adapter. In the extended position shown in FIG. 7B , the pin 236 longitudinally couples the housing drive member 210 and the tool dock 220 . The thrust sleeve 234 may be held in this position by the piston and cylinder assembly 231 , 232 to retain the pin 236 in the extended position.

In order to decouple the drive member 210 and the tool dock 220 , the piston and cylinder assembly is actuated to longitudinally lower the thrust sleeve 234 . The main spring 235 returns to a relaxed position, shown in FIG. 7A . The circular spring 237 biases the pin 236 towards the retracted position to longitudinally decouple the drive member 210 and the tool dock 220 . The drive member 210 is then lifted or the tool dock 220 lowered to disengage the splines, thereby rotationally decoupling the drive member 210 from the tool dock 220 .

FIGS. 8 and 9 illustrate a CMC 300 , according to a third embodiment. The CMC 300 includes a drive member 310 , a tool dock 320 , and a latch assembly 330 . The drive member 310 may include a housing 311 . The housing 311 may have a bore therethrough. The housing 311 may include one or more sections 311 a - c . The housing section 311 a may include an upper tubular portion and a lower disc portion. The housing section 311 b may be an L-shaped flange. Splines may be formed along an inner surface of the housing section 311 b . The splines may extend radially inward from the inner surface of the housing section 311 b . The splines may facilitate alignment of housing section 311 c and an adapter 321 of the tool dock 320 . Corresponding splines may be formed on an outer surface of the adapter 321 . The splines of the housing section 311 c and corresponding splines of the adapter 321 may be configured to torsionally couple the housing section 311 c and the adapter 321 . The splines of the housing section 311 c and corresponding splines of the adapter 321 may permit longitudinal movement of the adapter 321 relative to the housing section 311 c . Splines may be formed on an outer surface of the flange 312 . The splines of the flange 312 may extend radially outward. The splines of the flange 312 may facilitate alignment of housing section 311 b and housing section 311 c . Corresponding splines may be formed on an inner surface of housing section 311 b . The splines of flange 312 and corresponding splines of the housing section 311 b may be configured to torsionally couple the housing section 311 c and the housing section 311 b . The splines of flange 312 and corresponding splines of the housing section 311 b may permit longitudinal movement of the housing section 311 b relative to the flange 312 and housing section 311 c . A recess may be formed between the housing section 311 b and housing section 311 a . A counter spring 313 may be disposed in the recess. The counter spring 313 may be an elastomer. The counter spring 313 may be an annular ring. The housing section 311 c may have a bore therethrough. The housing section 311 c may be configured to receive the tool dock 320 . The housing section 311 c may have a flange 312 formed at an upper longitudinal end thereof. The flange 312 may be integrally formed with the housing section 311 c . A recess may be disposed between an outer surface of the housing section 311 c and the flange 312 . A port 314 may be formed through a wall of the housing section 311 c . The port 314 may be disposed through a wall adjacent the recess. Splines may be formed along an inner surface of the housing section 311 c . The splines may extend radially inward from the inner surface of the housing section 311 c . The splines may assist in alignment during insertion of the tool dock 320 .

The latch assembly 330 may include a piston 331 and cylinder 332 assembly, a lock member, such as thrust sleeve 334 , a first biasing member, such as main spring 335 , and a latch member, such as pin 336 . The cylinder 332 may be connected to the outer surface of the housing section 311 a . A fluid line may be connected to the cylinder 332 to operate the piston 331 and cylinder 332 assembly. A longitudinal end of the piston 331 may be disposed in the cylinder 332 and longitudinally movable relative thereto. A longitudinal end of the piston opposite the cylinder 332 may be connected to the thrust sleeve 334 . The piston 331 and cylinder 332 assembly may be configured to longitudinally move the thrust sleeve 334 relative to the housing 311 . The thrust sleeve 334 may be an annular ring. The thrust sleeve 334 may be disposed on an outer surface of the housing 311 . The thrust sleeve 334 may be at least partially disposed in the recess between the flange 312 and the housing section 311 c . The thrust sleeve 334 may be longitudinally movable relative to the housing 311 between an extended position, shown in FIG. 10A , a coupled position, shown in FIG. 10B , and a seal position, shown in FIG. 10C . The main spring 335 may be disposed in the recess between the flange 312 and the housing section 311 b . The main spring 335 may be an annular ring. The main spring 335 may be an elastomer, such as rubber. The main spring 335 may be supported by an upper longitudinal end of the thrust sleeve 334 . The main spring 335 may be longitudinally constrained in the recess between the thrust sleeve 334 and the flange 312 . The thrust sleeve 334 may be configured to compress the main spring 335 . The main spring 335 may be configured to engage the pin 336 during radial expansion. The thrust sleeve 334 may be configured to engage the main spring 335 . The main spring 335 may be configured to radially expand within the recess when subjected to longitudinal compression. The pin 336 may be at least partially disposed in the recess between the flange 312 and the housing section 311 c . The pin 336 may be at least partially disposed in the port 314 . The pin 336 may be radially movable between a retracted position, shown in FIG. 10A , and an extended position, shown in FIGS. 10B and 10C . The thrust sleeve 334 may be configured to retain the pin 336 in the extended position. The pin 336 may have a lip configured to prevent the pin from falling into the bore of the housing section 311 c . A circular spring 337 may be disposed around the pin 336 . The circular spring 336 may be disposed between the shoulder of the pin and the outer surface of the housing section 311 c . The circular spring 337 may be disposed in a recess of the housing section 311 c . The circular spring 337 may be an elastomer. The circular spring 337 may bias the pin 336 towards the retracted position.

The tool dock 320 may include an adapter 321 . The adapter 321 may be similar to the adapter 221 . The adapter 321 may include quick connection pins disposed at a longitudinal end thereof. The quick connection pins may stab into receivers formed in an inner surface of the housing section 311 a . The quick connection pins may be configured to transfer electricity, data, hydraulics, and/or pneumatics between the top drive and the tool. A seal 322 may be disposed at an upper longitudinal end of the adapter 321 . The seal 322 may be disposed around an upper end of the bore of the adapter 321 . The seal 322 may engage the housing section 311 a . The seal 322 may prevent fluid from entering an annulus between the tool dock 320 and the housing section 311 c . The seal 322 may be an elastomer.

FIGS. 10A-C illustrate operation of the CMC 300 . The CMC 300 is operable to torsionally and longitudinally couple the top drive to the tool. First, the adapter 321 is inserted into the bore of the housing 311 . The tool dock 320 may be raised or the drive member 310 lowered to begin the process. The splines on the adapter 321 and housing section 311 c facilitate alignment. In addition, the splines on the adapter 321 and the housing section 311 c torsionally couple the drive member 310 and the tool dock 320 . Reception of the splines of the adapter 321 within the recesses between the splines on the housing section 311 c rotationally couples the top drive to the tool bidirectionally. As shown in FIG. 10A , the adapter 321 has been inserted into the housing section 311 c . Recesses on the adapter 321 are in alignment with the pin 336 . Next, the piston and cylinder assembly is actuated to longitudinally move the thrust sleeve 334 . The thrust sleeve 334 moves longitudinally upwards relative to the housing 311 . Movement of the thrust sleeve 334 longitudinally compresses the main spring 335 between the flange 312 and an outer surface of the thrust sleeve 334 . As a result, the main spring 335 expands radially inward toward the housing section 311 c and the pin 336 . The main spring 335 expands radially and engages the pin 336 to move the pin 336 to the extended position. The main spring 335 engages and pushes the pin 336 inwards through the port 314 formed in the housing 311 . The pin 336 acts against the biasing force of the circular spring 337 and at least a portion of the pin 336 moves into the recess formed in the adapter 321 . In the extended position shown in FIG. 7B , the pin 336 longitudinally couples the housing drive member 310 and the tool dock 320 .

Next, the piston and cylinder assembly is further actuated to seal a gap between the housing section 311 a and the adapter 321 . The piston and cylinder assembly longitudinally move the thrust sleeve 334 . When the main spring 335 has fully expanded, the longitudinal force of the piston and cylinder assembly is transferred to the housing section 311 c . The piston and cylinder assembly longitudinally moves the housing section 311 c relative to the housing sections 311 a,b . The longitudinal force is also transferred from the pin 336 to the adapter 321 . As a result, the adapter 321 and housing section 311 c longitudinally move relative to the housing sections 311 a,b . The counter spring 313 is compressed within the recess between the housing sections 311 a,c . Longitudinal movement of the adapter 321 and housing section 311 c causes the seal 322 to engage the housing section 311 a . The engaged seal 322 prevents fluid passing through the bore of the housing section 311 a from entering the annulus between the housing section 311 c and the adapter 321 . The thrust sleeve 334 may be held in this position by the piston and cylinder assembly 331 , 332 to retain the pin 336 in the extended position.

In order to decouple the drive member 310 and the tool dock 320 , the piston and cylinder assembly is actuated to longitudinally lower the thrust sleeve 334 . The counter spring 313 biases the housing section 311 c away from the housing section 311 a . The seal 322 disengages from the housing section 311 a . Next, the thrust sleeve 334 moves longitudinally relative to the housing section 311 c . The main spring 335 returns to a relaxed position, shown in FIG. 10A . The circular spring 337 biases the pin 336 towards the retracted position, shown in FIG. 10A , to longitudinally decouple the drive member 310 and the tool dock 320 . The drive member 310 is then lifted or the tool dock 320 lowered to disengage the splines, thereby rotationally decoupling the drive member 310 from the tool dock 320 .

FIGS. 11 and 12 illustrate a CMC system 400 , according to a fourth embodiment. The CMC 400 includes a drive member 410 and a tool dock 420 . The drive member 410 includes a housing 411 . The housing 411 may be tubular having a bore therethrough. The housing 411 may be configured to receive an adapter 421 of the tool dock 420 . The housing 411 may have splines formed longitudinally along an inner surface thereof. The housing 411 may have a window formed through an outer wall thereof. The window may be circular. The window may extend at least partially through the bore of the housing 411 . The window may be formed at least partially off-center from a radial axis of the housing 411 . A second window may be formed on an opposite side and at the same height through the housing 411 as the window. A seal 414 may be disposed in the bore of the housing 411 . The seal 414 may be an elastomer. The seal 414 may be configured to prevent fluid entering an annulus between the housing 411 and the adapter 421 .

The tool dock 420 may include an adapter 421 . The adapter 421 may be similar to the adapter 221 . The adapter 421 may include quick connection pins disposed at a longitudinal end thereof. The quick connection pins may stab into receivers formed in an inner surface of the housing section 411 . The quick connection pins may be configured to transfer electricity, data, hydraulics, and/or pneumatics between the top drive and the tool. The adapter 421 may be tubular having a bore therethrough. The adapter 421 may have splines 422 formed on an outer surface thereof. A lip 423 may be formed at an upper longitudinal end of the adapter 421 . A recess 424 may be formed between the lip 423 and the splines 422 .

FIGS. 13 and 14 illustrate the latch assembly 430 of the CMC 400 . The latch assembly 430 may include an actuator, such as piston and cylinder assembly 431 , levers 432 a,b , and crankshafts 433 , 434 . The piston and cylinder assembly 431 may be longitudinally coupled to the housing 411 at an upper longitudinal end. The piston may be coupled to the levers 432 a,b an opposite end. The piston and cylinder assembly 431 may be configured to actuate the levers 432 a,b . The piston and cylinder assembly 431 may be configured to turn the crankshafts 433 , 434 between a locked position, shown in FIG. 13 , and an unlocked position, shown in FIG. 14 . The lever 432 a may be a straight metal arm. The lever 432 a may be coupled to an arm 433 a of the crankshaft 433 . The lever 432 b may be coupled to an arm 434 a of the crankshaft 434 . The crankshafts 433 , 434 may be cylindrical in shape. The windows may be configured to receive the crankshafts 433 , 434 . The crankshafts 433 , 434 may include eccentric middle portions 433 b , 434 b ( FIG. 15A ) having a smaller cross-sectional area than the remainder of the crankshafts 433 , 434 . The middle portions 433 b , 434 b may be disposed off-center from a longitudinal axis of the crankshafts 433 , 434 .

FIGS. 15A and 15B illustrate operation of the CMC 400 . The CMC 400 is operable to torsionally and longitudinally couple the top drive to the tool. First, the adapter 421 is inserted into the bore of the housing 411 . The tool dock 420 may be raised or the drive member 410 lowered to begin the process. The splines 422 on the adapter 421 and housing 411 facilitate alignment. In addition, the splines 422 on the adapter 421 and the housing 411 torsionally couple the drive member 410 and the tool dock 420 . Reception of the splines 422 of the adapter 421 within the recesses between the splines on the housing 411 rotationally couples the top drive to the tool bidirectionally. As shown in FIG. 15A , the adapter 421 has been inserted into the housing 411 . The adapter 421 is inserted into the housing 411 until the recess 424 is positioned adjacent the crankshafts 433 , 434 . The seal 414 engages an upper longitudinal end of the adapter 421 . Next, the piston and cylinder assembly 431 actuates the levers 432 a,b . Actuation of the levers 432 a,b rotates the crankshafts 433 , 434 . The rotation of the crankshafts 433 , 434 moves the middle portions 433 b , 434 b into the recess 424 , as shown in FIG. 15B . The eccentric middle portions 433 b , 434 b engage the lip 423 to longitudinally couple the adapter 421 and the housing 411 .

In order to decouple the drive member 410 and the tool dock 420 , the piston and cylinder assembly 431 is actuated to shift the levers 432 a,b back to the position shown in FIG. 14 . The crankshafts 433 , 434 rotate within the windows. The middle portions 433 b , 434 b rotate and disengage from the lip 423 . The middle portions 433 b , 434 b continue to rotate out of recess 424 to longitudinally decouple the adapter 421 and the housing 411 . The drive member 410 is then lifted or the tool dock 420 lowered to disengage the splines, thereby rotationally decoupling the drive member 410 from the tool dock 420 .

FIGS. 16 and 17 illustrate a CMC 500 , according to a fifth embodiment. The CMC 500 includes a drive member 510 , tool dock 520 , and latch assembly 530 . The drive member 510 may be integrally formed with the top drive. The drive member 510 may include a housing 511 . The housing 511 may be bell-shaped having an upper tubular section 511 a and a lower bell section 511 b . The housing sections 511 a,b may have a bore therethrough. An upper end of the housing section 511 a may be integrally formed with the top drive. The bell section 511 b may have connections 512 formed at an upper end thereof. The connections 512 may be hooks configured to connect to an actuator. The actuator may be a piston and cylinder assembly. The bell section 511 b may have a groove 513 formed along an outer surface thereof. The groove 513 may be longitudinally aligned. The groove 513 may have a tapered surface. A hole may be formed through the bell section 511 b at a lower end of the groove 513 . The bell section 511 b may have a shoulder 515 formed at a lower end thereof. An inner recess may be formed through a lower end of the bell section 511 b , adjacent the shoulder 515 . The inner recess may extend longitudinally through the bell section 511 b towards the tubular section 511 a of the housing 511 . The inner recess may be configured to receive an adapter 521 of the tool dock 520 . A cone 516 may be formed in the inner recess of the bell section 511 b . The cone 516 may extend longitudinally through the inner recess towards a lower end of the bell housing 511 b . The bore of the housing 511 may extend through the cone 516 . The cone 516 may have a lip formed at a lower end thereof.

The tool dock 520 may include the adapter 521 . The adapter 521 may be integrally formed with the tool dock 520 . The adapter 521 may have a bore therethrough. The adapter 521 may have an upper pin section and a lower tubular section. The pin section may have a cone 522 formed at an upper end thereof. The cone 522 may be configured to receive the cone 516 of the bell section 511 b . A seat may be formed along an inner surface of the cone 522 . The seat may be configured to receive the lip of the cone 516 . The inner recess of the bell section 511 b may be configured to receive the pin section. A window may be formed in an outer wall of the cone 522 . The window may be aligned with the hole of the bell section 511 b . A shoulder 525 may be formed at a lower end of the pin section. The shoulder 525 may be configured to engage the shoulder 515 of the bell section 511 b.

The latch assembly 530 may include a lever 531 , a latch member, such as block 532 , and a lock member, such as locking ring 533 . The lever 531 may be disposed in the groove 513 of the bell section 511 b . The lever 531 may be substantially L-shaped. The lever 531 may be pivotally movable relative to the bell section 511 b . A pin may couple a lower end of the lever 531 to the block 532 . The block 532 may be disposed in the hole of the bell section 511 b . The window may be configured to receive the block 532 in a locked position of the latch assembly 530 . The locking ring 533 may be an annular ring. The locking ring 533 may be disposed on an outer surface of the bell section 511 b . The locking ring 533 may have a hook 535 formed on an outer surface thereof. Hook 535 may be configured to longitudinally couple the locking ring 533 to an actuator. The locking ring 533 may be longitudinally movable relative to the bell section 511 b.

The CMC 500 is operable to longitudinally and torsionally couple the top drive to the tool. The locking ring 533 is in a first position, engaging an upper longitudinal end of the lever 531 . The force applied to the lever 531 by the locking ring 533 retains the block 532 in a retracted position. The block 532 may be partially disposed in the hole of the bell section 511 b in the retracted position. First, the adapter 521 is stabbed into the inner recess of the bell section 511 b . The tool dock 520 may be raised into the drive member 510 or the drive member 510 lowered onto the tool dock 520 to begin the stabbing process. The cone 516 of the bell section 511 b is stabbed into the cone 522 of the pin section. The lip of the cone 516 engages and seals against the seat of the cone 522 . The hole of the bell section 511 b moves into alignment with the window of the cone 522 . Once the pin section has been stabbed into the inner recess of the bell section 511 b , the actuators longitudinally move the locking ring 533 relative to the housing 511 and tool dock 520 . The locking ring 533 is lowered around the outside of the bell section 511 b . As the locking ring 533 moves longitudinally towards the tool dock 520 , the locking ring 533 engages a lower end of the lever 531 . The lever 531 pivots relative to the housing 511 , moving the block 532 into the locked position, disposed in the window of the cone 522 . In the locked position, the block 532 serves to longitudinally and torsionally couple the tool dock 520 to the drive member 510 . Reception of the block 532 within the window of the cone 522 rotationally couples the top drive to the tool bidirectionally. The locking ring 533 retains the block 532 in the locked position.

In order to unlock the tool dock 520 and the drive member 510 , the actuators move the locking ring 533 longitudinally away from the tool dock 520 . The locking ring 533 engages the upper end of the lever 531 , causing the lever 531 to pivot relative to the housing 511 . The pivotal motion of the lever 531 causes the block 532 to move radially out of the window to the retracted position.

FIGS. 18 and 19 illustrate a CMC 600 , according to a sixth embodiment. The CMC 600 includes a drive member 610 , a tool dock 620 , and a latch assembly 630 . The drive member 610 may be integrally formed with the top drive. Alternatively, the drive member 610 may have a coupling, such as a threaded coupling, formed at an upper longitudinal end thereof for connection to the top drive. The drive member 610 may include a housing 611 . The housing 611 may be tubular having a bore therethrough.

The tool dock 620 may be integrally formed with the tool. Alternatively, the tool dock may have a coupling at a lower longitudinal end thereof for connection to the tool. The tool dock 620 may include the adapter 621 . The adapter 621 may be tubular having a bore therethrough. The adapter 621 may have a protrusion 622 formed on an outer surface thereof. The protrusion 622 may have a cylindrical shape. The protrusion 622 may be configured to receive an arm of a lever. A second protrusion may be formed on the outer surface of the adapter 621 . The second protrusion may be formed 180 degrees apart from the protrusion 622 . A signal connector 623 may be formed on the outer surface of the adapter 621 . The signal connector 623 may be configured to receive and transmit power, electrical, data, hydraulic, pneumatic and/or other connections between the top drive and the tool.

The latch assembly 630 may include a sleeve 631 , a latch member, such as lever 632 , an actuator, and a signal pin 633 . The sleeve 631 may be tubular having a bore therethrough. The sleeve 631 may be disposed on an outer surface of the housing 611 . The sleeve 631 may at least partially extend past a lower longitudinal end of the housing 611 . The sleeve 631 may have a notch 634 formed at a lower end thereof. The notch 634 may be configured to receive the protrusion 622 . A second notch may be formed at a lower end of the sleeve 631 and may be configured to receive the second protrusion. The lever 632 may be pivotally coupled by the sleeve. The lever 632 may be pivotally movable relative to the sleeve 631 between an unlocked position, shown in FIG. 18 , and a locked position, shown in FIG. 19 . The actuator (not shown) may be a piston and cylinder assembly. The actuator may be coupled to the lever 632 . The actuator may be operable to actuate the lever 632 between the positions. The signal pin 633 may be disposed on an outer surface of the sleeve 631 . The signal pin 633 may be configured to connect to the signal connector 623 .

In operation, the CMC 600 torsionally and longitudinally couples the tool dock and the top drive. The adapter 621 is inserted into the bore of the sleeve 631 . The tool dock 620 may be raised or the drive member 610 lowered to begin the process. The protrusion 622 is aligned and enters the notch 634 . The protrusion 622 continues moving through the notch 634 until reaching an upper longitudinal end of the notch 634 . The protrusion 622 and notch 634 provide torsional coupling between the drive member 610 and the tool dock 620 . Reception of the protrusion 622 within the notch 634 rotationally couples the top drive to the tool bidirectionally. The signal pin 633 and signal connector 623 engage and provide power, electrical, data, hydraulic, pneumatic and/or other connections between the drive member 610 and the tool dock 620 . Next, the actuator is operated to shift the lever 632 to the locked position, shown in FIG. 19 . The lever 632 pivots relative to the sleeve 631 . An arm of the lever 632 hooks underneath the protrusion 622 to support the adapter 621 . The lever 632 and protrusion 622 longitudinally couple the drive member 610 and the tool dock 620 .

In order to decouple the drive member 610 and the tool dock 620 , the actuator returns the lever 632 to the unlocked position, shown in FIG. 18 . The drive member 610 is then lifted or the tool dock 620 lowered to disengage the protrusion 622 from the notch 634 , thereby torsionally decoupling the tool dock 620 from the drive member 610 .

In one embodiment, a coupling system for a top drive includes a housing having a bore therethrough, a latch member at least partially disposed within the housing and radially movable between an extended position and a retracted position, wherein the latch member is configured to longitudinally couple the housing to a tool, and a lock member longitudinally movable relative to the housing and configured to move the latch member between the extended and the retracted positions.

In one or more of the embodiments described herein, the lock member is at least partially disposed within the housing.

In one or more of the embodiments described herein, the coupling system includes an actuator configured to longitudinally move the lock member.

In one or more of the embodiments described herein, the actuator is disposed on an outer surface of the housing.

In one or more of the embodiments described herein, the actuator is a piston and cylinder assembly.

In one or more of the embodiments described herein, the housing has a port formed through a wall thereof.

In one or more of the embodiments described herein, the coupling system includes a tool dock.

In one or more of the embodiments described herein, the tool dock includes an adapter having a bore therethrough and longitudinally movable relative to the housing.

In one or more of the embodiments described herein, the adapter further includes quick connection pins located at a longitudinal end thereof.

In one or more of the embodiments described herein, the housing is configured to receive the adapter.

In one or more of the embodiments described herein, the latch member is at least partially disposed in a recess of the adapter in the extended position.

In one or more of the embodiments described herein, the lock member engages the latch member to retain the latch member in the extended position.

In another embodiment, a coupling system for coupling a top drive to a tool includes a housing having a bore therethrough, a sleeve disposed on an outer surface of the housing, a latch member disposed on an outer surface of the sleeve, wherein the latch member is configured to longitudinally couple the housing to the tool, and a tool dock integrally formed with the tool and configured to receive the latch member.

In one or more of the embodiments described herein, the coupling system includes a signal pin disposed on an outer surface of the sleeve.

In one or more of the embodiments described herein, the coupling system includes a signal connector disposed on an outer surface of the tool dock, wherein the signal connector is configured to receive the signal pin.

In one or more of the embodiments described herein, the coupling system includes a protrusion formed on an outer surface of the housing and configured to receive the latch member.

In one or more of the embodiments described herein, the coupling system includes a notch formed at a longitudinal end of the sleeve and configured to receive the protrusion.

In one or more of the embodiments described herein, the latch member is a lever pivotally coupled to the sleeve.

In another embodiment, a coupling system for coupling a top drive includes a housing having a bore therethrough, a latch member at least partially disposed through a wall of the housing and rotatable relative to the housing, wherein the latch member is configured to longitudinally couple the housing to a tool, and an actuator disposed on an outer surface of the housing and configured to rotate the latch member.

In one or more of the embodiments described herein, the latch member comprises at least one crankshaft including an eccentric middle portion.

In one or more of the embodiments described herein, the coupling system includes a linkage coupling the actuator to the at least one crankshaft.

In one or more of the embodiments described herein, the actuator is a piston and cylinder assembly.

In one or more of the embodiments described herein, a coupling system for a top drive and a tool includes a housing of the top drive having a bore therethrough, an adapter of the tool, a latch member at least partially disposed within the housing and radially movable between an extended position and a retracted position, wherein the latch member is configured to longitudinally couple the housing to the adapter, a lock member at least partially disposed within the housing and longitudinally movable relative to the housing, wherein the lock member is configured to move the latch member between the extended and the retracted positions, and an actuator configured to longitudinally move the lock member.

In one or more of the embodiments described herein, the lock member is configured to retain the latch member in the extended position.

In one or more of the embodiments described herein, the adapter includes a bore configured to receive the housing.

In one or more of the embodiments described herein, wherein the lock member includes a tapered surface configured to engage the latch member.

In one or more of the embodiments described herein, wherein the actuator is a piston and cylinder assembly.

In one or more of the embodiments described herein, wherein the housing has a port formed therethrough.

In one or more of the embodiments described herein, wherein the actuator is at least partially disposed through the port.

In one or more of the embodiments described herein, the adapter further includes a recess disposed therein.

In one or more of the embodiments described herein, the adapter further comprising quick connection pins located at a longitudinal end thereof, wherein the quick connection pins are configured to transfer at least one of power, data, electronics, hydraulics, and pneumatics.

In one or more of the embodiments described herein, further including a biasing member, the biasing member configured to bias the latch member towards the retracted position.

In one or more of the embodiments described herein, wherein the latch member is at least partially disposed in the recess in the extended position.

In one or more of the embodiments described herein, wherein the lock member engages the latch member to retain the latch member in the extended position.

In one or more of the embodiments described herein, wherein the bore of the housing is configured to receive the adapter.

In one or more of the embodiments described herein, a method of coupling a top drive and a tool includes moving a top drive adjacent a tool, the top drive including a housing, a lock member at least partially disposed within the housing, and a latch member at least partially disposed within the housing and the tool including an adapter. The method further includes inserting the adapter into the housing, shifting the lock member longitudinally relative to the housing, and moving the latch member radially between an extended position and a retracted position to couple the top drive and the tool.

In one or more of the embodiments described herein, the method includes retaining the latch member in the extended position using the lock member.

In one or more of the embodiments described herein, the method includes biasing the latch member towards the retracted position.

In one or more of the embodiments described herein, the method includes engaging a biasing member using the lock member.

In one or more of the embodiments described herein, the method includes expanding the biasing member radially to move the latch member to the extended position.

In one or more of the embodiments described herein, the method includes transferring at least one of power, data, electronics, hydraulics, and pneumatics between the adapter and the housing using quick connection pins.

In one or more of the embodiments described herein, the method includes engaging splines of the housing with splines of the adapter, thereby transferring torque between the housing and the adapter.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.