Automated assembly cell for oilfield drill bits specialist ReedHycalog

Citation

(2006), "Automated assembly cell for oilfield drill bits specialist ReedHycalog", Industrial Robot, Vol. 33 No. 6. https://doi.org/10.1108/ir.2006.04933faf.004

Automated assembly cell for oilfield drill bits specialist ReedHycalog

Automated assembly cell for oilfield drill bits specialist ReedHycalog

Keywords: Robotics, Assembly

Cutting-edge process automation and industrial robotics specialist, Barr & Paatz of Totnes, has supplied and commissioned a fully automated assembly cell for ReedHycalog, one of the world's leading manufacturers of oilfield drill bits and related applications technology. Occupying a footprint of just three metres square, the installation includes the first UK application of the Mitsubishi RV-3S industrial robot, an all-new compact and powerful six-axis machine, said to be the fastest in its class (Plate 3).

Plate 3 The fully automated assembly cell, supplied to ReedHycalog by Barr & Paatz

The ReedHycalog assembly cell, which also incorporates a 64 bit multi- tasking robot controller and Rexroth EcoSafe modular guarding system, replaces a previously labour-intensive manual operation, assembling hundreds of thousands of fixed cutter PDC cutting elements annually. Apart from maintaining consistent product quality and readily handling a variety of drill bit configurations, the Barr & Paatz- designed cell has actually doubled throughput, leading to early payback on automation investment. So impressed is ReedHycalog that the company is already planning two further assembly cells and actively considering further robotic applications.

With its UK headquarters in Stonehouse, Gloucestershire and manufacturing operations in Houston, Texas and Jurong, Singapore, ReedHycalog offers a range of roller cone and fixed cutter product lines, intended for a variety of drilling operations and designed to reduce costs through the use of advanced materials and designs. It is part of the American Grant Prideco group, itself the world's largest producer of drill pipe and other drill stem products, as well as a leading provider of high performance connections and tubular technology.

The new assembly cell has been installed at the Stonehouse site, where ReedHycalog manufactures its fixed cutter drill bits and PDC cutting elements, including the exclusive, multi-patented TReX^w range and the latest Raptore design, both featuring thermostable PDC technology. The company pioneered the use of PDC (polycrystalline diamond compact) materials and its TReX design incorporates a self-sharpening, ultra wear-resistant layer on the face of a PDC cutter, setting new standards in drill cutting and dramatically improving ROP (rate of penetration).

TReX and other PDC cutting elements were previously assembled manually, leading to fatigue amongst staff and genuine health & safety concerns over repetitive strain injuries. Having decided to automate the assembly process and release operators for more skilled work, ReedHycalog initially struggled to find anyone capable of undertaking the project, but were eventually recommended Barr & Paatz, which has over 16 years' experience in this field.

The South West automation experts are official integrators for cutting-edge Mitsubishi, Stäubli, Festo and Rexroth technology and offer highly specialised skills in robotics, programming, mechanical, electrical and system design. Employing in-house 3D modelling software, Barr & Paatz configured and programmed the ReedHycalog cell, then ran simulation and test routines to prove the system prior to installation. This meant that the cell was able to be in full production within four weeks of the first delivery of parts to the Stonehouse site, which duly impressed ReedHycalog's Manufacturing Projects Engineer, Haydn Lamb.

Barr & Paatz selected the latest Mitsubishi RV-3S robot for this application, thanks to its compact footprint, high 3.5kg payload capacity, six degrees of freedom and standard compliance with IP65 across all axes. It is also the fastest robot in its class, with speeds up to 5,500mm/sec, and has an impressive repeatability of ^0.020mm, as well as a larger 640mm reach. For this assembly application it is suspended from an overhead gantry, to free up floorspace and provide a large working radius.

Although the company makes extensive use of modern CNC production machinery, this was its very first flexible automation project and, while it expected to improve the efficiency of PDC cutter processing and eliminate health & safety risks, the company had not predicted dramatically improved throughput. Nevertheless, Haydn Lamb reports a twofold increase in units per hour with full automation, compared to the old manual regime. This accelerated payback has prompted discussions with Barr & Paatz regarding two further assembly cells, together with a long- term goal of identifying fresh applications for robotics technology.

Further enquiries to Barr & Paatz, 7- 11 Paragon Units, Ford Road, Totnes Industrial Estate, Totnes TQ9 5LQ, Tel: 01803 869 833, e-mail s.paatz@barr-paatz.co.uk ReedHycalog can be contacted via its web site at: www.reedhycalog.com