INTELLIGENT TOP DRIVE FOR DRILLING RIGS

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.