Apparatus and method for measuring multiple inner diameters of the inner surface of a positive displacement motor stator.

Abstract

An apparatus and method for measuring multiple inner diameters of the inner surface of a positive displacement motor stator are disclosed. The apparatus includes: a detector assembly comprising a body, a wheel assembly, and a sensor assembly; the body including a sliding portion configured to slide in contact with the inner surface of the component; the wheel assembly being connected to the body on substantially opposite side of the sliding portion such that at least a portion of the wheel assembly protrudes from the body to roll in contact with the inner surface; the detector assembly being configured to displace relative to the sliding portion in response to a change in the diameter of the inner surface; the sensor assembly being disposed in the body and connected to the wheel assembly and configured to convert the displacement of the wheel assembly into an electrical signal representing the diameter of the inner surface of the component; and a translational assembly being connected to the detector assembly and configured to insert the detector assembly into the interior of the component and retract the detector assembly from the interior of the component.

Description

[0001] This application is a divisional application of the applicant’s patent application No. 201510708369.2, filed on October 27, 2015, entitled “Apparatus and method for measuring multiple inner diameters of the inner surface of a volumetric motor stator”. Technical Field

[0002] The inventions disclosed and taught herein generally relate to stator bore gauges, and more specifically to systems and methods for probing the stator portions of motors and pumps with structures similar to mud motors and Moyno-style pumps. Background Technology

[0003] Some devices (e.g., some motors and pumps) have stators with lobed sections whose dimensions are important for the proper operation of the device. For example, downhole power drills are commonly used in oilfield drilling operations, while moino pumps are often used in municipal water supply systems to deliver viscous materials. For the purposes of the following discussion, a downhole power drill has been described as an exemplary device; however, it should be understood that the subject matter described can be applied to other devices.

[0004] At a higher level, downhole power tools take the form of positive displacement pumps, comprising a long rotor section and a long stator section. The rotor section is typically formed of a hardened material such as steel and has an outer profile defining one or more helical lobes. The stator section typically defines a central bore and has a generally helical groove interior defining multiple lobes, wherein the number of lobes defined inside the stator differs from, and is typically greater than, the number defined outside the rotor. The interior of the stator bore is typically formed of or lined with an elastically deformable material, such as rubber.

[0005] Figure 1(Prior Art) shows a representative portion of an example power drill bit, taken from prior art patent application publication US 2011 / 0116959. In the figures shown, the rotor of the downhole power drill bit is represented by component 302, and the stator of the downhole power drill bit is represented by component 308. As shown, the interior of the stator bore 304 defines a plurality of different ridge-like elements that define a plurality of maximum internal stator bore diameter "recesses" and a plurality of ridges that define a plurality of minimum internal stator bore diameter ridges. Due to the shape of the interior of the stator bore, multiple ridges and recesses are encountered if one moves along the longitudinal (i.e., longitudinal) axis of the stator bore. Therefore, the shape of the interior bore is inconsistent, and the exact diameter of the inner diameter of the stator bore can change as one moves along the longitudinal axis of the stator bore. For most downhole power drill bits, the inner diameter of the stator bore can vary from approximately the size corresponding to the maximum inner diameter to approximately the size corresponding to the minimum inner diameter as it travels from one end of the stator bore along its longitudinal axis to the other end.

[0006] During operation, a pressurized fluid (which can be drilling fluid, drilling mud, compressed air or other gas, or any other suitable fluid) is propelled through the space between the rotor and stator, generating a torque that causes the rotor to rotate. This rotating rotor is typically connected to the drill bit via a drive shaft to facilitate drilling operations.

[0007] Proper fit between the rotor and stator of a downhole power drill string is crucial for the correct operation of the motor. To ensure proper fit, accurate measurements associated with the minimum diameter of the stator bore are advantageous. Knowing these dimensions allows for the selection of a suitable rotor size for a given stator and / or determination of whether the rubber lining of a previously used stator needs overhauling or replacement. Furthermore, knowing these dimensions can potentially allow for the determination of the stator's wear level and / or whether different areas within the stator are at different wear levels than others. Sometimes, stator bore gauges are used to obtain information related to the inner diameter of the downhole power drill string stator.

[0008] Known stator bore gauges, such as the SBG-5000 stator gauge from Gagemaker, typically use a long gauge head with a wide base and floating element shoe to measure the minimum inside diameter of downhole power drill string stators at various locations. This long gauge head usually has multiple stator bore ridges across its span. In such gauges, the gauge is typically preset or calibrated using a round setting standard and then inserted into the bore of the stator to be measured. The gauge is then positioned at predetermined intervals, and at each predetermined position, the operator actuates the rod to obtain dimensional readings from an analog indicator or a digital readout. These dimensional measurements are then analyzed to provide information related to the minimum stator bore diameter. A flat, long stator bore gauge extension can be used to allow the gauge to be used in stators of different sizes. In some cases, the gauge may include an electronic measuring device and a wired connection for providing measurement data to a computing device (e.g., a laptop computer) for display and processing.

[0009] exist Figure 2 The figure illustrates a representative example of the prior art stator bore gauge 200. As shown, the head 202 of a wide base with a wide, elongated floating measuring support is connected via a long (typically stainless steel or carbon fiber) ridge shaft 204 to a handle element 206 with a movable rod. The handle element 206 is connected via a connecting cable 208 to a computing device (such as a desktop or laptop computer) 210, which is powered via a standard wire 212. The long, flat support 214 can be used for large-diameter stator bores. In use, the stator bore gauge 200 is inserted into the stator bore and the operator moves the head 202 to a first position, actuating the rod on the handle element 206 to obtain a first reading. The operator then moves the head 202 to different positions and obtains a second reading. This process is repeated multiple times to obtain discrete measurements at specific locations.

[0010] Despite such combinations Figure 2 The known gauges described can provide accurate information related to the stator bore of the downhole power drill bit; however, it takes time to perform these multiple separate measurements, and the accuracy of the measurement varies depending on where the separate measurement is performed and the user's hand position during the measurement. Furthermore, because the head 202 spans several stator bore ridges, individual measurements of multiple minimum diameters within the stator bore are not obtained. Summary of the Invention

[0011] The present invention described and summarized herein relates to one or more different embodiments, none of which are intended to limit the scope of the appended claims. A brief description of at least one invention disclosed herein includes an apparatus for measuring a plurality of inner diameters of an inner surface, comprising a detector assembly having a body, a wheel assembly, and a sensor assembly; the body having a sliding portion configured to slide in contact with the inner surface of a member; the wheel assembly being connected to the body substantially on the opposite side of the sliding portion such that at least a portion of the wheel assembly protrudes from the body for rolling contact with the inner surface; the detector assembly being configured to displace relative to the wheel assembly and the sliding portion in response to a change in the inner surface diameter; the sensor assembly located in the body being connected to the wheel assembly and configured to convert the displacement of the wheel assembly into an electrical signal representing the inner surface diameter of the member; and a translational assembly connected to the detector assembly, configured to insert the detector assembly into the interior of the member and retract the detector assembly from the interior of the member.

[0012] Further summaries of the invention described herein can be derived from the appended claims and the several embodiments described herein. Attached Figure Description

[0013] The accompanying drawings form part of this specification and are included to further illustrate some aspects of the disclosed embodiments.

[0014] According to the various teachings here.

[0015] Figure 1 This demonstrates a prior art downhole power drilling tool.

[0016] Figure 2 The stator inner bore gauge of a prior art downhole power drill tool is shown.

[0017] Figure 3A and 3B An example stator inner bore gauge constructed based on some of the teachings here is shown.

[0018] Figure 4 This illustrates aspects of the stator inner bore gauge.

[0019] Figures 5A-5F Representative features of the end portion of a stator bore gauge constructed based on various teachings herein are shown.

[0020] Figure 6A and 6B Representative features of the end portion of a stator bore gauge, based on various teachings herein, are shown.

[0021] Figure 7A and 7BA connector is shown that can be used to connect an exemplary end to an exemplary handle portion in accordance with some of the teachings herein.

[0022] Figure 8A-8G Various forms of extension devices and supports are shown for use with one embodiment of the stator bore gauge described herein, so as to facilitate the use of the gauge for motor stator bores of various sizes.

[0023] Figure 9A An example form of an implementation of the handle assembly according to the teachings herein is shown.

[0024] Figure 9B An exemplary calibration curve for a linear sensor implementation is shown.

[0025] Figures 10A-10H An example human-machine interface for use with the stator bore gauge taught herein is shown, along with a simulated "screenshot" of the method of using the stator bore gauge.

[0026] Figure 11A-11F An optional example human-machine interface for use with the stator bore gauge taught herein is shown, along with a simulated "screenshot" of the method of using the stator bore gauge.

[0027] Figure 12 An optional structure for the stator inner bore gauge, as described herein, is shown.

[0028] Figures 13A-13D A method is shown in which a stator bore gauge, based on some teachings, can be used to detect ridges or protrusions in the stator bore and determine the minimum diameter of the stator bore.

[0029] Figure 14 An exemplary device for characterizing a given device is shown in the figure.

[0030] Although the invention disclosed herein can be modified and adapted in various ways, the accompanying drawings illustrate only by way of example, and the following detailed descriptions only cover a few specific embodiments. The accompanying drawings and detailed descriptions of these embodiments do not in any way limit the breadth or scope of the inventive concept or the appended claims. Furthermore, the drawings and detailed descriptions are intended only to illustrate the inventive concept to those skilled in the art and to enable them to make and use the invention. Detailed Implementation

[0031] In general, the invention taught herein can be implemented as a variety of devices capable of measuring multiple inner diameters of an inner surface. Such a device may include a detector assembly comprising a body, a wheel assembly, and a sensor assembly; the body includes a sliding portion configured to slide in contact with the inner surface of a member. The wheel assembly is connected to the body on substantially opposite sides of the sliding portion such that at least a portion of the wheel assembly protrudes from the body to roll in contact with the inner surface. The detector assembly is configured to displace relative to the wheel assembly and the sliding portion in response to a change in the diameter of the inner surface. The sensor assembly may be disposed in the body and connected to the wheel assembly and configured to convert the displacement of the wheel assembly into an electrical signal representing the diameter of the inner surface of the member. A translational assembly may be connected to the detector assembly and configured to insert the detector assembly into the interior of the member and retract the detector assembly from the interior of the member.

[0032] Such embodiments also include a support mechanism that converts the radial displacement of the wheel assembly into longitudinal displacement. The sensor assembly may include a linear displacement sensor. The wheel assembly can provide approximately 0.2 inches of radial displacement. The wheel assembly may include a biasing element configured to bias the wheel from the sliding portion to maximum radial displacement. The biasing force provided by the biasing element may not cause deformation of the inner surface. The biasing force provided by the biasing element may be approximately 0.3 pounds or less. The translation assembly includes a handle portion with a power supply and wires for transmitting signals from the sensor assembly to the handle portion. The translation assembly may have an adjustable length. The translation assembly may include one or more connectors configured to allow relative movement between the body and the handle. The one or more connectors may be ball joints or U-joints. The detector assembly is configured to continuously measure the diameter of the inner surface. The body includes one or more removable supports, each support having a sliding portion.

[0033] The embodiments of the invention shown herein may further include a human-machine interface with a visual display configured to display a representation of electrical signals from the sensor assembly. The human-machine interface is associated with the handle portion. The human-machine interface is wirelessly connected to the detector assembly.

[0034] Other embodiments of the invention taught herein may include a device capable of measuring multiple inner diameters of a positive displacement motor stator, and may further include: a detector assembly comprising a body, a wheel assembly, and a sensor assembly. The body may have one or more sliding portions configured to slide in contact with an inner surface of the stator. The wheel assembly may be connected to the body on substantially opposite sides of the at least one sliding portion, such that at least a portion of the wheel assembly protrudes from the body to roll in contact with the inner surface of the stator. The detector assembly is configured to displace relative to the wheel assembly and the at least one sliding portion in response to a change in the diameter of the inner surface. The sensor assembly may be disposed in the body, operatively connected to the wheel assembly, and configured to convert the displacement of the wheel assembly into an electrical signal representing the diameter of the inner surface of the stator. A translational assembly may be connected to the detector assembly and configured to insert the detector assembly into the interior of the stator and retract the detector assembly from the interior of the stator. The translation assembly has an adjustable length and includes a handle portion and one or more connectors. The handle portion has a power supply and wires for transmitting signals from the sensor assembly to the handle portion. The connectors are configured to allow relative rotation between the body and the handle. A human-machine interface may be provided, configured to wirelessly communicate with the body and display a diameter measurement of the inner surface when the body retracts from the stator.

[0035] Other embodiments of the invention taught herein may include a method for measuring multiple inner diameters of an inner surface of a component using an apparatus such as, but not limited to, the apparatus described above. Such a method may include: calibrating the apparatus such that an electrical signal provided by the sensor assembly is correlated with a diameter measurement; setting a maximum diameter dimension between the sliding portion and the wheel assembly to match the inner surface to be measured; inserting the body into the interior of the component; and measuring the diameter of the inner surface as the body is retracted from the component.

[0036] Such a method may further include determining the minimum diameter of the inner surface of the component. As the body is retracted from the component, a diameter measurement of the inner surface is displayed on a human-machine interface wirelessly connected to the body. The device is calibrated such that the electrical signal provided by the sensor assembly is correlated with the diameter measurement. The maximum diameter dimension between the sliding portion and the wheel assembly is set to match the inner surface to be measured. The body is inserted into the stator. The diameter of the inner surface is measured as the body is retracted from the stator. The minimum diameter of the inner surface of the stator is determined. The rotor dimensions for the stator are determined based on one or more of the diameter measurements obtained as the body is retracted from the stator.

[0037] We will now describe in more detail some of the many possible embodiments of the apparatus and methods that can be used to implement the invention taught herein, with reference to the accompanying drawings. Specifically, Figure 3A and 3B An improved device 300 is shown for detecting a downhole motor power system, and specifically for detecting the stator bore.

[0038] In the illustrated embodiment, device 300 includes a handle element 310, which in some embodiments may house battery-operated electronics useful in the operation of device 300 and one or more rechargeable batteries for powering the electronics.

[0039] Despite Figure 3A As not shown in 3B, however, device 300 may also be used with a human-machine interface. This human-machine interface may take many forms, including but not limited to: a dedicated device comprising a screen and interface circuitry connected to device 300 via a wired or wireless link (e.g., Bluetooth, RF, IR, etc.); a general-purpose programming computer connected to device 300 via a wired or wireless link; or a handheld device, such as a desktop phone or smartphone (e.g., Android or iOS services), designed to operate for a dedicated application of device 300. Other forms of human-machine interfaces may be used without departing from the teachings herein.

[0040] exist Figure 3A and 3B In this example, the handle element 310 also includes a button 312 for powering on or off the electronics within the housing. The handle element 310 can be made of any suitable material. Figure 3A and 3B In one embodiment, it is made of molded plastic.

[0041] In the example shown, the handle element 310 is connected to the handle tube 40. The handle tube is sized to fit within the smallest stator bore to be inspected using the device 300. For inspecting shorter sections of the downhole power drill string stator, the handle tube can be long enough to allow the detection element of the device 300 (described below) to extend into the stator bore to be inspected, such that the detection element can be positioned at one open end of the stator bore (or just outside it), and the handle element 310 can be positioned outside the other open end of the stator bore, with the handle tube 314 extending through the stator bore therebetween. In other embodiments, for use with longer sections of the stator bore, the handle tube 314 can be sized to allow the detection element to extend to, and preferably beyond, the midpoint of the longest section of the stator bore to be inspected, thereby obtaining measurements along all points of the stator bore by operating the device 300 from both ends of the stator being inspected.

[0042] The handle element 310 is preferably hollow and / or has embedded conductors for transmitting electrical or optical signals from a detection sensor (described below) to electronics within the handle element 310, and / or for transmitting electrical energy from the handle element 310 to the sensor. The electronics within the handle 310 may include one or more storage systems for storing measurement data acquired during use, other relevant data, and / or operating procedures or software for the device 300. The one or more storage systems may include mobile storage systems, such as, but not limited to, USB-based mobile memory; or SD or microSD memory chips. Preferably, but not necessarily, the storage system is configured to allow continuous recording of measurement data. The continuously recorded measurement data can be analyzed quasi-real-time during measurement to provide feedback, or it can be analyzed retrospectively to generate specific reports about the measurement process. Alternatively or optionally, the electronics may include a wireless communication system, such as, but not limited to, the Bluetooth communication standard, configured to transmit streaming or batch measurement data to a website, cloud-based system, computer, and / or remote recording system.

[0043] Furthermore, the electronic device may include one or more sensor feedback systems, including but not limited to circuitry for providing auditory indications to the user of device 300; circuitry for providing visual indications to device 300; circuitry for providing vibration indications to the user of device 300; or any combination of such feedback systems. The purpose of these feedback systems may be to prompt the user of device 300 to observe the position of the device within the stator bore, rather than focusing on a screen or other display of measurement data. This minimizes operator error caused by unintentional movement of the device within the bore (e.g., pushing or jamming the device within the bore).

[0044] The handle element 310 is preferably formed of a substantially raised, lightweight material, such as aluminum or a suitable plastic or composite material. In one embodiment, the handle tube 314 is made of carbon fiber, which makes the element very strong and lightweight.

[0045] The end of the handle tube 314 opposite to the handle element 310 is connected to the detector assembly. In the illustrated embodiment, the detector assembly is formed as three main parts: an end assembly 318, an intermediate assembly 320, and a wheelhouse assembly 322. At a high level, in the illustrated embodiment, the wheelhouse assembly 322 includes a pulley contact element movable in a direction generally perpendicular (i.e., orthogonal) to the longitudinal axis or longitudinal axis of the handle tube 314. For ease of reference, the axis extending along the length of the handle tube 314 is referred to as the longitudinal or “X” axis; the axis representing the movement of the pulley contact element is referred to as the “Y” axis; and the axis perpendicular to the X and Y axes is referred to as the “Z” axis.

[0046] In the illustrated embodiment, a wheeled contact element is mechanically connected to a conveying mechanism and a conveying shaft, thereby converting the general Y-axis movement of the wheeled contact element into X-axis movement of the conveying shaft. In this embodiment, the conveying shaft is connected to a linear sensor, which converts the X-axis movement of the shaft into movement by one or more conductors (made by...). Figure 3B Element 324 (represented in the original text) transmits an electrical signal to the electronics in the handle element 310. Generally, during operation, the device is energized, calibrated (optionally), and then the detector assembly is inserted into and removed from the stator bore of the stator to be probed. As the gauge is inserted into and / or removed from the stator bore, movement of the contact wheel causes the sensor to provide electrical signals to the electronics in the handle assembly, including altered electrical signals. These signals are processed by the electronics to provide useful information relating to the internal conditions of the stator bore, which may include, but is not limited to, the minimum inner diameter dimension.

[0047] Figure 4 Additional details of an example embodiment of the wheel chamber assembly 322, intermediate assembly 320, and end assembly 318 are shown. For illustrative purposes, wires extending from the sensor in the end assembly 318 are not shown. In the example embodiment, the main components of the wheel chamber assembly 322, intermediate assembly 320, and end assembly 318 are all formed of metal.

[0048] First refer to Figure 4 The chamber assembly 322 includes a chamber housing 402 and a contact wheel 404 movable along an axis perpendicular to the longitudinal axis of the chamber assembly 322. As shown, the contact wheel 404 is designed such that it rotates in the insertion / removal direction when the detector assembly is inserted into and removed from the stator bore for probing. Figure 4As shown, the contact wheel 404 is connected to a conveyor shaft 406, which moves back and forth along the longitudinal axis (i.e., along the X-axis) of the detector assembly as the contact wheel 404 moves along the Y-axis. As shown, in the illustrated embodiment, the conveyor shaft 406 has sufficient length to extend through a hollow hole formed inside the intermediate assembly 320.

[0049] Figures 5A-5F The example wheel chamber assembly 322 is shown in more detail. In some of these figures, the wheel chamber housing 402 is shown as transparent, thus revealing the internal components.

[0050] like Figure 5A , 5B As shown in 5C, 5D, and 5F, the wheel chamber assembly 322 includes a main wheel chamber housing 402, which defines an open cavity. A first component or element 502 is disposed in this cavity, one end of which is fixed to the wheel chamber housing 402 (by means of a mounting pin 518 or other suitable mechanism), while the other end is connected to a contact wheel 404. The element 502 is connected to the wheel chamber housing 402 and the contact wheel 404 such that this end of the element 502 is fixed in the wheel chamber housing and cannot move along the X direction 520, but can rotate through the interior of the stator bore of the contact wheel 404 as the contact wheel 404 moves up and down, pivoting as the other end of the element 502 arcs about a fixed point generally along the Y axis 522.

[0051] A second component or element 504 is also connected to the contact wheel 404. This second element 504 has one end connected to the contact wheel and another end, which is not fixed relative to the X-axis 520 and is connected to one end of the conveyor shaft 406. As shown, movement of the contact wheel 404 generally in the Y direction 522 causes the conveyor shaft to move in the X direction 520.

[0052] exist Figure 5A , 5B In the specific embodiments shown in 5C and 5D, the relationship between a given increment of movement of the contact wheel 404 in the Y direction and the resulting movement of the conveyor shaft in the X direction is not necessarily the same, and the amount of X movement of the shaft obtainable for a given increment of Y movement 522 is not necessarily constant, but varies based on the actual position of the contact wheel 404 and the first and second elements 502 and 504 in the increment of movement. Therefore, to ensure accurate measurement, the device may generally be initially characterized by reflecting a specific relationship between the Y movement of the contact wheel 404 and the X movement 520 of the conveyor shaft 406. An exemplary initial calibration method is described below.

[0053] refer to Figure 5A and 5B As can be seen, the conveyor shaft 406 extends into and through the intermediate assembly 320. In the example shown, sleeve assemblies 506 and 508 are provided to facilitate smooth movement of the conveyor shaft 406. The intermediate assembly 320 can be connected to the wheel chamber assembly 322 in any suitable manner. In the embodiment described herein, the connection is achieved by a threaded connection, wherein the protruding threaded end of the intermediate assembly 320 is received in a threaded socket of the end assembly 322.

[0054] Best place Figure 5B As shown, the end of the conveyor shaft 406 extends through the intermediate assembly 320 and is generally adjacent to the linear sensor 510 disposed in the intermediate assembly 318. It should be noted that... Figure 5B In the illustration, the conveyor shaft 406 is shown as not actually contacting the sensor 510. However, in any actual implementation, the end of the shaft will likely actually be in contact with the end of the sensor.

[0055] exist Figures 5A-5D In one embodiment, the linear sensor 510 applies a force along the X-direction that tends to move the contact wheel 404 toward its furthest point from the wheel housing 402 on the Y-axis. In many embodiments, this force is sufficient to move the contact wheel 404 to its “outermost” position along the Y-axis (which is typically the position when the detector assembly is outside the stator bore) without applying pressure to it. In other embodiments, such as... Figures 5A-5C In the embodiment shown, a recoil spring, such as spring 512, may be used to ensure that the contact wheel 404 is properly biased.

[0056] In an alternative implementation, a single recoil spring may not be sufficient to properly bias the contact wheel and ensure that the wheel is pressed against the inner diameter of the stator bore to be inspected with appropriate force. In this application, an external bias spring can be used (alone or in combination with a recoil spring) to control and adjust the bias of the contact wheel.

[0057] Figure 5E An exemplary method for adjusting the bias of contact wheel 404 is shown. Figure 5EIn this embodiment, an external bias spring 514 and a rotatable collar 516 are provided. The external bias spring tends to apply a force to the aforementioned contact wheel mechanism to bias the contact wheel 4404 away from the body of the device. By adjusting the force provided by the external spring 514, the user can increase or decrease the bias force provided to the contact wheel 404, and thus the force by which the wheel 404 contacts the inner diameter of the stator bore to be detected. The bias force provided by the external spring can be adjusted in at least two ways. In one way, the external spring 514 can be selected to provide the desired bias force, and if a different bias force is required, the initially used spring can be removed and replaced. In another embodiment, a single bias spring can be used, and the collar 516 can be adjusted to compress or decompress the spring 514, and thus adjust the bias force provided by the spring. Other foreseeable alternatives for adjusting the spring force include using multiple replaceable springs individually, or in combination with an adjustment mechanism such as the collar 516.

[0058] In the example shown, the internal spring and kick spring 512 in sensor element 510 combine to apply a compressive force to the inner surface of the stator bore when the contact wheel 404 contacts the inner surface of the stator bore. In a preferred embodiment, the sensor spring and kick spring are configured such that the maximum force provided by the contact wheel 404 against the inner surface of the stator bore is below a level that could cause permanent deformation of the stator bore. The precise level of force that deforms the inner stator bore can vary based on the material used to form the bore. In a preferred embodiment with a stator bore material, this assembly is configured such that the maximum compressive force provided by the contact wheel to the inner stator bore of the stator is 0.3 pounds or less.

[0059] Figure 5F Another of the many possible embodiments of the invention is shown, in which an angular displacement sensor 524 is used instead of the linear displacement sensor 510 of the previous embodiments. Figure 5F A contact wheel 404 is shown rotatably connected to the end of an arm or bracket 502, which is operatively connected to an angle sensor 524, for example, via a pin or conveyor shaft 526. It should be understood that as the wheel rotates about the pin 526 (i.e., moves generally in the Y-axis direction 522), the angle sensor converts this movement into a signal representing Y-axis displacement. Furthermore, as... Figure 5F As shown, biasing element 528, such as a spring, is configured to bias the contact wheel to its outermost position, as described above with respect to the linear sensor embodiment. Optionally, angle sensor 524 may have a biasing element integrally formed with the sensor body.

[0060] As shown in the figure, a wheel chamber cover 512 can be provided to cover and protect the internal components of the wheel chamber assembly 322 and control the movement of the contact wheel 404 and the first and second components 502 and 504. The advantage of controlling the movement of the contact wheel is that minimizing the amount of movement of the contact wheel 404 improves accuracy.

[0061] In some embodiments, only the minimum inner diameter of the stator bore can be measured. In such an embodiment, the cover 512 may cooperate with the contact wheel 404 and the first and second components 502 and 504 to allow the contact wheel to contact the interior of the stator when it is at or near the minimum inner diameter of the stator bore, but not at other times. In such an embodiment, the movement of the contact wheel may allow a maximum movement of approximately 0.200 inches from its point of maximum distance along the Y-axis from the end assembly 322 to its minimum distance along the same axis.

[0062] One advantage of using contact wheel 404 and related components, such as components 502 and 504, is that it allows the device to independently measure each of the multiple smallest inner diameters of the stator bore simply by moving the contact wheel assembly 404 over the inner bore. This is because the contact wheel is sized such that the contact point between the contact wheel and the interior of the stator bore is only a small percentage of the total distance of a conventional stator lobe along the X-axis. This allows the device described herein to measure each lobe individually as it is pulled through the stator bore. In one embodiment, contact wheel 404 and related components allow measurements at a resolution of approximately 3 / 1000 inch or less. In another embodiment, measurements are performed at a resolution of 1 / 10,000 inch. These resolutions are substantially smaller than the size of a conventional lobe in the stator bore.

[0063] Another advantage of using contact wheel 404 and components that convert the movement of the contact wheel into the movement of a conveyor shaft, such as shaft 406 or 526, is that it allows for rapid and efficient measurements. Instead of moving the probe to discontinuous positions along the stator bore and actuating the probe at these discontinuous positions, the contact wheel can move within the stator bore and measurements can be performed continuously as the contact wheel passes through the stator interior. As described above, these continuous measurements can be recorded in one or more storage systems associated with device 300, or can be transmitted (wired or wirelessly) to a remote recording system.

[0064] The intermediate component 320 can be connected to the end component in any suitable manner. Since it is advantageous to detach the intermediate component from the end component to allow for the detection, maintenance, and replacement of the sensor 510 in the end component, an embodiment that allows easy separation of the intermediate component 320 from the end component 318 is foreseeable. Figure 5BThis embodiment is illustrated in the figure. As shown, in the illustrated embodiment, the intermediate component 320 (shown as transparent) includes a protrusion extending into a cavity of the end component 318 (also shown as transparent). A groove 520 is formed in the protrusion, and one or more screws pass through an opening in the end component 318 to engage with the groove and hold the intermediate component 320 and the end component 318 together.

[0065] exist Figure 5B In this embodiment, the tension of the connecting screw can hold the intermediate component 320 in a fixed relationship relative to the end component 318, thus preventing relative movement between the two components, or it can be configured to allow full or limited rotational movement between the two components (e.g., movement about the Z-axis but not along the X-axis). This embodiment may be necessary in applications where rotational movement of the handle is desired. Allowing some rotational movement between the intermediate component 320 and the end component 318 can mitigate any rotational movement of the handle as it moves toward the contact wheel 404, and minimize the impact of this rotational movement of the handle element 310 on measurements taken from the center wheel.

[0066] Figure 6A and 6B Details of the end assembly are shown. For illustrative purposes, the main housing 602 of the end assembly is shown as transparent.

[0067] refer to Figure 6A and 6B The end assembly includes a locating pin or pin 604, which is positioned in a fixed position within the end assembly 318. Abutting against the locating pin 604 is the end of a locating element 606, which includes a shaft abutting against the locating pin 604 and an opening slot at the other end. Set within the opening slot of the locating element 606 is a linear probe 608 with a movable end. The linear probe 608 can be any probe capable of converting movement along an axis into a digital or electronic signal. In one embodiment, the probe 608 can be a #DK812SBR5 probe, available from Magnescale Americas, Inc., which has a 12mm stroke, 0.5-micron resolution, and a response speed of approximately 100 m / min.

[0068] The end assembly may also include one or more temperature sensors configured to convert the actual ambient temperature of the end assembly into a signal (electrical or optical) that can be used by device-associated electronics (e.g., circuitry in the handle). Suitable temperature sensors include, but are not limited to, thermocouple sensors, resistance thermometers (RTDs); infrared sensors; thermistors; silicon bandgap temperature sensors; or combinations thereof. Temperature measurement may, but is not required to, be a direct or indirect continuous recording of the measurement data. It should be understood that the operating temperature of the end assembly can be used to correct or calibrate the measurement data in real time or retrospectively.

[0069] The end assembly may also include one or more cameras or other vision sensors configured to "see" the area of ​​the stator that is actually being measured, has been measured, or will be measured. In one such embodiment, a real-time video signal is provided to the handle, and a video transmission cable transmits the signal from the handle to a processing and / or display system. Optionally, the handle (as described herein) may include a vision display capable of displaying the video captured by the end assembly. Furthermore, the video signal may be continuously recorded as described above regarding measurement data and temperature data. It should be understood that "still" shots may be captured in lieu of video or as a supplement to video. It should be understood that one embodiment of device 300 may capture a snapshot of the stator bore when a predetermined event occurs, such as a minimum measurement value, a measurement value "jumping," or other abnormal or anomalous measurement value.

[0070] The end assembly 318 can be connected to the handle tube 314 in any suitable manner. In one embodiment, the connection is such that relative movement on another axis between the end assembly 318 and the handle tube 314 is permitted. Allowing this relative movement is advantageous because if such relative movement is not permitted, then any movement (even slight unintentional movement) of the handle assembly 310 by the operator will affect the measurements performed by the detection components.

[0071] Figure 7A An exemplary connection configuration is shown for connecting the handle tube 314 to the end assembly 318, such that the handle tube 314 is movable relative to the end assembly 318. Reference Figure 7AThe illustrated connection includes a "ball-and-socket" assembly comprising two spherical washers 702 and 704 sized to mate within a receiving cavity of end assembly 318. These two spherical washers 702 and 704 are positioned around a ball joint element 706, one end of which is fixedly connected to a handle tube 314. In the illustrated example, the ball joint element 706 defines one or more generally cylindrical voids, and the end assembly 318 defines a threaded opening 708 capable of receiving a screw 710. In this example, the outer diameter of the screw 710 is smaller than the inner diameter of the cylindrical void 712, thereby allowing the ball joint element 318 and therefore the tubular handle 314 to move relative to the end assembly 318. In the illustrated embodiment, an open ring 714 mates in a slot in the end assembly 318 to hold the two components together.

[0072] Other optional connection means that allow relative movement between the end assembly 318 and the handle tube 314. For example, a U-shaped connector may be used to provide this connection in a foreseeable embodiment. Figure 7B One such optional connection is shown. Figure 7B In an exemplary embodiment, a U-shaped connector is disposed between the end assembly 318 and the handle tube 314. Referring to the drawings, the illustrated U-shaped connector includes a first element 716 connected to the handle tube 314 and an intermediate element 718 connected to the first element 716, such that the first element 716 is pivotable relative to the intermediate element 718 about a first axis. The illustrated connection also includes a second element 720 connected to the intermediate element 718. The second element 718 is connected to the end assembly 318. The second element 720 is connected to the intermediate element 718 in such a manner that the second element 720 is pivotable relative to the intermediate element 718 along a second axis. In the illustrated embodiment, the second axis is perpendicular to the first axis.

[0073] Further optional connections for connecting the handle end 314 to the end assembly 318 are foreseeable. For example, they can be used in... Figure 7B Only one of the pivot connections shown.

[0074] For a stator inner hole of a specific size, in Figure 3A and 3BThe device shown can be used to inspect the interior of a stator bore. For larger bores, an expansion shoe can be used in conjunction with the device. One purpose of using the expansion shoe is to ensure that the contact wheel is properly positioned relative to the interior of the stator bore to be measured. Generally, the contact wheel should be positioned such that the maximum deflection of the contact wheel is small and less than about 1 / 10 inch. In a preferred embodiment, the contact wheel and associated structure are such that the maximum deflection of the wheel is about 75 / 1000 inch.

[0075] Figure 8A A nose assembly 802 is shown that can be used to allow efficient connection between expansion struts of different sizes and devices.

[0076] refer to Figure 8A The nose assembly 802 is connected to the end of the wheel chamber assembly 322 via a screw element 804 received in the wheel chamber assembly. The nose assembly 802 includes a helical nose 806, a drive nut 808, and a locating pin 810, the ends of which protrude from each side of the drive nut. By rotating the helical nose, the drive nut can move back and forth along the longitudinal axis of the wheel chamber assembly 322, thereby causing the locating pin 810 to move relative to the wheel chamber assembly. A second locating pin 812, located at a fixed position on the end assembly 318, is not present. Figure 8A As shown in the image.

[0077] Figure 8B A first type of expansion brace 814 is shown, which can be used to allow the device 300 to be used in a stator bore with a small diameter. The brace 814 is a tubular element with fork-like openings at each end, sized to receive locating pins 810 and 812. In use, the brace 814 slides on the detector assembly before being connected to the nose assembly 802. One of the fork-like ends is then connected to the locating pin on the end assembly 318, and then the nose assembly 802 is connected to the wheel chamber assembly 322. By adjusting the threaded nose 806, the drive nut 810 is activated, and thus the locating pin 810 is moved inward toward the brace 814 until the pin 810 engages with and holds the fork-like end of the brace 810 in position. Alternatively, the nose assembly may define a conical element that is driven into the bore of the brace to hold it in position.

[0078] Figure 8CAnother embodiment of the expansion brace that can be used in device 300 is shown. The expansion brace 816 shown is a slide on an expansion brace that can be used for stator bores with a relatively intermediate diameter. As shown, the expansion brace 816 defines receiving portions 818 and 820 sized to receive locating pins 810 and 812. In use, the brace 816 is slid onto the device so that receiving portions 88a and 88b substantially receive the locating pins or wedges 810 and 812. The nose assembly is then adjusted by removing the pins 810 from the brace 816 until the brace is securely positioned relative to the detector assembly. In cases where large-diameter stator bores are being probed, or where additional support is required, a support rod can be connected between the handle element 310 and the handle tube 314.

[0079] In general, the brace and / or bar should be sized to ensure that the gap between the outer surface of the device opposite the brace and the minimum size of the stator bore is less than a predetermined amount, in one embodiment 50 / 1000 inch. Providing this small gap tends to ensure that the device is properly aligned when inserted into the stator bore and during the pulling of the device through the stator bore. This alignment method ensures that measurements taken by the device when pulled through the stator bore are constant between different users and between different repeated measurements by the same user. For example, when the device / brace is sized to ensure the aforementioned maximum distance is 50 / 10000 inch or less, the error level of repeated measurements is expected to be within 3 / 1000 to 5 / 1000.

[0080] In the above situation, the device and support are sized to ensure that the distance to the preferred minimum inner diameter is less than a predetermined amount. Measurements indicating that the distance is greater than this amount can indicate or suggest wear or other problems in the inner diameter of the stator being probed, and measurements above this range can cause the inner diameter to fail to be probed.

[0081] Figure 8D Another support design is shown, which is used for a stator inner bore with a larger diameter. The support 822 shown includes mounting plates (824 and 826), which include components related to the above. Figure 8C The similar receiving section is attached. Connected to the mounting plate are multiple struts 828, 830, and 832, designed to position the struts within the stator bore. To minimize weight, these struts 828, 830, and 832 can be made of carbon fiber.

[0082] Figure 8EAn alternative method for connecting a support to a detector assembly is shown. In this alternative method, portions of the detector assembly define notches such as notches 834 and 836. The support is fitted with protruding elements 840, 842, which are shaped to fit into the notches or wedges. In operation, the support is placed in the desired position and then the nose assembly is adjusted to hold the support in place.

[0083] Figure 8F and 8G Another embodiment is shown that allows for the probing of bores of different sizes without the need for connecting supports. In this embodiment, a scissor-type assembly 844 is connected to a detection assembly connected to a handle tube 314. The scissor-type assembly includes a central component and multiple rods (four in this example) connected to the central component via scissor-type connectors. The scissor-type connectors can be adjusted by a fixed setting, operation of elements (e.g., screws) in the intermediate component, or any other suitable method to extend to the size required for suitable probing of various stator bores.

[0084] In a preferred design, the diameter of the strut or struts is carefully selected to closely correspond to the ideal maximum inner diameter of the stator bore to be probed. This close fit between the outer diameter of the strut / struts and the ideal inner diameter of the stator tends to ensure that the probe assembly is generally in proper axial alignment. This allows the operator to use the disclosed device by simply inserting it into the stator to be probed and pulling it out through the stator bore without any twisting or rotation of the device. The ability of the device to allow proper proberization without twisting or rotating the device, and to ensure proper axial alignment with minimal or no user effort, guarantees more accurate and efficient proberization. This also ensures appropriate measurements and consistency between different operators or between the same operator and different proberizations.

[0085] When a large-diameter stator bore is to be inspected, or when additional support is required to support a strut or another device to allow the device described herein to be used for bores of different sizes, the strut may be connected between the handle element 310 and the handle tube 314. Figure 8D The use of support bar 814 is shown.

[0086] It should be understood that the embodiment described in device 300 is merely one possible implementation of the subject matter disclosed and claimed herein, and other designs are possible. For example, the detector assembly shown and illustrated has three parts—a wheel chamber assembly 322, an intermediate assembly 320, and an end assembly 318. The detector can be constructed as a single element or as an element having more parts than described above. Furthermore, in some embodiments, different forms of sensing devices can be used. As an example, in the sensor described, the contact wheel moves in the Y direction and the sensor moves in the X direction. An embodiment in which the sensor is aligned with the contact wheel (other movable element) is foreseeable, such that both the movable element and the sensor move in the Y direction without requiring the conversion of movement of the movable element in one direction into movement of the sensor in the other direction. Still additionally, other methods and approaches can be used to connect the handle tube to the end assembly of the detector (or to a single detector assembly), and embodiments in which the handle tube is integrally formed with the detector assembly are foreseeable. As yet another example, embodiments without a handle or handle tube are foreseeable, wherein the device is connected to the sensor element by one or more wires, and wherein the detector assembly is pulled through the stator bore to be probed by a connecting wire. This implementation can be used in situations where a compact device is required and / or where the length of the stator inner bore to be tested is difficult to find a handle tube of suitable length.

[0087] Based on the above embodiments, it should be understood that all or some of the electronic devices described above may be disposed on the detector assembly itself, rather than on the handle. Additionally, some electronic devices, such as data acquisition systems and data transmission systems (wired or wireless), may be disposed on the detector assembly, while other electronic devices, such as processing electronic devices, may be remotely disposed.

[0088] In another embodiment, the housing containing optical elements and a laser or focusing light source can be used to detect the outer contour of the stator inner hole being probed.

[0089] Communication between the device and the human-machine interface can be provided in other ways. In one embodiment, a Bluetooth connection can be established between the device and a programming personal computer or laptop. In an alternative embodiment, a wired connection can be used. Other embodiments are foreseeable, in which the device does not provide any immediate readable output, but instead stores data in a storage device (e.g., an SD memory card), so that the stored data can later be accessed by another device (e.g., a remote computer).

[0090] Figure 9A The handle assembly 310 is shown in more detail. As described above, the handle assembly includes a body that can be sized to include electronics for the device and a battery for powering the electronics, and provides a handle for the user. Figure 9AIn the embodiment shown, the handle device 310 includes a power button 312 and a trigger button 902. The power button is used to power on and off the device, and the trigger button 902 can be pressed to cause the device 300 to start measurement readings.

[0091] The device can detect the inner diameter of the stator of a downhole power drill bit in a variety of ways. According to a preferred method of one example, the method of using the system may include an initial characterization step, wherein the precise relationship between the Y-movement of the contact wheel and the X-movement of the delivery shaft (and therefore the delivery shaft) is characterized by actual measurements relevant to the specific device, and then the characterization data is stored in the electronics of the device.

[0092] As described above, the relationship between the Y-movement of the contact wheel and the X-movement of the conveyor shaft (and therefore the sensor) is not linear and can vary depending on the positions of the contact wheel and the conveyor shaft. Furthermore, due to manufacturing tolerances, the precise relationship between the Y-movement of the contact wheel and the conveyor shaft (sensor) can vary slightly between devices. With this in mind, devices constructed according to the teachings herein can be characterized after assembly by taking into account actual X-to-Y position readings at several positions of the contact wheel. These position measurements, combined with some extrapolation, can be used to form a specific X-to-Y curve for a particular unit, and this curve can be used to accurately convert the specific X readings from the sensor into the specific Y position of the contact wheel.

[0093] Since the physical characterization of a given device is not expected to change perceptibly over the device's lifespan, this characterization step is likely to need to be performed only once for each device. However, additional characterization steps may be required or demanded as the device wears out or if the device is altered or its components are changed or replaced (e.g., if the sensor is replaced).

[0094] In the absence of characterization of individual devices, representative X-to-Y characterization curves can be used, pre-programmed, or pre-stored in the devices. Figure 9B An example of a contact wheel displacement versus X-axis displacement curve for an embodiment of the invention using a linear sensor 510 is shown. As shown, the relationship between the movement of the contact wheel 404 and the displacement along the X-axis 520 (e.g., the displacement of the transport shaft 406) is not linear. In this X-to-Y relationship, the first part of the curve may show greater sensitivity than the latter part. When designing a stator bore gauge using one or more aspects of the invention disclosed herein, this nonlinearity and altered sensitivity can be considered. For example, but not limitingly, the support or sled used for the gauge may be sized such that the desired minimum diameter of the stator bore appears in the region of high sensitivity.

[0095] Once the device is characterized, or the X-to-Y curve is otherwise stored or programmed into the device, it can be placed in the field for use. In field use, the device can be used according to a method that typically includes the following steps: (1) identifying the required dimensions of the stator to be probed; (2) determining whether any expansion braces are needed for probed, and if so, selecting and installing suitable expansion braces; (3) identifying suitable setup criteria associated with the stator to be probed; (4) calibrating component 20 using the selected setup criteria, and then (5) probing one or more stator bores of the same expected dimensions using the calibration device. This process can be facilitated by using a human-machine interface, in the example shown, which is a smartphone based on the Android system.

[0096] Figures 10A-10H A screenshot of an example human-machine interface in the form of a laptop connected to device 300 via a wired or wireless link is shown, which helps to illustrate the process of using the device described herein.

[0097] Initially, in Figure 10A In this system, a standard device is associated with a specific desired inner diameter, and each standard is assigned a specific serial number. The standard should be manufactured with tightness tolerance so that the inner diameter of the standard closely matches the standard size associated with that standard.

[0098] Once the desired standard is relevant to various bore diameters to be measured, the user can input the desired bore diameter into the human-machine interface and be provided with instructions on which standard to use. This is in... Figure 10B The diagram illustrates a process where the user inputs the optimal bore diameter (1,500 inches in this example) for the device to be probed into the human-machine interface (HMI), and the HMI provides indications of standards (or multiple standards) that can be used for probes. In the example shown, standards labeled 1002, 1004, and 1006 are relevant to the input bore diameter and are applicable for the purpose of probes. At this step, the HMI may also indicate whether a support attachment should be used, and if so, which type of support to use.

[0099] After selecting a suitable standard, the stator inner bore gauge should be calibrated. This calibration process should begin initially at... Figure 10C As shown in the image. (Reference) Figure 10C The human-machine interface initially requires the operator to input data related to the specific pump / motor being probed, the operator, and the temperature. Once this data is entered, the user is prompted to move the gauge past the standard until the maximum reading corresponding to the standard's maximum inner diameter is detected. This is in... Figure 10D and 10E As shown in the image.

[0100] Once the device is calibrated, for example, Figure 9B As shown, the detection part of the device (e.g., the part with the contact wheel) and any support are inserted into the stator bore to be tested. The device is then triggered, and the user pulls the device through the bore. The device then performs measurements and records the maximum readings (or, optionally, the minimum readings). This is in Figure 10F and 10G As shown in the diagram. These readings are then output to... Figure 10H The readable file shown.

[0101] Figure 10E The diagram illustrates the use of the aforementioned device to probe a specific stator bore. As shown, the specific device can first be identified by the user entering a serial number associated with it. Alternatively, this identification information can be obtained via a barcode or other scannable information. In addition to the input identification information, other information about the device being probed (e.g., compound, tolerance, etc.) can be added.

[0102] After the identification information associated with the device being probed is input into the human-machine interface, the device can be inserted into the stator bore, the measurement button (or trigger) is pressed, and the device sweeps across the gauge, so that the contact wheel sweeps across all or part of the stator bore being probed. The device can then generate a report representing each detected small diameter and, for each small diameter, generate information related to: (i) the deviation from the reference position formed during the calibration process, and (ii) the actual calculated minimum diameter. This is in Figure 10G This is reflected in the image. The process can be repeated for accuracy and / or, for longer stator bores, repeated from the other side of the bore.

[0103] Figure 11A-11F A screenshot of an example human-machine interface from a smartphone device is shown, which helps to illustrate the process of using the device described herein. This process is related to the above regarding... Figures 10A-10H The process is similar. At the initial point, such as... Figure 11A As shown, the device is calibrated for probing stators of a specific size. The process may include, for example... Figure 11A The location shown actually begins the calibration process, and then the specific model of the stator inner hole to be tested is selected, such as... Figure 11B As shown in the illustration. In the illustrated embodiment, once the stator bore model to be probed is selected, the human-machine interface can perform a search and provide the user with visual indications for a specific support (or other sizing adjuster) to allow proper probement of the required stator bore size. This is in Figure 11C As shown in the image.

[0104] Once a suitable support (or other dimensional adjustment device) has been selected and properly connected, the sensing part of the device (e.g., the part with the contact wheel) is inserted into a gauge corresponding to the nominal size of the stator bore being probed. The device is then moved back and forth until the maximum reading of the gauge is obtained. This is achieved by positioning the gauge at one of the smallest diameter positions of the stator bore. Figure 11D As shown, an image can be provided to allow the user to correctly locate the maximum position. Once the device is properly positioned and the maximum reading is obtained, the device can be calibrated by the user pressing the measurement trigger during the calibration phase, pressing a separate calibration button, or interacting with the human-machine interface.

[0105] In the example described, the calibration of the device essentially establishes a zero reference for the device. Once the device is calibrated, a differential measurement is available, reflecting the degree of deviation from the reference point established during the calibration process. Generally, a calibration process should be performed when a device calibrated for one stator size is used for another size, and each time the device is powered on, although calibration for each power-on may be unnecessary if the device is used to probe a stator of the same nominal size.

[0106] Figure 11E The diagram illustrates the use of the aforementioned device to probe a specific stator bore. As shown, the device can first be identified, for example, by the user entering a serial number associated with the device. Optionally, the identification information can be obtained via barcode or other scanning information. In addition to the input identification information, other information related to the device being probed (e.g., compound, tolerance, etc.) can be added.

[0107] After the identification information of the device used for the probe is input into the human-machine interface, the device can be inserted into the stator bore, the measuring button (or trigger) is pressed, and the device sweeps across the gauge, so that the contact wheel sweeps across all or part of the stator bore being probed. The device can then generate a report representing each detected small diameter, and for each small diameter, generate information related to: (i) the deviation from the reference position formed during the calibration process, and (ii) the actual calculated minimum diameter. This is in Figure 11F This is reflected in the process. The process can be repeated for accuracy, and / or, for longer stator bores, repeated from the other side of the bore.

[0108] Figure 12 An alternative implementation is shown, in which the human-machine interface takes the form of a smartphone, and the handle assembly 310 is in the form of a pistol grip 1202 and includes a bracket 1204 for mounting the smartphone device. Other alternative configurations of the device are foreseeable.

[0109] exist Figures 13A-13D An example procedure for identifying the smallest diameter point in the stator bore is shown in the figure. Figures 13A-13D The process is illustrated using a linear sensor 510 or an angle sensor 524, which provides a signal (e.g., a digital output) corresponding to a specific position at the end of the probe. Figures 13A-13D In the example, the probe makes it suitable for use in the above arrangement (e.g., in combination with...) Figure 5B The signal can reach its peak value when the contact wheel corresponds to the smallest point of the stator inner hole. Although Figures 13A-13D The process shown involves pushing the gauge through the stator bore; however, it should be understood that the gauge according to the invention can be pushed and / or pulled through the stator bore.

[0110] As described above Figures 5A-5C As stated above, and with reference to Figures 13A-13D The contact wheel 404 and related elements (e.g., components 502, 504, 406, and 512) enable the contact wheel to contact a portion of the stator's inner diameter, and prevent it from contacting the corresponding portion of the stator's maximum diameter, which may be obstructed by multiple elements. Optionally, the contact wheel may be allowed to contact all surfaces of the stator's inner bore to provide the minimum, maximum, and all diameters in between. Thus, as the contact wheel 404 is pulled through the surface of the stator's inner bore, the count can be achieved at an example point 1302 ( Figure 13A The point at which the contact wheel does not contact the stator inner bore is the minimum point, but it is within the range mentioned above. Figures 5B-5C (Or, the fixed point created by the configuration described above, in contact with the maximum diameter). As the device sweeps through the inner bore, point 1304 can be reached. Figure 13B The contact wheel contacts the interior of the stator bore, and the operation of the device begins to move the end 404 of the linear probe. At this point, the count output from the probe can begin to increase. Due to the sensitivity of the probe and the non-uniformity of the bore, this count may not increase smoothly and may vary due to small imperfections on the surface of the stator bore. As the wheel contacts roll across the stator bore, it may finally contact point 1306. Figure 13C This is typically related to the maximum count / number of the corresponding stator's minimum diameter. Subsequently, as the device passes through the inner bore and the diameter increases by 1308 ( Figure 13D The probe count may begin to decrease, and the count may change again due to a small defect in the stator bore.

[0111] In one implementation, the device (e.g., electronics in the handle end) monitors the values ​​from the probe and: (i) seeks a peak value 1306, and (ii) if no intervening peak value is reached, seeks a point 1308 where the count is a certain amount below the peak value. Once the count falls from the peak value 1306 to point 1308 or 1304, a certain amount below the peak value, in the absence of another intervening peak, the device determines that the true peak count (corresponding to the minimum stator bore in the current example) has been reached. This process can be repeated if another intervening peak is reached after the initial peak is detected. In this way, this example can accurately detect the true minimum diameter of the probed stator bore.

[0112] In another implementation, the device first seeks an increase in the value from a point (e.g., zero), such as point 1304, and monitors the system to detect an increase in the count (which occurs as the wheel contacts and rolls through point 1304), followed by a decrease in the count (which occurs as the wheel contacts and rolls through point 1308), and then a second increase in the count (which occurs as the roller moves through point 1310). Upon detecting the second increase in the count, the device then seeks the maximum count that occurs between the first and second increases and associates this maximum count (in this example, the count at point 1306) with the minimum inner bore diameter. As another example, it is expected that as the probe 402 is pushed through the stator inner bore, the sensor signal will increase, indicating a decrease in the inner diameter. These diameter representations may be recorded in a gauge-associated cyclic buffer memory, FIFO buffer, static memory, or transmitted or telemetry and sent to a device or location remote from the gauge. The maximum signal (i.e., the minimum diameter) can be determined based on the signal starting to decrease (which indicates an increase in the stator bore diameter). The maximum value of this stored diameter expression can be found from the recorded values, or alternatively, the maximum value can be calculated by interpolation or other means from the recorded values. Additionally, the recorded data can be used to generate curves or profiles inside the stator bore.

[0113] Once the count corresponding to the minimum diameter is obtained, the device can then use the X-to-Y characterization data and the reference set point to calculate the actual minimum stator bore measurement for each minimum diameter.

[0114] It should be understood that the method described is merely exemplary, and other methods may be used. For example, another method may be used for a linear probe, wherein the count decreases (rather than increases) when the contact wheel approaches the minimum of the stator bore.

[0115] To ensure the precise purpose of the apparatus, it is advantageous to characterize each unit of the apparatus after its assembly and / or after any component of the apparatus has been modified. This is because variations can occur during the manufacture of the components of the apparatus, causing each unit to operate in a slightly different manner than other devices of similar construction. Figure 14 The document illustrates exemplary apparatus and procedures for characterizing a given device. (Reference) Figure 14 The image shows a wheel gauge assembly mounted in a characterization mount. This mount includes a support for securing the wheel gauge assembly in a fixed position and a micron calibration reference 402. The calibration reference 402 includes an extension element that contacts the wheel of the wheel assembly. It can be controlled to provide precise, accurate movement of the extension element, allowing the extension element to move in precise steps of 10 / 10,000 inches or less.

[0116] In order to use Figure 14 The structure of the device is characterized by first moving the extension element of reference device 402 to a near-fully retracted position, causing the wheel to move to or near its fully extended position. The probe value is then zeroed. The extension element then extends in controlled steps (e.g., 10 / 10,000-inch steps), and the probe value is recorded at each step. The relationship between the probe count and the distance from the zero position (as determined by reference device 1402) can be determined by moving the extension element from a position corresponding to the confirmed zero position to a position smaller than the smallest stator bore diameter to be detected by the device. This relationship can be non-linear for various reasons.

[0117] In one embodiment, the distance values ​​and counts from zero are used in a curve fitting algorithm to generate a mathematical formula that provides the distance from zero (along an axis parallel to the movement of the extension element of the reference device) in response to any given probe value. Any suitable curve fitting algorithm will be used to generate this formula. In a second embodiment, the proven distance values ​​are stored in a table or matrix, and the device can use this data to: (i) select the distance value if the proven value corresponds identically to one of the values ​​obtained during the characterization process; or (ii) use an interpolation algorithm to generate estimated distance values ​​by interpolation between data points stored during the characterization process. In both embodiments, the nonlinearity of the device, and the specific distance-probe relationship for each individual device, are addressed, and the accuracy of the measurement is improved.

[0118] The accompanying drawings and descriptions of specific structures and functions are not intended to limit the scope of the applicant's invention or the scope of the appended claims. Rather, the drawings and descriptions are provided to teach those skilled in the art to make and use the claimed invention. Those skilled in the art will understand that, for clarity and understanding purposes, not all features of a commercial implementation of the invention are described or shown. Those skilled in the art will also understand that the development of a practical commercial implementation incorporating features of the invention may require various specific implementation decisions to achieve the developer's ultimate goals for a commercially viable approach. These specific implementation decisions may include, but are not limited to, system-related, business-related, governmental-related, and other limitations, which may vary depending on the specific application, location, and time. While the developer's work may be complex and time-consuming in an absolute sense, such work will ultimately serve as a routine for those skilled in the art who will benefit from this disclosure. It should be understood that the invention disclosed and taught herein is subject to various modifications and alternative forms. Finally, the use of singular terms, etc., does not limit the quantity of items. Furthermore, the use of relational terms in the specification, such as but not limited to “top,” “bottom,” “left,” “right,” “up,” “down,” “upward,” and “downward,” is merely for the purpose of clearly referring to the accompanying drawings in the specification and does not limit the scope of the invention or the appended claims.

[0119] Preferred and other embodiments of the invention have been described in context, but not all embodiments of the invention have been described. The components, sub-components, or functions described with respect to specific embodiments may be combined with any other components, sub-components, or functions described with respect to other specific embodiments. Obvious modifications and changes can be made to the described embodiments by those skilled in the art. The disclosed and undisclosed embodiments do not limit or restrict the scope and application of the invention as made by the applicant, but rather, in accordance with patent law, the applicant intends to fully protect all modifications and improvements falling within the equivalent scope of the appended claims.

Claims

1. An apparatus (300) for determining the diameter of an inner surface, characterized in that include: A detector assembly includes a body, a wheel assembly, and a sensor assembly, wherein the sensor assembly is disposed within the body and connected to the wheel assembly; The wheel assembly is connected to the body such that at least a portion of the wheel assembly protrudes from the body; The body has at least one sliding portion on the side opposite to the wheel assembly for sliding contact with the inner surface; A translation component (314) is connected to the body, the translation component facilitating movement of the body along the inner surface; A human-machine interface, which communicates wirelessly with the main body, and The detector assembly is configured to displace relative to the wheel assembly and the sliding portion in response to a change in the diameter of the inner surface, and the sensor assembly converts the radial movement of the wheel assembly into a signal representing the diameter of the inner surface for wireless communication to the human-machine interface.

2. The apparatus as claimed in claim 1, characterized in that, The wheel assembly is a wheel rotatably connected to a support mechanism configured to convert radial displacement into longitudinal displacement.

3. The apparatus as described in claim 1, characterized in that, The sensor assembly includes a linear displacement sensor.

4. The apparatus as claimed in claim 2, characterized in that, The wheel assembly provides a radial displacement of approximately 0.2 inches relative to the body.

5. The apparatus as claimed in claim 1, characterized in that, The wheel assembly is connected to a biasing element configured to bias the wheel assembly from the body to a maximum radial displacement.

6. The apparatus as claimed in claim 5, characterized in that, The force provided by the biasing element does not cause deformation of the inner surface.

7. The apparatus as claimed in claim 6, characterized in that, The biasing element provides a force of approximately 0.3 pounds or less.

8. The apparatus as claimed in claim 1, characterized in that, The translation assembly also includes a handle and a power source, as well as wires for transmitting signals from the sensor assembly to the handle.

9. The apparatus as claimed in claim 8, characterized in that, The translation component has an adjustable length.

10. The apparatus as claimed in claim 8, characterized in that, The translation component includes one or more joints configured to allow relative movement between the body and the handle.

11. The apparatus as claimed in claim 10, characterized in that, The one or more connectors are ball joints or U-shaped joints.

12. The apparatus as claimed in claim 1, characterized in that, The human-machine interface also includes a visual display configured to display a representation of electrical signals from the sensor components.

13. The apparatus as claimed in claim 12, characterized in that, The human-machine interface is associated with a handle connected to the body.

14. The apparatus as claimed in claim 1, characterized in that, The device is configured to continuously measure the diameter of the inner surface.

15. The apparatus as claimed in claim 1, characterized in that, The body includes one or more detachable supports, each support having a sliding portion.

16. A method for measuring a plurality of inner diameters of the inner surface of a component using the apparatus as described in claim 1, characterized in that... include: The device is calibrated such that the electrical signal provided by the sensor assembly is correlated with the diameter measurement value; The maximum diameter dimension is set between the at least one sliding portion of the body and the wheel assembly to match the inner surface to be measured; Insert the body into the interior of the component; The diameter of the inner surface is measured as the body moves within the component; as well as Determine the minimum diameter of the inner surface of the component.

17. The method as described in claim 16, characterized in that... It also includes a human-machine interface configured to communicate wirelessly with the body and display a diameter measurement of the inner surface when the body is retracted from the component.

18. A method for measuring a plurality of inner diameters of the inner surface of a stator using the apparatus as described in claim 12, characterized in that... include: The device is calibrated such that the electrical signal provided by the sensor assembly is correlated with the diameter measurement value; The at least one sliding portion of the body is configured to match the maximum diameter of the wheel assembly to the inner surface to be measured; Insert the body into the stator; The diameter of the inner surface is measured as the body moves from inside the stator; as well as Determine the minimum diameter of the inner surface of the stator; and The size of the rotor for the stator is determined based on one or more of the diameter measurements obtained when the body is retracted from the stator.

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