Strain gauges for detecting plate strain deformation

Abstract

A bottom hole assembly (BHA) of a drill string includes: a chassis; a plate, the plate coupled to the chassis; and a strain gauge, the strain gauge coupled to the plate. The strain gauge is used to output a signal associated with the strain deformation of the plate. The plate and the chassis can be included in a drill collar that is subjected to strain, and the strain deformation of the drill collar can be transmitted to the chassis and the plate. The plate can be subjected to strain in the form of torsional bending, in-plane bending, out-of-plane bending, axial tension or compression. The plate can include or be coupled to an electronic board having strain gauges to measure different types of strain in isolation from other types of strain.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Patent Application No. 62 / 880,997, filed on July 31, 2019, and entitled “Strain Gauges for Detecting Strain Deformations of a Plate,” and is related to U.S. Patent Application No. 62 / 880,918, filed on July 31, 2019, and entitled “Indirect Detection of Bending of a Collar.” Each of the foregoing is expressly incorporated herein by such reference. Background Art

[0003] Oil and gas industry processes include exploration, drilling, logging, extraction, transportation, refining, retailing, etc. of natural resources such as oil, gas, and water. Natural resources may be located underground, and as such, drilling systems may be used to perform some of the processes. For example, a drilling system may form a wellbore in a formation to discover, observe, analyze, or extract a natural resource.

[0004] While drilling, forces acting on the drilling system may negatively affect the performance of the drilling system. For example, such forces may introduce energy input into the drilling system and generate vibrations or heat (e.g., through friction). When vibrations and heat are generated, some of the input energy is lost and the system will operate at reduced efficiency. The wellbore may also be planned to extend in a particular direction, and the forces acting on the drilling system may affect the trajectory of the drill bit, causing the drill bit to drill a wellbore that deviates from the planned trajectory or path. Summary of the invention

[0005] During the operation of a drilling system to form a wellbore, certain forces may affect components of the drilling system to cause deformation of the components. Therefore, determining the deformation of the components may facilitate determining the forces applied to the components. Due to the cost, complexity, or inherent disadvantages of implementing conventional techniques (e.g., forming channels in drill collars), it may be difficult to use conventional techniques to directly determine the deformation of certain components of the drilling system (such as drill collars) (e.g., by using sensors attached to certain components). Therefore, the currently disclosed systems and methods can indirectly determine the deformation of such components by determining the deformation of alternative components, and then using the determined deformation of alternative components to determine the forces applied to the drilling system and / or set the operation of the drilling system. In some embodiments, the determined forces can then be used to estimate the position or trajectory of the drilling system to facilitate, for example, steering of the drilling system.

[0006] Various improvements to the features mentioned herein may exist with respect to various aspects of the present disclosure. Additional features may also be incorporated into these various aspects as well. These improvements and additional features may exist alone or in any combination. For example, the various features discussed below with respect to one or more of the embodiments shown may be incorporated into any of the various aspects described above of the present disclosure alone or in any combination. Furthermore, the brief overview herein is intended only to familiarize the reader with certain aspects and backgrounds of the embodiments of the present disclosure, without limiting the subject matter claimed for protection.

[0007] A drilling system includes an internal component and a drill collar coupled to and enclosing the internal component. The internal component has a chassis and a strain gauge coupled to the chassis, and the strain gauge can output a signal associated with the strain deformation of the internal component. The coupling of the internal component and the drill collar causes the strain deformation of the drill collar to cause the strain deformation of the internal component.

[0008] A drilling component includes a chassis having a compartment, a rod within the compartment, and a sensor coupled to the rod. The sensor can determine a parameter associated with strain deformation of the rod.

[0009] A bottom hole assembly (BHA) of a drill string includes: a chassis; a controller, the controller being at least partially located within the chassis; a drill collar, the drill collar being coupled to and enclosing at least a portion of the chassis; and a sensor, the sensor being coupled to the chassis and communicatively coupled to the controller. The sensor can transmit a signal indicating a bending strain of the chassis to the controller.

[0010] A BHA of a drill string includes a chassis, a plate coupled to the chassis, and a strain gauge coupled to the plate. The strain gauge is configured to output a signal associated with a strain deformation of the plate.

[0011] A BHA for a drill string includes an electronics board configured to operate the BHA and a strain gauge coupled to the electronics board. The strain gauge transmits a signal indicative of strain deformation to the electronics board so that the electronics board controls the operation of the BHA based at least in part on the signal indicative of the strain deformation.

[0012] A plate in a bottom drilling assembly includes a first surface, a second surface opposite the first surface, and a torsional strain gauge coupled to the first surface or the second surface. Two in-plane bending strain gauges are also each coupled to the first surface or each coupled to the second surface and are located on opposite sides of a centerline of the plate and are simultaneously aligned along a transverse axis of the plate. A first out-of-plane bending strain gauge is coupled to the first surface of the plate along the centerline of the plate, and a second out-of-plane bending strain gauge is coupled to the second surface of the plate along the centerline and is aligned with the first out-of-plane bending strain gauge along a vertical axis of the plate. A first axial strain gauge and a second axial strain gauge are also coupled to the first and second surfaces of the plate, respectively, along the centerline of the plate and are aligned with each other along the vertical axis.

[0013] An electronics board within a bottom drill assembly includes a board. At least one torsional strain gauge, at least one in-plane strain gauge, at least one out-of-plane strain gauge, and at least one axial strain gauge are coupled to the board. The torsional strain gauge measures torsional strain deformation of the board and is isolated from measuring in-plane bending, out-of-plane bending, and axial strain deformation of the board. The in-plane strain gauge measures in-plane bending strain deformation of the board and is isolated from measuring torsion, out-of-plane bending, and axial strain deformation of the board. The out-of-plane strain gauge measures out-of-plane bending strain deformation of the board and is isolated from measuring torsion, in-plane bending, and axial strain deformation of the board. The axial strain gauge measures axial strain deformation of the board and is isolated from measuring torsion, in-plane bending, and out-of-plane bending strain deformation of the board.

[0014] The above summary is not intended to provide a comprehensive description of the features. The present disclosure encompasses various features that are not present in the summary but are described or shown in the specification, drawings or claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to describe the manner in which the above-mentioned and other features of the present disclosure can be obtained, a more particular description will be presented by reference to specific embodiments of the present disclosure shown in the accompanying drawings. The embodiments are described and illustrated in more detail by the accompanying drawings, in which:

[0016] Figure 1 is a schematic diagram of an embodiment of a drilling system having a drill string;

[0017] Figure 2 is a partial cross-sectional view of a bottom hole assembly (BHA) with a drill collar;

[0018] Figure 3 and Figure 4 is a cross-sectional view of a BHA having a strain gauge coupled to a BHA component such as a shunt;

[0019] Figure 5 is a schematic cross-sectional view of a BHA having strain gauges attached to internal components;

[0020] Figure 6 is a schematic cross-sectional view of a BHA having a bottom plate within a drill collar;

[0021] Figure 7 is a schematic cross-sectional view of a BHA having a rod within a chassis compartment, wherein the BHA is experiencing bending;

[0022] Figure 8 is a schematic cross-sectional view of a BHA having a rod within a chassis compartment;

[0023] Fig. 9 When the BHA is bent Figure 8 A schematic cross-sectional view of a BHA;

[0024] Fig.10 is a schematic diagram of a rod located in the chassis compartment and which can be used to determine the bending of the BHA;

[0025] Fig.11 It is along line 11-11 Fig.10 A cross-sectional view of a rod;

[0026] Fig.12 is in a bent configuration Fig.10 Schematic diagram of the rod;

[0027] Fig.13 It is taken along line 13-13 Fig.12 a cross-sectional view of the third rod;

[0028] Fig.14 is a perspective view of a BHA having an electronic board with a plurality of strain sensors;

[0029] Fig.15 is a top view of an electronics board of a BHA, wherein a plurality of strain sensors are attached to the electronics board;

[0030] Fig.16 It is a bottom view of the electronic board of the BHA, and has multiple strain sensors;

[0031] Fig.17 is a graph of the strain of different components of the BHA over time;

[0032] Fig.18 is a side cross-sectional view of a BHA having a strain sensor coupled to a component other than an electronics board;

[0033] Fig.19 is a perspective view of a BHA having strain gauges coupled to a flexure plate responsive to torsional strain;

[0034] Fig. 20 is a top view of a strain gauge coupled to a cross-plate responsive to torsional strain;

[0035] Fig.21 is a perspective view of a three-dimensional plate used to measure bending about multiple axes;

[0036] Fig. 22 and Fig.23 It is used to measure around Fig.21 Schematic diagram of the strain gauge circuit for bending of the axis;

[0037] Fig.24 is a top view of a three-dimensional plate including a cross-shaped portion having strain gauges responsive to torsional strain; and

[0038] Fig.25 is a flow chart illustrating a method for operating a drilling system based on determined strain deformation. DETAILED DESCRIPTION

[0039] Embodiments of the present disclosure generally relate to determining strain deformation, and more specifically to determining strain deformation within a downhole drilling system. More specifically, internal components or parts of the downhole drilling system may include strain gauges or other sensors for determining the strain experienced by the components of the downhole drilling system. Optionally, strain measurements are made using sensors that are isolated from other bending or strain modes.

[0040] Some embodiments of the present disclosure relate to strain determination within a drilling system that uses a drill string to form a wellbore that extends to or toward a hydrocarbon field. The drilling system can rotate all or part of the length of the drill string and drive a drill bit that cuts into the geological formation where the hydrocarbons are located. During operation, the drilling system can determine or infer the position, path, or movement of the drill string to adjust the operation of the drilling system. For example, the drilling system can drive the drill string (including the drill bit) toward a target location in a geological formation while monitoring and controlling the movement of the drill string to ensure that the drill string moves through the geological formation as needed.

[0041] During operation, forces act on the drill string and affect the performance of the drilling system or affect the structural integrity of components of the drill string. Exemplary forces include weight (gravity), drilling fluid pressure, friction between the drill string and the formation, drill string torque generated by the surface system or downhole motor, intermolecular forces due to increased temperature due to friction or downhole conditions, etc. Forces may negatively affect the operation of the drilling system, such as by moving the drill string away from the target location, by reducing efficiency due to the generation of vibration or heat, etc.

[0042] Forces on the drill string may also structurally change components of the drill string. Thus, identifying structural changes to the drill collar may enable inference or other determination of the forces applied, and may be used to establish or control drilling system operations to avoid or limit undesirable consequences of the forces applied to the drill collar. The present disclosure primarily discusses determination of structural changes associated with strain deformation (including torsional strain, out-of-plane bending strain, in-plane bending strain, axial strain, and combinations thereof); however, other types of strain deformation (e.g., shear strain) may be determined.

[0043] In a downhole system, it may be difficult to directly determine the strain deformation of a drill collar or other component (e.g., by using a sensor on the drill collar). For example, certain types of strain deformation may affect the readings of other types of strain deformation (e.g., torsional strain may affect out-of-plane strain readings, etc.). In another example, it may be difficult, inefficient, or both difficult and inefficient to directly couple a sensor to a drill collar or other component in a manner that enables the sensor to determine structural changes of the component while the drill string is operating. For example, the sensor may alternatively be directly coupled to the drill collar in a controlled environment (e.g., a temperature-controlled laboratory) and by trained personnel to enable the sensor to provide accurate readings. In this way, implementing the sensor may increase the costs associated with manufacturing the drill string, or may only operate in a narrow range of applications that may not include harsh downhole environments. In addition, the sensor may have to be connected to electrical components within the drill string, requiring cutting of channels through support components, and may potentially affect the structure of the component by weakening component integrity or creating stress concentration sites.

[0044] Therefore, it is currently recognized that a sensor that determines structural changes in a component (e.g., by indirect means such as by means not mounted on the component itself) can reduce the costs associated with determining the forces acting on the component. Thus, the present disclosure describes a sensor and process in which the sensor is coupled to an alternative component of a drill string (e.g., relative to a drill collar or other component where strain is being measured), but still detects forces on the other component. The alternative component can be coupled to a first component (e.g., a drill collar) so that strain deformation of the drill collar is transferred to the alternative component. The sensor can then determine the transmitted strain deformation, which is associated with the strain deformation of the drill collar. The alternative component is another existing component of the drill string, such as a chassis or electronic control board coupled to the drill collar. Therefore, the sensor can directly determine the strain deformation of the existing component and indirectly determine the strain deformation of the drill collar or other component supporting the existing component. The alternative component is a supplementary component that is coupled to an existing component of the drill string. The supplementary component can enable the sensor to be more easily coupled to the existing component than by attaching the sensor directly to the existing component. In this way, the sensor can determine the strain deformation of the supplementary component, and the strain deformation of the supplementary component can correspond to the strain deformation of the existing component, the drill collar, or both. In any case, the drilling system can be operated or the structural condition of the drilling system can be monitored based on the strain deformation determined by the sensor.

[0045] To help illustrate the techniques described in this article, Figure 1 An exemplary drilling system 10 is shown in a wellsite environment, where the drilling system 10 can be used to form a wellbore 12 through a geological formation 14 on land or offshore. The drilling system 10 facilitates: milling operations for cutting metals, composites, elastomers, or other objects typically within the wellbore 12, plug and abandon operations for closing the wellbore 12, hydraulic fracturing or slot recovery operations for stimulating or expanding hydrocarbon recovery, remedial operations for improving downhole conditions or tools, or any number of other downhole operations. The drilling system 10 may include a drill string 16 suspended within the wellbore 12, and the drilling system 10 may have a bottom hole assembly (BHA) 18, wherein the bottom hole assembly 18 includes a drill bit 20 at its lower end, wherein the drill bit 20 engages the geological formation 14. In the present disclosure, the drill bit 20 includes any cutting structure (e.g., a reamer, a milling cutter, etc.) that can be used to engage and cut the geological formation 14, the wellbore casing, or other downhole materials.

[0046] The drilling system 10 also includes a surface system 22 that rotates and drives the drill string 16. The drilling system 10 includes a kelly system having a rotary table 24, a kelly 26, a hook 28, and a rotary swivel 30. The drill string 16 may be coupled to the hook 28 via the kelly 26 and the rotary swivel 30. The rotary swivel 30 may be suspended from the hook 28, which is attached to a traveling block (not shown) that drives the drill string 16 relative to the surface system 22 along an axis 32 extending through the center of the wellbore 12. The rotary swivel 30 may allow the drill string 16 to rotate relative to the hook 28, and the rotary table 24 may rotate in a rotational direction 33 to drive the drill string 16 to rotate concentrically about the axis 32. Alternatively, the drilling system 10 may be a top drive system that rotates the drill string 16 via an internal drive (e.g., an internal motor) of the rotary swivel 30. That is, the drilling system 10 may not use the rotary table 24 and the kelly 26 to rotate the drill string 16. Instead, the internal drive of the rotary swivel 30 may drive the drill string 16 to rotate relative to the hook 28 in a rotational direction 33 concentrically about the axis 32. A downhole motor (e.g., a positive displacement motor, a turbine motor, etc.) may include a drive shaft that is coupled to the drill bit 20 and used to rotate the drill bit 20. The drill string 16 may not rotate when the motor is used, or may rotate, but where the downhole motor provides the primary rotational force to the drill bit 20.

[0047] In any event, as the surface system 22 or downhole motor rotates the drill string 16, and weight (e.g., by gravity) is applied to the drill bit 20, the drill string 16 can be driven in an axial direction to engage the drill string 16 with the geological formation 14. For example, the drill string 16 can be driven through the wellbore 12 into the geological formation 14 along a first axial direction 34, which can be a generally downward / downhole vertical direction. Additionally, the drill string 16 can be removed from the wellbore 12 along a second axial direction 36 that is opposite to the first axial direction 34. That is, the second axial direction 36 can be a generally upward / uphole vertical direction. The axial movement of the drill string 16, together with the rotational movement of all or a portion of the drill string 16, can facilitate engagement of the drill bit 20 with the geological formation 14. Although Figure 1 The drill string 16 is shown driven in a generally vertical direction, but the drill string 16 may travel through the wellbore 12 in directions that deviate from the first and second axial directions 34 and 36 , such as one or more angled directions that effect a transition to a generally horizontal direction.

[0048] The surface system 22 may also include mud or drilling fluid 40, which may be directed into the drill string 16 to cool and lubricate the drill bit 20 and carry drill cuttings upward to the surface. In addition, the drilling fluid 40 may exert mud pressure on the geological formation 14 to reduce the likelihood of fluids from the geological formation 14 flowing into or out of the wellbore 12. The drilling fluid 40 is stored in a tank or pit 42 located at the well site. A pump 44 may fluidly couple the pit 42 and the faucet 30, wherein the pump 44 may deliver the drilling fluid 40 to the interior of the drill string 16 through a port in the faucet 19, thereby causing the drilling fluid 40 to flow downward through the drill string 16 in the first axial direction 34. The drilling fluid 40 may also exit the drill string 16 through a port in the drill bit 20 or other portion of the drill string 16 and flow into the wellbore 12 toward the surface (e.g., toward the surface system 22). While drilling, drilling fluid 40 may circulate upward in the second axial direction 36 through the annular region between the exterior of the drill string 16 and the wall of the wellbore 12, thereby carrying drill cuttings away from the bottom of the wellbore 12. Once at the surface, the returning drilling fluid 40 may be filtered to separate the drill cuttings, and the fluid may be transported back to the pit 42 for recirculation and reuse.

[0049] Figure 1 The BHA 18 of the drilling system 10 may include various downhole tools, such as a logging while drilling (LWD) module 120 or a measurement while drilling (MWD) module 130. In general, the downhole tools may facilitate determining or controlling the performance of the drill string 16, such as by determining parameters of the drill string 16, determining parameters of the surrounding geological formations 14, communicating with the surface, etc. It should also be noted that more than one LWD module 120 or MWD module 130 may be employed. For example, the BHA 18 may include additional LWD or MWD modules 120A, 130A closer to the drill bit 20. As such, references to the LWD module 120 may also refer to the LWD module 120A, and references to the MWD module 130 may also refer to the MWD module 130A.

[0050] The LWD module 120, the MWD module 130, or both may each be housed in a special type of drill collar coupled to the drill string and may contain one or more types of logging or measurement tools. Typically, the LWD module 120 may include capabilities for measuring, processing, and storing formation or environmental information, and the MWD module may include one or more devices for measuring characteristics of the drill string 16 or drill bit 20 and for communicating with surface equipment. Figure 1In the drilling system 10, the LWD module 120 or the MWD module 130 may include one or more of the following types of measurement devices: a weight on bit (WOB) measurement device; a torque measurement device; a bending measurement device; a vibration measurement device; an impact measurement device; a stick-slip measurement device, a direction measurement device; an inclination measurement device; a temperature measurement device; a pressure measurement device; a rotational speed measurement device; or a position measurement device.

[0051] The MWD module 130 includes equipment for generating electrical energy. For example, the MWD module 130 may include a mud turbine generator that generates electrical energy through the flow of drilling fluid 40. The drilling system 10 may include a power source 148, such as a generator or an electrical energy storage device, that supplies energy to the drilling system 10. In any case, the electrical energy may be used to operate various aspects of the drilling system 10, such as to control the BHA 18.

[0052] The BHA 18 may also include a motor 150, a rotary steerable system (RSS) 152, or other modules coupled to the drill bit 20 (e.g., crossover, hydraulic release, circulation, etc.). The motor 150, RSS 152, or other modules may be directly coupled to the LWD module 120, the MWD module 130, other modules, or directly or through one or more additional tubulars 154 to the drill bit 20. The motor 150 and RSS 152 are used to adjust the operation of the drill bit 20 to engage the geological formation 14. For example, the RSS 152 may orient the drill bit 20 in a desired direction while the motor causes the drill bit 20 to continuously rotate to drill the wellbore 12. Producing continuous rotation may achieve improved transportation of drilled cuttings to the surface, better cutting of the wellbore 12 (e.g., improving wellbore quality, reducing stick-slip or drill bit whirl, etc.), limited stress imposed on the drill bit 20 by the geological formation 14, etc. In addition, the RSS 152 may enable control of the engagement of the drill string 16 with the geological formation 14. For example, the RSS may enable the drill string 16 to communicate with the surface system 22. Thus, the surface system 22 may control the direction or path of the drill string 16 to form the wellbore 12 or the manner in which the drill string 16 engages the geological formation 14 (e.g., rotation and sliding of the drill string 16).

[0053] The drill string 16 includes or is communicatively coupled to a data processing system 160, which can adjust the operation of the drilling system 10, such as to guide the drill string 16 through the wellbore 12 or the path of the drill string 16 when extending the wellbore 12. The data processing system 160 may include one or more processors 162, such as a general-purpose microprocessor, a special-purpose processor (ASIC), or a field programmable gate array (FPGA) or other programmable logic device, or a combination of the foregoing. The processor 162 can execute instructions stored in a memory 164 or other storage device 166, which can be a read-only memory (ROM), a random access memory (RAM), a flash memory, an optical storage medium, a hard drive, etc. The data processing system 160 can also be communicatively coupled to a sensor 167, which can determine the operating parameters of the drill string 16. For example, the sensor 167 may be a strain gauge (e.g., any strain gauge or circuitry herein and combinations thereof) that facilitates determining strain or deformation of a section of the BHA 18, and the sensor 167 may send a signal or feedback indicative of the determined strain to the data processing system 160, either directly or through other components. The data processing system 160 may operate the drilling system 10 based on the feedback received from the sensor 167, such as to adjust the direction through which the drill string 16 forms the wellbore 12.

[0054] Although the data processing system 160 is shown as being external to the drill string 16, the data processing system 160 may alternatively be a part of the drill string 16 in whole or in part, such as within the BHA 18. The data processing system 160 may include a device proximate to the drilling operation (e.g., at the surface system 22, at the BHA 18, etc.) or a remote data processing device located remote from the drilling system 10, such as a mobile computing device (e.g., a tablet, a smart phone, a laptop, a desktop computer, etc.) or a server remote from the drilling system 10. In any case, the data processing system 160 may process downhole measurements in real time, near real time, or at some time after the data is collected. In general, the data processing system 160 may store and process collected data, such as data collected by the BHA 18 via the LWD module 120, the MWD module 130, the sensor 167, or any suitable telemetry device (e.g., an electrical signal pulsed through the geological formation 14 or a mud pulse telemetry device using the drilling fluid 40). A separate data processing system 160 may also be used to guide, orient, or control the drill string 16 to rotate the drill string 16 (eg, using surface torque, by flowing fluid to a downhole motor, etc.), or to raise or lower the drill string 16 .

[0055] The data processing system 160 may also include a user interface 168 that allows a user to interact with the data processing system 160. For example, a user may input properties, instructions (e.g., control commands), or parameters to the data processing system 160 through the user interface 168. To this end, the user interface 168 may include buttons, a keyboard, a microphone, a mouse, a touch pad, a touch screen, an audio input device, etc. The user interface 168 may also include a display, which may be any suitable electronic display that displays a visual representation of information, such as a graphical representation of the collected data.

[0056] Further, the data processing system 160 may include an input / output (I / O) port 170 that enables the data processing system 160 to communicate with various electronic devices. For example, the I / O port 170 may enable the data processing system 160 to be directly coupled to another electronic device (e.g., a remote or mobile device) so that data can be transmitted between the data processing system 160 and the electronic device. The I / O port 170 may additionally or alternatively enable the data processing system 160 to be indirectly coupled to other electronic devices. In another example, the I / O port 170 may enable the data processing system 160 to be coupled to a network, such as a personal area network (PAN), a local area network (LAN), a wide area network (WAN), or any combination of the foregoing. Thus, the data processing system 160 performs one or more of the following: receiving data (e.g., as a signal) from another electronic device (e.g., a base station control system) via the I / O port 170, or communicating data to another electronic device via the I / O port 170.

[0057] Figure 2 1 is a partial cross-sectional view of the BHA 18, which includes a drill collar 200 that provides weight to the BHA 18. The provided weight supplies force in the first axial direction 34 through gravity to engage the geological formations 14 while drilling and form the wellbore 12. The data processing system 160 can control the amount of weight applied by the drill collar 200 to form the wellbore 12 (e.g., by controlling how much weight the surface system or downhole hanger carries the drill string).

[0058] The BHA 18 may include a mandrel assembly or other internal assembly 201, which generally refers to an assembly of components within the drill collar 200 and potentially fully or partially enclosed by the drill collar 200. The internal assembly 201 may extend along at least a portion of the length of the drill collar and may include a plurality of components that may each be referred to as a chassis. For example, a first chassis 202 may support or include physical components, tools, or sensors of the internal assembly 201 and may be a tool chassis. A second chassis 204 may support other physical components, tools, or sensors of the internal assembly 201 and may be an instrument chassis 204. The chassis 204 may enclose or support instrument tools of the BHA 18, such as the sensor 167.

[0059] The bottom pans 202, 204 may have any suitable configuration. For example, the bottom pan 202, the bottom pan 204, or both may have an annular configuration. For example, the bottom pan 202 is shown as being annular and having a flow path therethrough. The bottom pan 204 is shown as having an internal compartment but not having a flow path extending completely therethrough. Alternatively, the bottom pan 202 or the bottom pan 204 may include or be formed as a flow diverter 206 that directs the drilling fluid 40 through the BHA 18 to the drill bit 20. For example, Figure 2 The flow diverter 206 in the embodiment is included in or formed by the chassis 204 and is located within the annular fluid flow and directs the fluid flow into a flow path within the chassis 202. More specifically, the drilling fluid 40 can be directed around the chassis 204 and away from the instrument tool within the chassis 204, and the flow diverter 206 can then converge the drilling fluid 40 into a channel 208 within the tool chassis 202. The drilling fluid 40 can then be directed in a downhole direction (such as toward the drill bit 20 (see FIG. 2 )) within the channel 208. Figure 1 )) for guidance.

[0060] As described herein, implementing sensors (e.g., strain gauges) to determine strain deformation associated with the BHA 18 to control the operation of the BHA 18 may be difficult or inefficient. For example, in conventional approaches, placing sensors on the drill collar 200 to directly determine the strain deformation of the drill collar 200 may be expensive or difficult to implement (e.g., have limited robustness making it unsuitable for downhole use). As such, the sensor 167 may be positioned in an alternative location, such as within the internal component 201 or within a groove or cavity formed in the BHA 18 (e.g., along the bottom plate 204, in a cover / cover of the internal component 201, or in a groove or cavity on an interior surface of the drill collar 200), or an alternative sensor may be used to determine the strain deformation associated with the BHA 18. The sensor 167 in an alternative location (e.g., in a cover of a groove or a plate attached to the cover) may enable or facilitate additional embodiments, such as pressure measurement. Alternatively, rather than directly determining the strain of the drill collar 200 (eg, using a sensor on the drill collar 200 that expects strain), the sensor 167 may determine another parameter that is representative of the strain of the drill collar 200 .

[0061] In some cases, the BHA 18 may be subjected to bending strains, some of which may drive the BHA 18 in an undesirable direction when forming the wellbore 12, or may weaken or fatigue the BHA 18. Therefore, strain gauges (e.g., foil strain gauges, fiber optic strain gauges, piezoresistive strain gauges, micro-optical electromechanical systems (MOEMS) strain gauges, vibrating wire strain gauges, capacitive strain gauges, etc.) may be used to determine the bending strains experienced by the BHA 18. As an overview, each strain gauge may include an electrical circuit through which a current having an associated voltage may travel. The electrical circuit may include a resistance related to the length of the strain gauge. For example, increasing the length of the strain gauge may increase the resistance of the strain gauge, while decreasing the length of the strain gauge may decrease the resistance of the strain gauge. The resistance may be provided by a conductor or a resistor, and may be determined, for example, by applying a voltage through the circuit, sensing the voltage along the circuit, and determining the difference between the applied voltage and the sensed voltage.

[0062] The strain gauge can determine a change in the resistance of a resistor or the entire strain gauge, where the change in resistance is related to a change in the length of the strain gauge (i.e., strain deformation). The strain gauge can provide a signal or feedback indicating the resistance, and another component (e.g., a controller) can receive the signal and use the resistance to determine the change in the length of the strain gauge and the corresponding strain deformation of the strain gauge. The strain gauge can provide a signal or feedback directly indicating the strain deformation. For example, the strain gauge can be attached to a component. The component can experience a strain deformation that changes the length of the component, and the strain deformation can change the length of the strain gauge, thereby changing the resistance of the strain gauge. The strain gauge can then send a signal indicating the change in resistance associated with the strain deformation of the strain gauge. The strain gauge can record strain deformation measurements, resistance changes, etc. in a local storage medium or by sending the data to another component that stores information.

[0063] Figures 3 to 5 Strain gauges are shown coupled to various existing components of the BHA 18 in addition to being bonded directly to the drill collar 200. Such strain gauges may be used to determine the bending of components of the BHA 18 located within the drill collar 200, and the determined bending may be correlated to the bending of the BHA 18 and the drill collar 200. Figures 3 to 5 The use of strain gauges to determine bending of the BHA 18 or drill collar 200 is primarily discussed, but the strain gauges may additionally or alternatively facilitate determining other types of strain deformations of the BHA 18 , such as torsional or axial strain.

[0064] Figure 3 201. FIG. 201 is a cross-sectional view of the BHA 18 with the strain gauge 230 coupled to or integral with the diverter 206 of the internal assembly 201. It should be noted that the diverter 206 can be integral with the drill collar 200 and the chassis 204 or manufactured separately therefrom. In particular, when the diverter 206 is manufactured in whole or in part as a separate component, the strain gauge 230 can be conveniently and easily attached to and detached from the diverter 206. Therefore, if an installed diverter 206 is to be replaced with a replacement diverter 206, the same strain gauge 230 can be detached from the installed diverter 206 and attached to the replacement diverter 206, thereby limiting the cost of replacing the diverter 206. As mentioned herein, the diverter 206 can direct the flow of fluid in a downhole direction (such as toward the drill bit 20( Figure 1 )) The flow diverter 206 can direct the drilling fluid 40 flowing through the BHA 18 around the bottom plate 204. For example, the flow diverter 206 can direct the drilling fluid 40 through the BHA 18 around the bottom plate 204. The flow diverter 206 can be located in a near-bit location (e.g., within 10 feet (3 m) from the drill bit 20), and the flow diverter 206 can be considered a lower flow diverter. In this way, the flow diverter 206 can direct the drilling fluid 40 directly into the drill bit 20.

[0065] The strain gauges 230 may facilitate determining the strain deformation of the chassis 204 or the flow diverter 206 transmitted from the strain deformation of the drill collar 200. The BHA 18 may include one or more seals 232 (e.g., O-rings, square rings, T-rings, I-rings, X-rings, Q-rings, etc.) around the flow diverter 206. The seals 232 may abut both the flow diverter 206 and the drill collar 200 to increase the friction between the flow diverter 206 and the drill collar 200. For example, a first side (e.g., an upstream side) of one of the seals 232 may have a high pressure (e.g., in contact with a high pressure fluid), and a second side of the seal 232 may have a low pressure. In addition, the flow diverter 206 is also subjected to a high pressure (e.g., filled with a high pressure fluid). The pressure differential between the flow diverter 206 and the low pressure at the second side of the seal 232 may cause the flow diverter 206 to expand radially, thereby pushing the outer surface of the seal 232 against the inner surface of the drill collar 200. The amount of force applied to radially push the seal 232 against the drill collar 200 can be based on various parameters (such as the length of the diverter 206, the gap between the diverter 206 and the drill collar 200, the thickness of the diverter 206, etc.) to control the restriction of dynamic movement between the diverter 206 and the drill collar 200. In this way, the seal 232 facilitates limiting axial movement (e.g., sliding) between the diverter 206 and the drill collar 200, and the strain deformation of the drill collar 200 can be directly transmitted to the bottom plate 204 and / or the diverter 206 and determined using the strain gauge 230. In this way, the strain gauge 230 can facilitate determining the strain deformation associated with the drill collar 200.

[0066] In the illustrated flow diverter 206, a strain gauge 230 is attached to the flow diverter 206 within a chamber 234 radially located between the outer surface of the flow diverter 206 and the inner surface of the drill collar 200. Thus, the flow diverter 206 serves as a chassis for the strain gauge 230. The chamber 234 can be filled with a fluid (e.g., oil) that can increase the pressure between the drill collar 200 and the flow diverter 206, and the strain gauge 230 can be located within a groove, cavity, or recess of the chamber 234. The pressure from the fluid can balance the pressure applied by the drilling fluid 40 flowing through the flow diverter 206, thereby limiting deformation of the flow diverter 206 caused by the flow of the drilling fluid 40, and the recess of the chamber 234 can be optionally sealed to cover the strain gauge 230, thereby shielding the strain gauge 230 from the fluid. There may be components (e.g., pistons, bellows, diaphragms) configured to transfer pressure between the drilling fluid 40 and the fluid within the chamber 234 to balance the pressure between the chamber 234 and the diverter 206, or otherwise reduce strain deformation of the diverter 206 caused by the pressure difference between the chamber 234 and the diverter 206.

[0067] If the flow diverter 206 is in the near-bit position, the strain deformation determined using the strain gauge 230 may be extrapolated or otherwise used to determine the position of the drill bit 20. The BHA 18 may then be controlled to guide the drill bit 20 based on the position. For example, the strain gauge 230 may be communicatively coupled to a first electronic board 236 (e.g., a first control board) within the chassis 204, such as by physical wiring directed through the flow diverter 206. The first electronic board 236, which may include a controller or processor, may receive a signal indicating the strain experienced by the strain gauge 230 (e.g., a degree of resistance of the strain gauge 230), determine the strain deformation experienced by the strain gauge 230 based on the signal, determine or estimate the position or orientation of the drill bit 20 based on the strain deformation (e.g., based on determining or inferring the bending experienced by the drill collar 200), and operate the BHA 18 based on the determined position of the drill bit 20 or the drill collar 200. Additionally or alternatively, the first electronic board 236 may receive signals indicative of strain and store information about the strain for further analysis (eg, determining strain deformations for various operations to, for example, improve future designs or operational modeling).

[0068] Figure 4 is a cross-sectional view of the BHA 18 with a strain gauge 260 positioned on an additional or alternative flow diverter 206 within the inner component 201 (eg, in an optional groove or cavity of the inner component 201 ). Figure 4 The splitter 206 is Figure 5 The diverter 206 is located further from the drill bit (e.g., 20 feet (6 m) to 2000 feet (600 m)). When used with the lower diverter, Figure 4 The flow divider 206 can be considered as an upper flow divider. Figure 4 The upper shunt 206 may be adjacent to (or near) a turbine 207 that generates or otherwise provides electrical power to the BHA 18 or mechanical shunt. Figure 4 In, for example, flow diverter 206 is on the well of turbine 207 and diverts the flow of fluid before the fluid enters turbine 207 .

[0069] The flow diverter 206 may include a cavity 262 in which other components (e.g., a second electronic or control board 264) may be located, and the flow diverter 206 may direct the drilling fluid 40 toward the drill bit 20 around the cavity 262. A strain gauge 260 may be attached to the flow diverter 206 in another chamber 234, which may be filled with a fluid to optionally reduce the pressure differential between the chamber 234 and the flow channel within the flow diverter 206 and reduce strain deformation caused by the pressure differential.

[0070] The BHA 18 may also include a seal 232 that facilitates increasing friction between the diverter 206 and the drill collar 200, thereby further enabling strain deformation of the drill collar 200 to be transferred to the diverter 206, and vice versa. The strain gauge 260 may be communicatively coupled to a second electronic board 264 within the diverter 206, such as by physical wires routed through the diverter 206. Such wires may also be routed through a sleeve 266 of the BHA 18, which may optionally be a chassis of the diverter 206, or a tubular element. Additionally or alternatively, the strain gauge 260 may be wirelessly coupled to the second electronic board 264. The strain gauge 260 may be coupled to another electronic board, such as Figure 3 In any case, the electronic board coupled to the strain gauge 260 can receive a signal indicative of the strain experienced by the strain gauge 260 to determine a bend in the drill collar 200, which can also correspond to a position or orientation of the drill bit 20, operate the BHA 18 based on the determined position of the drill bit 20 or the bend in the drill collar 200, or store strain deformation information based on the signal.

[0071] Figure 5 is a schematic cross-sectional view of a BHA 18 with strain gauges 290 attached to a chassis 204 within the internal assembly 201. The chassis 204 is centralized within the drill collar 200 by one or more centralizers 292. Movement of the drill collar 200 may be transmitted to the chassis 204 by the centralizers 292. Thus, bending of the drill collar 200 due to the centralization from the centralizers 292 may cause the chassis 204 to bend. The strain gauges 290 may then facilitate determining the bending of the chassis 204, and therefore estimating the bending of the drill collar 200. The strain gauges 290 may be coupled to the chassis 204 in any suitable manner. For example, the strain gauges 290 may be coupled directly to the exterior or surface of the chassis 204. The strain gauges 290 may be coupled to a diverter or other tool formed or carried by the chassis 204, or may be located within a recess or chamber, as described with reference to FIG. Figure 3 and Figure 4 The

[0072] In some tool designs and environments, some strains of the drill collar 200 may not be directly or proportionally transmitted to the chassis 204. For example, this may occur when the drill collar 200 can move axially or radially relative to the chassis. The radial clearance between the outer surface of the centralizer 292 and the inner surface of the drill collar 200 and the radial clearance between the centralizer 292 and the pressure housing 294 surrounding the chassis 204 (see Figure 6) may affect (e.g., reduce) the bending of the base plate 204. Therefore, the reading of the strain gauge 290 may not be directly equal to or proportional to the strain deformation of the drill collar 200. To this end, the reading of the strain gauge 290 may be calibrated or adjusted to compensate for any bending measurement loss, thereby providing a more accurate representation of the strain deformation of the drill collar 200.

[0073] Sometimes it may not be desirable to place strain gauges on certain components of the BHA 18. For example, strain gauges may be attached to the BHA 18 by trained personnel in a controlled environment so that the strain gauges can accurately determine the strain deformation of the BHA 18. However, some existing components, such as the chassis 204 and the drill collar 200, may be manufactured or assembled at different locations separate from the controlled environment. Therefore, in order to attach some strain gauges to the existing components of the BHA 18, it may be desirable to transport the existing components to a controlled environment or perform additional manufacturing processes to enable the strain gauges 290 to determine the strain deformation of the existing components. Such additional operations may increase the time or cost of implementing the strain gauges.

[0074] Sometimes, an additional component is mounted on the BHA 18 and includes an alternative sensor for determining the strain deformation of the additional component. The additional component can then be attached to the existing component of the BHA 18, and the readings of the strain deformation of the additional component can be correlated with the strain deformation of the existing component, the drill collar, and the BHA 18 without having to mount the strain gauge directly on the BHA 18. In other words, it may be easier, more cost-effective, and more convenient to attach the alternative sensor to the additional separate component and attach the additional component to the existing component than to attach the strain gauge directly to the existing component. The alternative sensor can then be communicatively coupled to the data processing system 160, the first electronic board 236, a data storage device, or any suitable component that can control the operation of the BHA 18, or store strain deformation information based on the readings of the alternative sensor.

[0075] For example, Figure 6 1 is a schematic cross-sectional view of a BHA 18 having an internal assembly 201 including a chassis 204. The chassis 204 includes a rod 310 (which may be solid or tubular) within a compartment 312 of the chassis 204, and the rod 310 is used to determine the bend of the BHA 18. Opposite axial ends 314 of the rod 310 terminate near the axial center of one of the centralizers 292 so that movement of the centralizer 292 can effectively bend the rod 310 so that the bend of the rod 310 substantially matches the bend of the BHA 18. As will be seen in FIG. Figures 7 to 13As described in the foregoing, the rods may facilitate determining the bending of the BHA 18 in different ways. The BHA 18 may include any combination of the features discussed. For example, the different rods discussed herein may be implemented at various lengths along the BHA 18. Furthermore, in addition to (e.g., to confirm the measurements of) the strain gauges, or as (e.g., Figures 3 to 5 As an alternative to attaching strain gauges to the BHA 18 (as discussed in ), additional components or alternative sensors may also be used.

[0076] Figure 7 3 is a schematic cross-sectional view of a BHA 18 having an internal assembly 201 with a first rod 330. The first rod 330 is positioned within the compartment 312 and within the interior of the chassis 204. The first rod 330 can be substantially coupled to the chassis 204 such that strain deformation of the chassis 204 is transmitted to the first rod 330. For example, the chassis 204 can apply a clamping force to the end 314 of the first rod 330. Therefore, strain deformation of the chassis 204 (e.g., caused by strain deformation of the drill collar 200) can also cause strain deformation of the first rod 330. In addition, a strain gauge 334 can be attached to the first rod 330, such as near one or both of the ends 314, to achieve greater accessibility and accurate measurement results of the strain gauge 334. The strain gauge 334 can be used to determine the strain deformation of the first rod 330. The strain deformation of the first rod 330 can then be used to determine the strain deformation of the BHA 18, because the strain deformation from the BHA 18 can be transferred to the chassis 204, and from the chassis 204 to the first rod 330. The first rod 330 can have any suitable cross-sectional shape, and optionally a uniform cross-sectional shape along its length, so that the strain deformation of the first rod 330 can be uniformly transmitted through the length of the first rod 330, so that the strain deformation of the first rod 330 is not affected by changes in the geometry of the first rod 330, thereby causing inaccurate readings of the strain gauge 334.

[0077] The first rod 330 and the strain gauge 334 may be assembled together in a process separate from the process of manufacturing the chassis 204 to the BHA 18. For example, the first rod 330 and the strain gauge 334 may be attached to each other in a controlled environment so that the strain gauge 334 can facilitate accurate determination of the strain deformation of the first rod 330, and the first rod 330 including the strain gauge 334 may then be attached to the chassis 204 in a separate environment or process. In this way, the chassis 204 does not have to be in the same controlled environment as the strain gauge 334 is installed within the BHA 18, thereby reducing the cost of manufacturing and assembling the BHA 18 with the strain gauge 334.

[0078] Figure 81 is a schematic cross-sectional view of a BHA 18 having an internal assembly 201 with a second rod 350 also optionally located within a compartment 312 of a chassis 204. The second rod 350 includes two convex (e.g., spherical) portions 352, and the compartment 312 includes two concave portions 354. Each concave portion 354 generally captures one of the convex portions 352 of the second rod 350, thereby forming a joint (e.g., a spherical joint) that retains the second rod 350 within the compartment 312. One or more proximity sensors 356 may be coupled to the second rod 350, or additionally or alternatively to a wall 358 of the compartment 312. The proximity sensor 356 may include a Hall effect sensor, an optical sensor, a capacitive sensor, another suitable sensor, or a combination of one or more of the foregoing, and may determine a distance between the second rod 350 and the wall 358. The determined distance between the second rod 350 and the wall 358 may correspond to the bending of the chassis 204 and the BHA 18.

[0079] For example, Fig. 9 is in a bent configuration Figure 81. A schematic cross-sectional view of the BHA 18 of FIG. 1. In the bent configuration, the BHA 18, chassis 204, and compartment 312 are bent, but the second rod 350 remains straight or at least exhibits a small bend. For example, the bending of the compartment 312 causes the concave portion 354 of the compartment 312 to move or rotate around the convex portion 352 of the second rod 350. The movement of the curved portion 354 around the convex portion 352 can avoid applying a force to the second rod 350 that would cause a corresponding bending of the second rod 350. Thus, when the chassis 204 bends, the second rod 350 may not bend or may not bend a corresponding amount. In the bent configuration shown, the first inner wall 358A of the compartment 312 has moved closer to the first proximity sensor 356A illustratively located on the outer surface of the rod 350, and the second inner wall 358B of the compartment 312 has moved away from the second proximity sensor 356B illustratively located on the outer surface of the rod 350. Thus, the first proximity sensor 356A can determine that the distance between the second shaft 350 and the first wall 358A has decreased, and the second proximity sensor 356B can determine that the distance between the second shaft 350 and the second wall 358B has increased. The proximity sensor 356 can then send a signal or feedback (e.g., to the first electronic board 236) indicating the distance between the second shaft 350 and the wall 358. This feedback can then be used to determine the amount of bending of the chassis 204 and the BHA 18. For example, the distance or distance change between the second shaft 350 and the wall 358 can be associated with the bending angle of the BHA 18 (e.g., a greater distance change corresponds to a greater amount of bending). Although two proximity sensors 356 can be attached to the second shaft 350 (e.g., to measure bending in more than one plane), any suitable number of proximity sensors 356 attached to the second shaft 350 can be used, such as one, two, or more proximity sensors 356. Sometimes, rather than placing a proximity sensor at a single axial position along the rod 350, one or more other proximity sensors may instead be offset at different axial positions.

[0080] Fig.10380, which is optionally located in whole or in part in the compartment 312 of the chassis 204 and can be used to determine the bending of the BHA 18. The third rod 380 is in an unbent configuration. An emitter 382 (e.g., a laser or light emitting diode) within the third rod 380 can emit light 384 having a low dispersion (e.g., a collimated laser beam) axially along and through at least a portion of the third rod 380, which can be tubular. The emitted light 384 can travel along the third rod 380 to a photodetector array 386, which can detect the presence of the light 384 and can send a signal or store an output when the presence of the light 384 is detected. The specific location of the light 384 emitted onto the photodetector array 386 across the third rod 380 can be determined based on the reading of a certain photodetector in the photodetector array 386 that detects the light 384. The location of the light 384 can be used to determine the amount of bending of the rod 380 and, therefore, the amount of bending of the BHA 18. For example, bending of BHA 18 may also bend third rod 380 to change the location where light 384 is emitted onto photodetector array 386. Thus, the amount of bending of BHA 18 may be determined based on the determined location of light 384 emitted onto photodetector array 386.

[0081] Fig.11 It is along Fig.10 The line 11-11 is intercepted Fig.10 18. A cross-sectional view of the third shaft 380 of FIG. 18. In the non-bent configuration of the third shaft 380, the light 384 is substantially straightened in the light detector array 386, assuming that the emitter 382 is straightened with respect to the light detector array 386. When the third shaft 380 is substantially straight, the emitter 382 can therefore emit the light 384 onto the center of the light detector array 386. Thus, determining that the light 384 is positioned at the center of the light detector array 386 indicates that the third shaft 380 and the BHA 18 are substantially straight. Sometimes, a known offset between the emitter 382 and the light detector array 386 can be used so that the position of the light at an off-center position can indicate that the third shaft 380 and the BHA 18 are substantially straight.

[0082] Fig.12 It is now in a bent configuration Fig.10 and Fig.11 A schematic diagram of a third rod 380. Fig.12As shown, in the bent configuration, light 384 emitted by the emitter 382 is eccentrically positioned onto the photodetector array 386. The bending of the third rod 380 caused by moving the end 400 of the third rod 380 along the first lateral direction 402 (e.g., due to the bending of the BHA 18) can cause the photodetector array 386 to emit light 384 onto the photodetector array 386 at an angle toward a second lateral direction 404 that is opposite to the first lateral direction 402. Alternatively, the bending of the third rod 380 caused by moving the end 400 of the third rod 380 along the second lateral direction 404 (e.g., due to the bending of the BHA 18) can cause the emitter 382 to emit light 384 onto the photodetector array 386 at another angle toward the first lateral direction 402.

[0083] Fig.13 It is taken along line 13-13 Fig.12 380. As described above, light 384 is positioned above the center of light detector array 386 along second lateral direction 404. A particular location of light 384 on light detector array 386 can be associated with a particular amount of bending of third rod 380. For example, a location of light 384 away from the center of light detector array 386 can indicate a greater amount of bending of third rod 380. Although light 384 is shown as being along (at Fig.13 The second lateral direction 404 is eccentrically positioned on the photodetector array 386, but the light 384 may be directed such as perpendicular to the first lateral direction 402 and the second lateral direction 404 (and in the Fig.13 18 (shown as a horizontal direction in FIG. 1 ) is positioned in other locations on the light detector array 386. In this way, the specific location of the light 384 on the light detector array 386 can be used to determine the angle of the third shaft 380 bend. In the event that the light detector array 386 is offset relative to the emitter 382 when the shaft 380 is in a non-bent configuration, the known offset can be used together with the detected location of the light 384 on the light detector array 386 to determine the bend of the shaft 380 and, therefore, the BHA 18 and optionally the chassis 204.

[0084] refer to Figures 3 to 13The described techniques may be used to determine bending strain deformation of the BHA 18 through the bending transmission of the BHA 18 to the drill collar 200 and the internal components 201 within the drill collar 200. The same or other techniques may optionally be used for other types of strain deformation, including torsion or axial strain of the drill collar. Additionally, it may be desirable to attach sensors to the BHA 18 in other ways. For example, in some cases, it may be undesirable to attach strain gauges to existing components by trained personnel in a controlled environment because it may increase costs associated with transporting the strain gauges or associated components (e.g., the chassis 204), training personnel, preparing and maintaining the controller environment, etc. As such, it may be desirable to implement sensors to the BHA 18 without installing the strain gauges on the BHA 18 in a controlled environment.

[0085] Figures 14 to 20 Involving placing a plurality of strain gauges on an intermediate component (e.g., an electronics board or other board) of the BHA 18 (e.g., coupled to a chassis or drill collar) to determine one or more types of strain deformation. Attaching the strain gauges to the intermediate component may be easier than other existing components of the BHA 18 (e.g., chassis 202, chassis 204, drill collar 200, or shunt 206). For example, a plurality of strain gauges may be implemented on the intermediate component in a controlled environment, and then the intermediate component may be coupled to the chassis 204 or drill collar 202 outside the controlled environment. To this end, the chassis 204 and other components of the BHA 18 do not have to be transported to or otherwise handled in a controlled environment for the purpose of implementing the strain gauges. Thus, for example, such a process may be easier, more convenient, less costly, less time consuming, and more efficient than attaching the strain gauges directly to the chassis 204 in a controlled environment.

[0086] Fig.142 is a perspective view of the BHA 18, in which certain components, such as a separate drill collar 200, are not shown in order to better visualize other aspects of the BHA 18. The BHA 18 may include an electronic board 430 (e.g., a third control board) coupled to the chassis 204. The electronic board 430 may be used in the operation of the BHA 18, such as to measure or record data within the wellbore, control the trajectory of the wellbore, send or receive data, etc. based on the strain deformation of the drill collar 200. In addition, the strain deformation of the drill collar 200 may be transmitted to the chassis 204 and transmitted to the electronic board 430 (or directly from the drill collar 200 to the electronic board 420, wherein the electronic board 430 is mounted in a groove or recess of the drill collar 200). For example, the electronic board 430 may be coupled to the chassis 204 by fasteners, welds, adhesives (e.g., epoxy), or another suitable component, which enables the strain deformation of the drill collar 200 to be transmitted to the chassis 204 and to the electronic board 430. In other words, for example, elongation of the drill collar 200 causes the chassis 204 to elongate, thereby elongating the electronics board 430 coupled to the chassis 204 (e.g., by elongation of an optional component that couples the electronics board 430 to the chassis 204 or directly to the drill collar 200). The strain deformation of the electronics board 430 can therefore be used to determine the corresponding strain deformation of the drill collar 200.

[0087] A plurality of strain gauges 432 may be attached to the electronics board 430 to determine strain deformation of the electronics board 430. The strain gauges 432 may include one or more different types of strain gauges, each different type providing a reading associated with a particular type of strain deformation of the electronics board 430. In some cases, the electronics board 430 may already be an existing component of the BHA 18 and may be used to control or monitor certain components of the BHA 18 or the wellbore. In this way, attaching the strain gauges 432 directly to the electronics board 430 may allow the strain gauges 432 to be installed into the BHA 18 without utilizing additional components, thereby limiting the cost of manufacturing the BHA 18. Sometimes, the plurality of strain gauges 432 may be attached to an additional component such as the plate 434, rather than being attached directly to the electronics board 430. The plate 434 may be coupled to or formed in the baseplate 204 or drill collar 200 by fasteners, welds, adhesives, another suitable component, or integral fabrication that enables strain deformation of the drill collar 200 to be transferred to the plate 434. By coupling the strain gauge 432 to the plate 434 instead of the electronics board 430, the strain gauge 432 may be easily attached to the BHA 18 or even removed from the BHA 18 without removing the electronics board 430 (e.g., to replace the strain gauge 432). The plate 434 may also be removable to allow removal of the strain gauge 432.

[0088] As used herein, the term "plate" is intended to cover any of a variety of different surfaces to which the strain gauge 432 may be coupled and which are distinct from the drill collar enclosing the internal components. Plates are not limited to having planar surfaces; however, the curved plates of the present disclosure will typically have a radius of curvature that is at least 2, 3, 5, 10, 15, or 20 times greater than the radius of curvature of the drill collar or chassis to which it is attached. For example, a chassis having a diameter of 8 inches (0.2 m) and a radius of 4 inches (0.1 m) may have a plate therein or thereon that is typically flat or has a radius of curvature of 10 inches (0.25 m) or greater, 20 inches (0.5 m) or greater, or 50 inches (1.3 m) or greater. Additionally, even in the case of three-dimensional or other contoured shapes, the plates of the present disclosure will provide substantially parallel opposing surfaces. Generally, for purposes of the present disclosure, an annular component having a flow path therethrough will not be considered a plate.

[0089] Fig.15 yes Fig.14 4. A torsional strain gauge 452 is coupled to the first surface 446 of the electronic board 430 and is optionally oriented and positioned along a centerline 453 extending through the electronic board 430. The resistance degree of the torsional strain gauge 452 can indicate a torsion of a component to which the electronic board 430 is coupled (e.g., the chassis 204 or the plate 434 about the centerline 453 as indicated by arrow 449), which causes shear strain and deformation of the electronic board 430. The shear strain can stretch or shorten the material fibers in the first section 448 of the torsional strain gauge 452 and the second section 450 of the torsional strain gauge 452 at a certain angle (e.g., at a 45° angle) so that the resistance degree of the torsional strain gauge 452 can be affected by the torsional strain. Therefore, the resistance degree of the torsional strain gauge 452 can be used to determine whether the component to which the electronic board 430 is coupled is experiencing torsion. However, the resistance reading of the torsional strain gauge 452 may be substantially unaffected by other strain deformations of the electronic board 430 because the other strain deformations may not stretch or shorten the material fibers in the first section 448 and the second section 450 at a 45° angle.

[0090] Additionally, in-plane bending strain gauges 456 (including strain gauges 456A and 456B) may be on the first surface 446 of the electronic board 430. The first in-plane bending strain gauge 456A is on one side 451 of the centerline 453, and the second in-plane bending strain gauge 456B is on the other side 455 of the centerline 453 and aligned with the first in-plane bending strain gauge 456A along a transverse axis 457 perpendicular to the centerline 453. The in-plane bending strain gauges 456 may be used together to determine the presence of bending the electronic board 430 about a vertical axis 458 (i.e., in-plane bending visible from a top view of the first surface 446). For example, bending the electronic board 430 along a first bending direction 460 may shorten the first in-plane bending strain gauge 456A and lengthen the second in-plane bending strain gauge 456B, thereby changing (e.g., decreasing) the degree of resistance of the first in-plane bending strain gauge 456A and changing (e.g., increasing) the degree of resistance of the second in-plane bending strain gauge 456B. In this way, the resistance degree of the in-plane bending strain gauges 456 relative to each other can be used to determine whether the electronic board 430 is experiencing in-plane bending. The in-plane bending strain gauges 456 may be substantially unaffected by other strain deformations of the electronic board 430, because other forms of strain deformation will equally affect the geometric changes of the in-plane bending strain gauges 456 and therefore do not change the resistance degree of the two in-plane bending strain gauges 456A, 456B relative to each other.

[0091] In addition, a first out-of-plane bending strain gauge 462A and a first axial strain gauge 464A may also be on the first surface 446. Both the first out-of-plane bending strain gauge 462A and the first axial strain gauge 464A are located along the centerline 453. The first out-of-plane bending strain gauge 462A can be used to facilitate determining whether the electronic board 430 is experiencing out-of-plane bending or bending about the transverse axis 457 (and observable from the side surface 447 extending the length of the electronic board 430). The first axial strain gauge 464A can be used to facilitate determining whether the electronic board 430 is experiencing a tensile (e.g., elongation) force or a compressive (e.g., shortening) force along the longitudinal axis 454. Such techniques will be discussed herein (including with respect to Fig.16 ) for further description.

[0092] Fig.164 is a bottom view of the second surface 490, which can be directly opposite the first surface 446 of the electronic board 430. The second out-of-plane bending strain gauge 462B can be along the centerline 453 on the second surface 490 and aligned with the first out-of-plane bending strain gauge 462A along the vertical axis 458. The resistance degree of the second out-of-plane bending strain gauge 462B relative to the resistance degree of the first out-of-plane bending strain gauge 462A can be used to determine whether the electronic board 430 is experiencing out-of-plane bending. For example, bending the electronic board 430 about the transverse axis 457 along the second bending direction 492 can lengthen the second out-of-plane bending strain gauge 462B and shorten the first out-of-plane bending strain gauge 462A, thereby changing (e.g., increasing) the resistance degree of the second out-of-plane bending strain gauge 462B and changing (e.g., decreasing) the resistance degree of the first out-of-plane bending strain gauge 462A. In this way, the resistance measurements of the out-of-plane bending strain gauges 462 relative to each other can be used to determine whether the electronic board 430 is experiencing out-of-plane bending, and the resistance measurements of the out-of-plane bending strain gauges 462 can be substantially unaffected by other strain deformations of the electronic board 430 .

[0093] The second axial strain gauge 464B may also be along the centerline 453 on the second surface 490 and aligned with the first axial strain gauge 464A along the perpendicular axis 458. The resistance degree of each axial strain gauge 464 may be used to determine the tensile / compressive strain deformation of the electronic board 430 along the longitudinal axis 454 and the transverse axis 457. For example, a tensile force applied to the electronic board 430 may cause the electronic board 430 to elongate along the first axial direction 494 along the longitudinal axis 454, and due to the Poisson effect, the tensile force may also cause the electronic board 430 to shorten along the second axial direction 496 along the transverse axis 457. That is, as the electronic board 430 is stretched along the longitudinal axis 454, it may become thinner along the transverse axis 457 because the material is pulled from the transverse axis 457 to along the longitudinal axis 454. The resistance degree of the two axial strain gauges 464 may indicate the elongation of the electronic board 430 along the first axial direction 494 and the shortening of the electronic board 430 along the second axial direction 496, and the resistance degree may be correlated to the tensile force. Furthermore, by placing the first axial strain gauge 464A on the first surface 446 and the second axial strain gauge 464B on the second surface 490, other strain deformations of the electronic board 430 do not substantially affect the resistance readings of the axial strain gauges 464. For example, out-of-plane bending of the electronic board 430 along the second bending direction 492 can increase the resistance readings of the second axial strain gauge 464B and can also reduce the resistance readings of the first axial strain gauge 464A. The corresponding changes in resistance can cancel each other out, so that the total resistance readings of the axial strain gauges 464 are not affected by out-of-plane bending of the electronic board 430. The axial strain gauges 464 can also be unaffected by torsion and in-plane bending. Thus, the strain gauges of the present disclosure can be connected to a bridge circuit so that each set of strain gauges selectively responds to a specific direction or type of deformation and is less sensitive or not sensitive at all to deformations along other directions.

[0094] Additional sensors may be included on the electronic board 430. For example, the electronic board 430 may include sensors that determine strain caused by vibration of the electronic board 430 relative to the chassis 204 or simply measure vibration. Such sensors may respond to movement of the electronic board 430 above a specific frequency (e.g., above 2.5 kHz, above 5 kHz, etc.). It should also be noted that other deformations of the electronic board 430 may not affect the strain deformation readings of the strain gauges 452, 456, 462, 464. For example, an increase in temperature may cause the electronic board 430 to stretch in each direction, thereby changing the resistance of the strain gauges 452, 456, 462, 464 in a manner that does not affect the corresponding readings of torsion, in-plane bending, out-of-plane bending, or axial strain. That is, temperature changes may affect the changes in the material fibers of each strain gauge 452, 456, 462, 464 equally and without changing the relative resistance readings that would indicate strain deformation. For example, for the axial strain gauges 464, an increase in temperature may cause the electronic board 430 to elongate along the longitudinal axis 454 and the transverse axis 457. The percentage of elongation of the first surface 446 of the electronic board 430 along the longitudinal axis 454 may be substantially equal to the percentage of elongation of the second surface 490 of the electronic board 430 along the longitudinal axis 454, and the percentage of elongation of the first surface 446 along the transverse axis 457 may be substantially equal to the percentage of elongation of the second surface 490 along the transverse axis 457. In this way, there is no substantial difference in resistance between the axial strain gauges 464, thereby indicating that there is no strain deformation caused by temperature changes. Therefore, the signals or feedback provided by the strain gauges 452, 456, 462, 464 accurately represent the specific strain deformation of interest and are temperature compensated.

[0095] Sometimes, the strain gauges 452, 456, 462, 464 may be used to monitor the condition of the electronic board 430. That is, the readings of the strain deformation may be used to determine the structural integrity of the electronic board 430, such as fatigue of solder joints or circuit traces associated with the electronic board 430. For example, the determined strain deformation of the electronic board 430 may be used to determine the strain load applied to the electronic board 430, or to determine whether the electronic board 430 is usable for operation of the BHA 18 or is to be replaced. In another example, the strain deformation may be used to determine how to improve the design of the electronic board 430 or how to implement the electronic board 430 in a location that will limit the applied strain deformation. For example, during operation of the drilling system 10 (e.g., by engaging a drill bit or drill collar with a geological formation 14), the load applied to the electronic board 430 may cause the electronic board 430 to deform. The strain deformation of the electronic board 430 may be used to determine a way to limit the forces applied to the electronic board 430 (e.g., attaching the electronic board 430 to a different location, implementing a protection system). For example, the electronics board 430 may store information regarding strain deformation, and the information may be analyzed during drilling operations or post-operations to determine the effects of the operation of the drilling system 10 on the electronics board 430 .

[0096] It should be noted that different strain gauges may be used in addition to or as an alternative to the strain gauges 452, 456, 462, 464 to determine the aforementioned strain deformation or to determine other types of strain deformation. In fact, the layout of the strain gauges 452, 456, 462, 464 may be modified in any suitable manner to determine any particular type of strain deformation of interest. In addition, the strain gauges 452, 456, 462, 464 may be implemented along different lengths or sections of the BHA 18. In this way, the strain deformation of different sections of the BHA 18 may be determined in order to determine a more accurate orientation of the BHA 18 at any given moment. The strain gauges 452, 456, 462, 464 may be foil strain gauges or any other suitable type of strain gauge.

[0097] Fig.175 is a graph 520 of strain of different components of the BHA 18 over time during an illustrative drilling operation. A first graph 522 shows strain of the chassis 204 over time, and a second graph 524 shows strain of the electronic board 430 over time. As shown in graph 520, the first graph 522 and the second graph 524 vary at approximately the same time and in the same direction, and thus correspond to each other in time and direction, indicating that the strain of the electronic board 430 approximately corresponds in time and direction to the strain of the chassis 204. The relative magnitudes of the measured strains may vary. For example, before time 526, the first graph 522 may be consistently greater than the second graph 524. To this end, a magnitude calibration or correction may be implemented to adjust the second graph 524 to more accurately represent the first graph 522. After time 526, the second graph 522 may show magnitudes that are consistently greater than the first graph 524. For example, at time 526, a particular event may impact the BHA 18 or the BHA 18 may operate in a particular operation to induce residual strain in the electronic board 430, which causes the strain deformation of the electronic board 430 to be greater than the strain deformation of the chassis 204. As a result, upon determining that such an event or operation has occurred, another magnitude calibration may be implemented to adjust the second curve 524 to more accurately represent the first curve 522. Additionally or alternatively, the graph 520 may be used to determine whether the electronic board 430 is securely coupled to the chassis. That is, the graph 520 may be used to determine whether the electronic board 430 is to be more securely coupled to the chassis 204 to limit movement between the electronic board 430 and the chassis 204. For example, by showing relative strains that do not correspond in time and direction, it may be determined that the electronic board 430 is moving relative to the chassis.

[0098] Fig.185 is a side cross-sectional view of the BHA 18, wherein the strain gauge 550 is coupled to a plate 552 that is separate from the electronic board 430. The plate 552 is coupled to the chassis 204 and the electronic board 430 by fasteners 554 such as screws or dowels (e.g., mechanical fasteners) to form a stacked configuration. The fasteners 554 can transmit strain deformation of the chassis 204 (or drill collar 200) to the electronic board 430 and the plate 552, so that the strain deformation determined by the strain gauge 550 indicates the corresponding strain deformation of the electronic board 430 and the chassis 204. In this way, the strain deformation determined using the strain gauge 550 can be used to control the BHA 18 to guide the BHA 18 through the wellbore 12, limit the strain deformation of the electronic board 430, evaluate tool design, evaluate operating parameters, etc. Sometimes, the plate 552 may be coupled to the chassis 204 or the electronics board 430 by another component (such as a weld, an adhesive, a mounting feature of the plate 552, or another suitable component) that transmits the strain deformation of the chassis 204 to the electronics board 430 and the plate 552. Sometimes, the plate 552 may be coupled to the chassis 204 without being coupled to the electronics board 430, or the plate 552 may be coupled to the drill collar 200 (e.g., to directly determine the strain deformation of the drill collar 200).

[0099] The plate 552 may be made of a material such as a metal, metal alloy, or polymer with a low stiffness (i.e., a more elastic material) or with a thinner cross-section to enable the chassis 204 to move to cause the plate 552 to move more easily, thereby limiting other movement of the plate 552 relative to the chassis 204 (e.g., due to sliding). In other words, the chassis 204 transmits strains to the plate 552 more easily without having to apply significant attachment forces to couple the plate 552 to the chassis 204. Thus, the strains of the plate 552 more accurately correspond to the strains of the chassis 204. In addition, the plate 552 may be made of a material having a similar coefficient of thermal expansion as the chassis 204 so that changes in temperature do not cause the plate 552 to move relative to the chassis 204.

[0100] The plate 552 can be easily coupled to and decoupled from the chassis 204 (e.g., by loosening or removing the fasteners 554). The assembly of the strain gauge 550 and the plate 552 can be implemented and removed from the BHA 18 without moving the BHA to a controlled environment. For example, the strain gauge 550 and the plate 552 can be easily removed from the BHA 18 and then reattached to the BHA 18, such as during maintenance, during replacement of a component of the BHA 18, or even at the well site. As another example, the strain gauge 550 and the plate 552 can be coupled to any existing BHA 18, such as to be retrofitted onto an existing chassis 204. In this way, the plate 552 provides greater flexibility to implement the strain gauge 550 onto a particular BHA 18.

[0101] The plate 552 may be formed into a specific shape that enables the plate 552 to be more responsive to specific strains and to avoid being affected by other strains. Fig.19 is a perspective view of a BHA 18 having a flex plate 580 that can be particularly responsive to torsional strain. The flex plate 580 can have two mounting surfaces 582A, 582B (collectively referred to as mounting surfaces 580) that can be coupled to the chassis 204, the drill collar 200, or another suitable component of the BHA 18 (e.g., within a groove or cavity formed in the component, within a cover of the tool, etc.). Each mounting surface 582 includes an opening 583 that enables a fastener to be inserted therethrough to couple the mounting surface 582 to the chassis 204, the drill collar 200, etc. Additionally or alternatively, the mounting surface 582 can be coupled to the chassis 204 or the drill collar 200 by a weld, an adhesive, etc. The flexure plate 580 may further have some sections 584A, 584B, 584C (collectively referred to as sections 584) removed to form two arms 586A, 586B (collectively referred to as arms 586). The arms 586 are generally straightened across the width or length of the flexure plate 580. Fig.19 As shown, the first section 584A of the first mounting surface 582A is removed, and the second section 584B and the third section 584C of the second mounting surface 582B are removed. The strain gauge 550 may then be attached to each arm 586.

[0102] The geometry of the flexure plate 580 may enable torsional deformation of the chassis 204 to be easily transferred to the flexure plate 580. For example, torsional deformation of the chassis 204 may be concentrated into the arms 586 and change the corresponding resistance of the strain gauges 550. The readings of the strain gauges 550 are compared to each other to determine the torsional strain of the flexure plate 580 and the chassis 204. For example, the first mounting surface 582A may be twisted in a first rotational direction 588, and the second mounting surface 582B may be twisted in a second rotational direction 590 opposite the first rotational direction 588. As a result, the first arm 586A may be extended and the second arm 586B may be shortened, thereby changing (e.g., increasing) the resistance reading of the first strain gauge 550A on the first arm 586A, and changing (e.g., decreasing) the resistance reading of the second strain gauge 550B on the second arm 586B. The difference in resistance readings between the strain gauges 550 may be used to determine the torsion of the flexure plate 580 and the BHA 18.

[0103] The geometry of the flex plate 580 and the placement of the strain gauges 550 on the flex plate 580 may prevent or limit other strain deformations from interfering with the torsional strain determination. More specifically, out-of-plane bending, in-plane bending, or axial strain may not affect the reading of the strain gauges 550 relative to each other, and such strain deformations may not be determined by the strain gauges 550. In this way, any changes in the relative resistance readings of the strain gauges 550 may be the result of the torsional strain of the flex plate 580, with minimal or no sensitivity to other types of strain.

[0104] Fig. 20 6 is a top view of a cross-plate 610 that can be used to couple the strain gauge 550 to the chassis 202, chassis 204, drill collar 200, BHA 18, or other component. The cross-plate 610 concentrates torsional deformation to more easily transfer torsional strain. The cross-plate 610 includes four legs 612 that extend away from a central section 614 that includes the strain gauge 550. Each leg 612 can be coupled to the chassis 204, drill collar 200, etc. (e.g., by a fastener inserted through a corresponding opening 616 of each leg 612). Under torsional loading of the cross-plate 610 (e.g., due to torsional strain of the chassis 204), the legs 612 can move relative to each other, thereby transferring torsional strain to the central section 614. The strain gauge 550, which can be similar to the torsional strain gauge 452, can then determine the transferred torsional strain to determine the torsional strain of the BHA 18.

[0105] The cross-plate 610 may enable torsional strain to be more directly transferred to the center section 614 for determination by the strain gauge 550 and provide a uniform strain field to measure the torsional strain. It should be noted that in some cases, the attachment between any plate and a component of the BHA 18 may affect the torsional strain readings associated with the plate. For example, there may be movement at the coupling points (e.g., fasteners) between the rectangular plate 552 and the component of the BHA 18 during torsion of the component, such as because the plate 552 is torsion-resistant. Such movement may limit the amount of torsional strain transferred to the plate 552 and determined by the strain gauge 550, thereby affecting the accuracy of the torsional strain readings generated by the strain gauge 550 that represent the torsional strain of the component. The movement may be taken into account in the torsional strain readings (e.g., the torsional strain readings may be calibrated or corrected based on the movement), or the movement may be limited by adding adhesive, implementing locking components, or other additional assembly steps. However, there may be less movement at the coupling points between the cross-plate 610 and the components because the cross-plate 610 enables torsional strain to be more efficiently transferred from the components to the cross-plate 610. As a result, the torsional strain readings generated by the strain gauges 550 may accurately represent the torsion of the components of the BHA 18 without having to perform additional assembly steps.

[0106] Fig.19and Fig. 20 The plates of the BHA 18 may easily transfer torsional strain, but other plates may be used for the same or other types of strain deformation. Therefore, the BHA 18 may employ plates with specific geometries that concentrate strain deformation in addition to torsional strain. Various plates may be positioned at different locations of the BHA 18. For example, a flex plate 580 or a cross plate 610 may be implemented at a section of the BHA 18 where torsional strain is of particular interest, and another plate may be positioned at a different section of the BHA where out-of-plane bending is of particular interest. Thus, the specific type of strain deformation of interest may be more accurately determined.

[0107] Fig.21 and Fig.23 Additional examples of plates and designs for force sensing structures are shown. The strain gauge arrangement is used with an electronic sensing circuit and can be adapted to measure bending strain in one, two or more directions. Fig.21 , an exemplary plate 752 has a three-dimensional shape represented by axes 769 (x-axis), 767 (y-axis), and 771 (z-axis). Plate 752 includes four posts 765 extending along a vertical axis 771. Two sidewalls 761 extend along a transverse axis 767 and a vertical axis 771. Posts 765 and sidewalls 761 can provide vertical elements or spacer elements that can be used to increase the spacing between strain gauges to exceed the spacing that can be provided by a relatively flat or two-dimensional plate. For example, in the case of a relatively flat plate, the physical spacing between strain gauges may be small because it may be the thickness of the plate. As a result, the signal from the strain gauge measuring bending may also be relatively low. By providing increased physical spacing, bending (e.g., out-of-plane bending) can be more easily detected because the signal can even be increased by at least one order of magnitude.

[0108] For plate 752, bending measurements can be made along multiple bending axes, such as x-axis 769 and vertical axis 771. Four strain gauges can be used to measure bending about each axis. For example, to measure bending about x-axis 769, four strain gauges 750A to 750D can be used. As shown, strain gauges 750A, 750B are mounted on the upper surface of side wall 761. Additional strain gauges 750C, 750D can be mounted on the bottom surface of side wall 761 or on another parallel surface. For example, at Fig.21, sidewall 761 includes a cutout, and the lower surface of the cutout provides a surface for positioning strain gauges 750C, 750D. Strain gauges 750A to 750D are aligned on the x-axis 769 (or aligned at the same location along the transverse axis 767), and strain gauges 750A, 750B are at the same height on the vertical axis 771. Strain gauges 750C, 750D may also be at the same height along the vertical axis 771, but at a different height than strain gauges 750A, 750B. The difference along the vertical axis 771 may provide a vertical or vertical offset between the upper strain gauges 750A, 750B and the lower strain gauges 750C, 750D, which may increase the differential bending signal between the two sets of strain gauges, which form a Fig. 22 As a result, when the plate 752 is deformed about the x-axis 769, the sidewall 761 will be in tension or compression, causing the strain gauges 750A to 750D to lengthen or shorten. Fig.21 When the x-axis 769 in FIG. 5 is bent, the strain gauges 750A and 750B may become longer (increase resistance), while the strain gauges 750C and 750D may simultaneously become shorter (decrease resistance).

[0109] Strain gauges 750E to 750H may be used in a similar manner to measure bending about vertical axis 771. In particular, strain gauges 750E, 750F may be located on the inner surface above the cutout of side wall 761, while strain gauges 750G, 750H may be located on the inner surface below the cutout of side wall 761. Due to this positioning, strain gauges 750F and 750H are located on the inner surface of side wall 761. Fig.21 However, strain gauges 750E to 750H are sometimes located on the outer surface of side wall 761.

[0110] The plate 752 (and corresponding strain gauges 750A-750H and sensing circuitry) selectively responds to the respective bending with no or negligible crosstalk to the output from bending about another axis. Thus, bending about the x-axis 769 has little or no crosstalk from bending about the vertical axis 771, and bending about the z-axis 771 likewise has little or no crosstalk from bending about the x-axis 769. Furthermore, the sensing circuitry described can compensate for any changes in ambient temperature and minimize mechanical crosstalk from other sensed strains. Such other strains can be caused, for example, by changes in bit weight (whether axial tension or compression), as well as those changes due to torsion. This may be the case because those forces produce equal or very small changes to the sidewall 761, so that the bridge circuit balance is not affected.

[0111] Plate 752 may also be used to provide a similar Fig.18 The described structures are stacked or nested. Fig.21 752, for example, circuit board 730 is shown in phantom lines. Circuit board 730 can be positioned in a cutout in post 765, or otherwise floated between the base and upper surface of board 752. When positioned in this manner, circuit board 730 can be isolated from flexing of the structure, such as by using elastomeric mounts, or can even be completely sealed inside using an electronic sealing compound (e.g., SYLGARD available from Dow Corning Corporation). Such a compound can secure the board inside board 752 while still allowing some flexing freedom on board 752 to allow the sensing circuit to operate.

[0112] The plate 752 may be used to detect torsional strain (eg, to determine torque on the plate 752 and ultimately the drill collar 200), optionally in combination with determining bending (eg, along the x-axis 769 or vertical axis 771). Fig.24 7 is a top view of a plate 752, wherein the plate includes a cross-shaped section 710. The cross-shaped section 710 can be integrally formed with or otherwise coupled to a sidewall 761, a post 765, or other component. For example, the four legs 712 of the cross-shaped section 710 can be coupled to a base 763 of the plate 752. The cross-shaped section 710 is integrally formed with or otherwise coupled to a base 763 or other portion of the plate 752 at a location that also allows a circuit board (e.g., circuit board 730) to also be coupled to the plate 752.

[0113] The cross-shaped section 710 may be similar to Fig. 20 The cross-plate 610 is used in the manner of a cross-plate 610 to couple the strain gauge 750J to a chassis, drill collar, BHA, circuit board, or other component. The cross-section 710 concentrates torsional deformation to more easily transfer torsional strain. Therefore, the four legs 712 can extend away from the center section including the strain gauge 750J. The legs 712 can also include openings to allow the cross-section 710 to be coupled to a circuit board, drill collar, chassis, etc.; however, the plate 752 can also be removably fastened to such components in other ways. For example, as Fig.21 and Fig.24As shown, the opening 716 can be positioned in the column 765 rather than in the leg 712. The opening 716 can be positioned to optionally allow retrofitting into an existing tool, or can be positioned for use in a custom tool. The specific type of fastener can vary, but can provide a secure and fully elastic coupling with little slip or plastic deformation. Through this connection, the strain gauge 750J can deform in response to torque applied to the drill collar. The strain gauge 750J itself can then have a pattern and attachment selected to be sensitive to such deformation (e.g., a V-shaped pattern can be used for torque), and calibration can be used to relate the strain measured on the cross-shaped section 710 to the torque applied to the drill collar.

[0114] Plate 752 is illustrative only and may vary in any number of ways and may also be made of any suitable material. For example, plate 752 may be formed of a metal, a metal alloy, a composite material, an organic material, or a polymer material, or a combination thereof. Plate 752 may also be formed in any suitable manner. For example, plate 752 may be machined, cast / molded, additively manufactured, or produced in any other suitable manner. The shape may also vary as desired, such as by modifying the shape of the cross-shaped segments, sidewalls, columns, etc. The size may also vary to provide greater or lesser spacing between strain gauges in the same bridge, and the strain gauges may be used to measure any suitable strain, and are not limited to in-plane bending, out-of-plane bending, axial strain, or torsional strain.

[0115] Fig.25 8 is a flow chart of a method 840 for operating a drilling system or a component thereof (e.g., the drilling system 10, the drill string 16, or the BHA 18) based on determined strain deformation. The method 840 may be performed by a controller such as the data processing system 160 and may be performed for any of the BHAs 18 described herein. At box 842, the data processing system 160 receives feedback or another signal from a sensor (e.g., the sensor 167), which may include any of the strain gauges or alternative sensors discussed herein or any other suitable sensor. Such feedback indicates strain deformation of the BHA 18, including out-of-plane bending, in-plane bending, torsion, or axial strain of a component (e.g., the chassis 204, the drill collar 200, the electronic board 430, etc.).

[0116] At block 844, the data processing system 160 operates the drilling system 10 based on the feedback received from the sensor 167. For example, the feedback (e.g., the out-of-plane bending strain is above a threshold strain) may indicate that the BHA 18 may be directing the drill bit 20 along a path that deviates from the desired wellbore path and is instead drilling the wellbore 12 toward an expected position that is away from the target position. As a result, certain operations of the drilling system 10 (such as the rotational speed or WOB of the drill bit 20) may be adjusted to change the bending and drive the BHA 18 toward the target position (e.g., when it is determined that the expected position differs from the target position by a threshold distance). In another example, the feedback may indicate that an undesirable force is being applied to the BHA 18 and may affect the performance of the BHA 18 (e.g., the quality of the wellbore 12) or the structural integrity or other health of the BHA 18. Therefore, the operation of the drilling system 10 may be adjusted to reduce or limit the effects of the undesirable force.

[0117] In order to provide a concise description, not all features of actual implementations are described. The terms "comprising," "including," and "having" are inclusive and mean that in addition to the listed elements, there may be additional elements. The description of a specific example is not intended to be interpreted as excluding the existence of additional examples or features that incorporate the same or other features. In addition, a list of alternative features or aspects connected by "or" is intended to indicate that one or more of such features or aspects may be included, rather than that such features are merely alternatives.

[0118] Although the description is primarily with reference to downhole drilling operations for extracting hydrocarbons, the embodiments of the present disclosure are not related to any particular environment, industry, or application. For example, drilling techniques for forming a wellbore to set a utility pipeline are also applicable to the present disclosure. In addition, any industry or application where the measurement of strain can affect the operating performance of equipment can utilize aspects of the present invention, including in the automotive, aerospace, construction, manufacturing, mining, and alternative energy industries and applications.

[0119] The examples herein are susceptible to various modifications and alternative forms. The claims are not intended to be limited to the particular forms disclosed, but rather are intended to cover all modifications, equivalents, and alternatives falling within the scope of the claims in light of the present disclosure.

Claims

1. A bottom hole assembly of a drill string, the bottom hole assembly comprising: Drill collars; a plate coupled to the drill collar; as well as a strain gauge coupled to the plate and configured to output a signal associated with a strain deformation of the plate, Wherein, the strain gauges include at least one torsional strain gauge, at least one in-plane strain gauge, at least one out-of-plane strain gauge and at least one axial strain gauge, the torsional strain gauge measures the torsional strain deformation of the plate and is isolated from measuring the in-plane bending, out-of-plane bending and axial strain deformation of the plate, the in-plane strain gauge measures the in-plane bending strain deformation of the plate and is isolated from measuring the torsion, out-of-plane bending and axial strain deformation of the plate, the out-of-plane strain gauge measures the out-of-plane bending strain deformation of the plate and is isolated from measuring the torsion, in-plane bending and axial strain deformation of the plate, and the axial strain gauge measures the axial strain deformation of the plate and is isolated from measuring the torsion, in-plane bending and out-of-plane bending strain deformation of the plate.

2. The bottom hole assembly of claim 1, further comprising: A base plate is coupled to the drill collar, wherein the drill collar is positioned about the base plate, the plate, and the strain gauge.

3. The bottom drilling assembly of claim 1 , further comprising an electronic board coupled to the board or as a part of the board and configured to receive the signal output by the strain gauge and perform one or more of operating the bottom drilling assembly based on the signal or storing strain deformation information based on the signal.

4. The bottom hole assembly of claim 1, wherein the board comprises an electronics board, the electronics board: communicatively coupled to the strain gauge; configured to receive the signal output by the strain gauge; and The bottom hole assembly is operated based on the signal, strain deformation information is stored based on the signal, or both.

5. The bottom hole assembly of claim 1, wherein the strain gauge comprises: Torsional strain gauges, in-plane bending strain gauges, out-of-plane bending strain gauges, axial strain gauges, or any combination thereof.

6. The bottom hole assembly of claim 5, the torsional strain gauge being on the first surface of the plate such that readings of the torsional strain gauge correspond to torsional deformation of the drill collar and are isolated from in-plane, out-of-plane and axial strain deformations.

7. The bottom hole assembly of claim 5, wherein the strain gauge comprises: a first in-plane bending strain gauge located on a first surface of the plate on a first side of a centerline of the plate; as well as and a second in-plane bending strain gauge located on the first surface on a second side of the centerline of the plate and substantially aligned with the first in-plane bending strain gauge along a transverse axis of the plate such that readings of the first and second in-plane bending strain gauges correspond to in-plane bending strain deformation of the drill collar and are isolated from torsional, out-of-plane and axial strain deformations.

8. The bottom hole assembly of claim 5, wherein the strain gauge comprises: a first out-of-plane bending strain gauge disposed on a first surface of the plate along a centerline of the plate; as well as and a second out-of-plane bending strain gauge on a second surface of the plate along the centerline and substantially aligned with the first out-of-plane bending strain gauge along a vertical axis of the plate such that readings of the first and second out-of-plane bending strain gauges correspond to out-of-plane bending strain deformation of the drill collar and are isolated from torsional, in-plane and axial strain deformations.

9. The bottom hole assembly of claim 5, wherein the strain gauge comprises: a first axial strain gauge disposed on a first surface of the plate along a centerline of the plate; as well as and a second axial strain gauge on a second surface of the plate along the centerline and aligned with the first axial strain gauge along a perpendicular axis of the plate such that readings of the first and second axial strain gauges correspond to axial strain deformation of the drill collar and are isolated from torsional, out-of-plane and in-plane strain deformations.

10. The bottom hole assembly of claim 1, the plate having a cross shape or including a portion having a cross shape, wherein the strain gauge is positioned at a center section of the cross shape.

11. A bottom hole assembly of a drill string, comprising: Chassis; an electronics board coupled to the chassis and configured to operate the bottom drilling assembly; as well as a strain gauge coupled to the electronics board and configured to transmit a signal indicative of strain deformation to the electronics board so that the electronics board controls operation of the bottom hole assembly based at least in part on the signal indicative of the strain deformation, Wherein, the electronic board includes a board, at least one torsional strain gauge, at least one in-plane strain gauge, at least one out-of-plane strain gauge and at least one axial strain gauge are coupled to the board, the torsional strain gauge measures the torsional strain deformation of the board and is isolated from measuring the in-plane bending, out-of-plane bending and axial strain deformation of the board, the in-plane strain gauge measures the in-plane bending strain deformation of the board and is isolated from measuring the torsion, out-of-plane bending and axial strain deformation of the board, the out-of-plane strain gauge measures the out-of-plane bending strain deformation of the board and is isolated from measuring the torsion, in-plane bending and axial strain deformation of the board, the axial strain gauge measures the axial strain deformation of the board and is isolated from measuring the torsion, in-plane bending and out-of-plane bending strain deformation of the board.

12. The bottom hole assembly of claim 11, the electronics board being configured to calibrate the strain deformation indicated by the signal to generate an additional strain deformation associated with the chassis.

13. The bottom hole assembly of claim 12, said further strain deformation representing a torsion on said bottom plate.

14. The bottom hole assembly of claim 11, wherein the electronic board is configured as: determining an estimated position of the bottom hole assembly based on the signal; comparing the predicted position to a target position; and The bottom hole assembly is operated to guide the bottom hole assembly toward the target location.

15. The bottom hole assembly of claim 11, the electronic board being configured to: based on the signal, operate the bottom hole assembly to reduce the strain deformation indicated by the signal, store strain deformation information, or both.

16. The bottom hole assembly of claim 11, wherein the strain deformation comprises: Torsional strain, out-of-plane bending strain, in-plane bending strain, axial strain, or any combination thereof.

17. The bottom hole assembly of claim 11, further comprising: Drill collars; as well as an internal component including the chassis and located at least partially within the drill collar, the internal component coupled to the electronics board such that the electronics board is located within the drill collar, and wherein the signal to the electronics board indicative of the strain deformation corresponds to a torque on the drill collar.

18. The bottom hole assembly of claim 11, further comprising: A plate is coupled to the strain gauge and removably coupled to the electronics board, the plate having a cross shape or including a cross-shaped portion.

19. A plate for use in a downhole tool within a bottom hole assembly, the plate comprising: a first surface; a second surface, the second surface being parallel to the first surface; a torsional strain gauge coupled to the first surface or the second surface; two in-plane bending strain gauges, each coupled to the first surface or each coupled to the second surface, the two in-plane bending strain gauges being located on opposite sides of a centerline of the plate and aligned along a transverse axis of the plate; a first out-of-plane bending strain gauge coupled to the first surface of the plate along the centerline of the plate; a second out-of-plane bending strain gauge coupled to the second surface of the plate along the centerline and aligned with the first out-of-plane bending strain gauge along a vertical axis of the plate; a first axial strain gauge coupled to the first surface of the plate along the centerline of the plate; as well as A second axial strain gauge is coupled to the second surface of the plate along the centerline and aligned with the first axial strain gauge along the vertical axis.

20. The board of claim 19, comprising an electronic board configured to receive corresponding signals from the torsional strain gauge, the two in-plane bending strain gauges, the first out-of-plane bending strain gauge, the second out-of-plane bending strain gauge, the first axial strain gauge, the second axial strain gauge, or any combination thereof, and to operate the bottom drilling assembly based on the corresponding signals received from the strain gauges.

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