A large-size high-speed shear valve type mud pulse generator

Abstract

The present invention belongs to the technical field of logging-while-drilling instruments, and discloses a large-size high-speed shear valve type mud pulser capable of improving transmission rate and displacement. It includes a vortex generator drill collar with an internal turbine generator, a circuit drill collar with an internal instrument circuit, a pulser drill collar with an internal pulse generator, and a hard connection drill collar with an internal hard connection. At both ends of the circuit skeleton in the circuit drill collar, an upstream flow channel converter connected to the turbine generator and a downstream flow channel converter connected to the pulse generator are respectively connected. The pulse generator includes a motor housing connected to the downstream flow channel converter, a motor stator fixed therein, a motor rotor located inside the motor stator, a torsion shaft connected to the motor rotor, a shear valve connected to the torsion shaft, and a shear valve plate connected to the motor housing and arranged in parallel and spaced apart from the shear valve. The torsion shaft at least includes a fixed section axially passing through the motor rotor and connected to the motor housing, a torsion section axially penetrating and suspended inside the motor rotor, and a shear valve installation section connecting the shear valve.

Description

Technical Field

[0001] The present invention relates to the technical field of logging-while-drilling instruments, and particularly relates to a large-size high-speed shear valve type mud pulse generator. Background Art

[0002] The high-speed mud pulse generator while drilling is used to supply power and transmit signals to downhole tools while drilling under the conditions of high temperature, high pressure and vibration downhole.

[0003] Conventional high-speed mud pulse generators only meet the power supply and two-way communication requirements for downhole tools while drilling in wellbores with a diameter of less than 8.5 inches. And restricted by the stator and rotor structures of the high-speed mud pulse generator, the maximum transmission rate of the instrument is 12 bps, and the maximum applicable displacement is 3.6 m 3 / min, which is not sufficient to meet the operation requirements of large displacement in surface wellbores. At the same time, restricted by the turbine structure, the maximum power of the turbine generator is 300 W, the number of downhole tools while drilling connected is limited, and the applicable displacement of existing downhole tools while drilling is fixed and cannot be adjusted for operation requirements outside the displacement range. In addition, all existing high-speed mud pulse generators adopt the process of directly cladding wear-resistant bands on the drill collar body. Eddy currents will be formed near the connection between the wear-resistant band and the drill collar during large-displacement downhole operations, which will cause the drill collar near the wear-resistant band to be easily eroded. The cost of repairing the drill collar is high, and the time consumption is long, resulting in huge losses. Summary of the Invention

[0004] In order to improve the transmission rate and displacement of the existing high-speed mud pulse generator, the present invention provides a large-size high-speed shear valve type mud pulse generator.

[0005] The large-size high-speed shear valve type mud pulse generator according to the present invention includes: a vortex generator drill collar, a circuit drill collar, a pulse generator drill collar and a hard connection drill collar that are sequentially threadedly connected. A turbine generator is arranged inside the vortex generator drill collar, an instrument circuit is arranged inside the circuit drill collar, a pulse generator is arranged inside the pulse generator drill collar, and a hard connection is arranged inside the hard connection drill collar. Both ends of the circuit skeleton inside the circuit drill collar are respectively fixedly connected with an upper flow channel converter and a lower flow channel converter. The upper flow channel converter is connected to the turbine generator, and the lower flow channel converter is connected to the pulse generator. Among them, the pulse generator includes a motor housing connected to the lower flow channel converter, a motor stator fixed inside the motor housing, a motor rotor coaxially arranged inside the motor stator, a torsion shaft connected to the motor rotor, a shear valve connected to the torsion shaft, and a shear valve plate fixedly connected to the motor housing. The shear valve and the shear valve plate are arranged in parallel at intervals. The torsion shaft at least includes a fixed section, a torsion section and a shear valve installation section that are sequentially connected. The fixed section axially passes through the motor rotor and is fixedly connected to the motor housing. The torsion section axially penetrates into and is suspended inside the motor rotor. The shear valve installation section is used to connect the shear valve.

[0006] Further, the torsion shaft further includes a first bearing mounting section and a second bearing mounting section connected between the torsion section and the shear valve mounting section, and a limiting section located between the first bearing mounting section and the second bearing mounting section. The pulse generator further includes a bearing group mounted on the first bearing mounting section, a small bearing mounted on the second bearing mounting section, and a leather bag mounted between the motor housing and the small bearing. One end of the leather bag is fixedly connected to the small bearing, and the other end is fixedly connected to the area of the motor housing near the limiting section. The area of the first bearing mounting section between the torsion section and the bearing group is fixedly connected to the motor rotor.

[0007] Further, the shear valve mounting section is configured as a special-shaped pentagonal structure, and a special-shaped pentagonal hole for cooperating with the special-shaped pentagonal structure is provided at the center of the shear valve.

[0008] Further, the shear valve includes a valve body and a plurality of valve leaves formed on the outer periphery of one side end face of the valve body. The special-shaped pentagonal hole axially penetrates through the center of the valve body. The shear valve further includes a reinforcing rib extending from the upper region of the valve leaf towards the other side end face of the valve body. The region where the reinforcing rib is connected to the valve leaf has a rounded corner. The outer diameter range of the shear valve is: 95 - 115 mm, the range of the number of opening angles is: 6 - 8, the range of the rounded corner is: R10 - R50 mm, the angle range of the reinforcing rib is: 35° - 60°, the thickness range of the reinforcing rib is: 8 - 16 mm. The shear valve sheet includes a shear valve sheet body and a plurality of valve sheets formed on the outer periphery of the shear valve sheet body. An overflow channel is formed between adjacent valve sheets. The outer diameter range of the valve sheet is: 90 - 110 mm, and the range of the number of opening angles is: 6 - 8.

[0009] Further, the pulse generator further includes a micro-reducer mounted on the first bearing mounting section and located at the front end of the bearing group.

[0010] Further, the turbo generator includes a generator body connected to the upstream flow channel converter, a guide wheel fixedly connected to the generator body, and a turbine magnetically coupled to the generator body. The turbine is located behind the guide wheel. High-speed mud flows towards the turbine under the guiding action of the guide wheel, causing the turbine to rotate, thereby driving the generator body to generate electricity.

[0011] Further, the guide wheel is integrally formed with the generator body, and the turbine is integrally formed.

[0012] Further, the outer surfaces of the guide wheel and the turbine, and the inner surfaces of the upstream flow channel converter and the downstream flow channel converter are sprayed with strength reinforcement materials.

[0013] Furthermore, the circuit skeleton includes a test section and a circuit board installation section which are connected in sequence, the test section is connected to the upper flow channel converter, the circuit board installation section is connected to the lower flow channel converter, a circuit board is installed on the circuit board installation section, a holding tube is provided on the outer cover of the circuit board, a circuit test port is opened on the area of ​​the circuit drill corresponding to the test section, a cover plate is detachably connected to the circuit test port, and a sunken wear-resistant belt is provided on the area of ​​the circuit drill near the cover plate and / or the outer peripheral wall of the holding tube.

[0014] Furthermore, grooves are provided in the area of ​​the circuit drill bit near the cover plate and / or on the outer peripheral wall of the clamping tube. The sunken wear-resistant belt includes a plurality of wear-resistant layers which are connected in sequence from bottom to top in the groove and are arranged in a stepped manner with gradually decreasing sizes. The wear-resistant layer at the bottom fills and is fixed in the entire groove, and its top end is flush with the opening of the groove.

[0015] Compared with the prior art, the large-size high-speed shear valve type mud pulser of the present invention has the following advantages:

[0016] 1) The structure of connecting the torsion shaft and the shear valve was first created, and the structure of the torsion shaft was optimized, so that each section has different functions and outer diameters, and the overall length of the torsion shaft is more slender, thus realizing the multi-speed selection of the swing frequency in the range of 12~60Hz, which can adapt to the maximum of 6m 3 / min high displacement mud flow, can meet the highest transmission rate of 40bps;

[0017] 2) The use of the bearing group enables the torsion shaft and the motor housing to be connected through a ball bearing, which ensures the concentricity of the inner and outer circles, reduces the friction between the rotation of the torsion shaft, reduces fatigue stress, and thus increases the service life of the torsion shaft;

[0018] 3) The torsion shaft and the shear valve are connected by a special-shaped five-sided structure, which can not only drive the shear valve to swing with less energy consumption, but also ensure that the fatigue stress under high-frequency swing is not too large, reducing the risk of slipping teeth, thereby further improving the service life of the torsion shaft;

[0019] 4) The size parameters of the shear valve and shear valve plate are optimized, effectively increasing the service life of the shear valve and shear valve plate;

[0020] 5) A small-sized reducer is installed in front of the bearing group of the torsion shaft, which reduces the swing frequency of the torsion shaft, increases the swing torque of the torsion shaft, reduces energy consumption, and thus reduces the output power of the motor;

[0021] 6) A limit arm is set between the torsion shaft and the motor housing to limit the swing amplitude of the torsion shaft and prevent the torsion shaft from breaking and failing due to excessive torsion;

[0022] 7) A leather bag is arranged between the motor housing and the small bearing, which can ensure that the internal and external pressures of the pulser assembly remain dynamically balanced under the action of mud. At the same time, a small bearing is installed at the front end of the torsion shaft shear valve, which can prevent the leather bag from deforming frequently due to the torsion of the torsion shaft and from failing due to excessive fatigue stress;

[0023] 8) Optimize the mechanical structures and processing technologies of the turbine, guide wheel, upstream flow channel converter, and downstream flow channel converter, and spray strength reinforcement materials on the turbine, guide wheel, upstream flow channel converter, and downstream flow channel converter, so that their erosion resistance performance is higher, the service life of the instrument is longer, and it is beneficial to meet the operation requirements of the instrument under high displacement;

[0024] 9) The structural design of the sunken wear-resistant belt enables the downhole mud to wash not the drill collar itself but the sunken wear-resistant belt. After the operation is completed, the sunken wear-resistant belt can be repaired, increasing the number of wells and the service time of the drill collar. At the same time, the mud flow field in the wellbore and the tool annulus is also optimized, which not only protects the tool body but also extends the service life of the tool. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A cross-sectional schematic diagram of the structure of a large-size high-speed shear valve type mud pulser according to an embodiment of the present invention;

[0026] Figure 2 is Figure 1 A schematic diagram of the structure of the first embodiment of the pulse generator shown;

[0027] Figure 3 is Figure 2 A cross-sectional schematic diagram taken along the B-B direction shown;

[0028] Figure 4 is Figure 1 A schematic diagram of the structure of the torsion shaft shown, where the upper figure shows the front structure of the torsion shaft and the lower figure shows the back structure of the torsion shaft;

[0029] Figure 5 is Figure 4 A cross-sectional schematic diagram of the shear valve installation section shown;

[0030] Figure 6 is Figure 2 A schematic diagram of the structure of the shear valve shown, where the upper figure shows the front structure of the shear valve and the lower figure shows the three-dimensional structure of the shear valve;

[0031] Figure 7 is Figure 2 A schematic diagram of the structure of the shear valve plate shown, where the upper figure shows the three-dimensional structure of the shear valve plate and the lower figure shows the front structure of the shear valve plate;

[0032] Figure 8 isFigure 1 Schematic structural diagram of the second embodiment of the pulse generator shown;

[0033] Figure 9 Is a three-dimensional schematic diagram of the structure of a large-size high-speed shear valve type mud pulsator according to an embodiment of the present invention;

[0034] Figure 10 Is Figure 9 Schematic structural diagram of the sinking wear-resistant belt shown;

[0035] Figure 11 Is Figure 1 Schematic structural diagram of the upper flow deflector assembly shown;

[0036] Figure 12 Is Figure 1 Schematic structural diagram of the lower flow deflector assembly shown.

[0037] Description of reference numerals: 100 - large-size high-speed shear valve type mud pulsator, 1 - vortex drill collar, 2 - circuit drill collar, 3 - pulsator drill collar, 4 - hard connection drill collar, 5 - upper flow deflector assembly, 6 - circuit skeleton, 7 - pulse generator, 8 - hard connection, 9 - upper flow channel converter, 10 - lower flow channel converter, 11 - turbo generator, 12 - lower flow deflector assembly, 13 - holding cylinder, 14 - circuit board installation section, 71 - motor housing, 72 - motor stator, 73 - motor rotor, 74 - torsion shaft, 75 - shear valve, 76 - shear valve plate, 77 - bearing group, 78 - leather bag, 79 - small bearing, 70 - first set screw, 741 - fixed section, 742 - torsion section, 743 - first bearing installation section, 744 - limiting section, 745 - second bearing installation section, 746 - shear valve installation section, 747 - limiting arm, 700 - special shape, 751 - valve body, 752 - valve leaf, 753 - special-shaped pentagonal hole, 754 - reinforcing rib, 755 - fillet, 756 - outer diameter of the shear valve, 761 - valve plate, 762 - flow-through channel, 763 - outer diameter of the valve plate, 701 - micro reducer, 702 - planet carrier, 703 - planet gear, 704 - internal gear ring, 705 - sun gear, 101 - sinking wear-resistant belt, 102 - cover plate, 104 - groove, 1011 - first wear-resistant layer, 1012 - second wear-resistant layer, 1013 - third wear-resistant layer, 51 - upper flow deflector, 52 - TIP head, 121 - lower flow deflector, 122 - hard connection piece. Detailed implementation manners

[0038] In order to better understand the purpose, structure and function of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0039] Figure 1 Shows the structure of a large-size high-speed shear valve type mud pulsator 100 according to an embodiment of the present invention. AsFigure 1 As shown, the large-size high-speed shear valve type mud pulse generator 100 may include: a vortex drill collar 1, a circuit drill collar 2, a pulse generator drill collar 3, and a hard connection drill collar 4 that are sequentially threadedly connected. A turbo generator 11 is built into the vortex drill collar 1, an instrument circuit is built into the circuit drill collar 2, a pulse generator 7 is built into the pulse generator drill collar 3, a hard connection 8 is built into the hard connection drill collar 4. At both ends of a circuit skeleton 6 in the circuit drill collar 2, an upstream flow channel converter 9 and a downstream flow channel converter 10 are respectively fixedly connected. The upstream flow channel converter 9 is connected to the turbo generator 11, and the downstream flow channel converter 10 is connected to the pulse generator 7. Among them, in combination with Figure 2 As shown, the pulse generator 7 may include a motor housing 71 connected to the downstream flow channel converter 10, a motor stator 72 fixed within the motor housing 71, a motor rotor 73 coaxially arranged within the motor stator 72, a torsion shaft 74 connected to the motor rotor 73, a shear valve 75 connected to the torsion shaft 74, and a shear valve plate 76 fixedly connected to the motor housing 71. The shear valve 75 and the shear valve plate 76 are arranged in parallel at intervals. In combination with Figure 4 As shown, the torsion shaft 74 at least includes a fixed section 741, a torsion section 742, and a shear valve mounting section 746 that are sequentially connected. The fixed section 741 axially passes through the motor rotor 73 and is fixedly connected to the motor housing 71. The torsion section 742 axially penetrates and is suspended within the motor rotor 73. The shear valve mounting section 746 is used to connect the shear valve 75.

[0040] The purpose of the large-size high-speed shear valve type mud pulse generator 100 of the embodiment of the present invention is to meet the high requirements of large-displacement wellbore operations. In the large-size high-speed shear valve type mud pulse generator 100 of the embodiment of the present invention, a structure in which the torsion shaft 74 is connected to the shear valve 75 is first created. By optimizing the structure and function of the torsion shaft 74, the large-size mud pulse generator can operate efficiently and stably under the conditions of high displacement and high transmission rate in a large wellbore. Among them, by optimizing the structure of the torsion shaft 74, each section thereof is different in function and outer diameter size. Such a segmented torsion shaft design adapts to the high torque requirements of the large-size shear valve, can achieve a wide frequency adjustment of 12 - 60 Hz, and meet high-displacement operations. The segmented torsion shaft design also makes the overall length of the torsion shaft 74 more slender, and the total length can be increased by 40%, which can adapt to a high-displacement mud flow rate of up to 6 m 3 / min and meet a transmission rate of up to 40 bps.

[0041] In a preferred embodiment as shown in Figure 4 As shown, the torsion shaft 74 may further include a first bearing mounting section 743 and a second bearing mounting section 745 connected between the torsion section 742 and the shear valve mounting section 746, and a limiting section 744 located between the first bearing mounting section 743 and the second bearing mounting section 745. As shown in Figure 2As shown, the pulse generator 7 may further include a bearing set 77 mounted on the first bearing mounting section 743, a small bearing 79 mounted on the second bearing mounting section 745, and a flexible bag 78 mounted between the motor housing 71 and the small bearing 79. One end of the flexible bag 78 is fixedly connected to the small bearing 79, and the other end is fixedly connected to the area of the motor housing 71 near the limiting section 744. The area of the first bearing mounting section 743 between the torsion section 742 and the bearing set 77 is fixedly connected to the motor rotor 73.

[0042] In this embodiment, a bearing set 77 is provided between the first bearing mounting section 743 of the torsion shaft 74 and the motor housing 71. The bearing set 77 can be a plurality of combined ball bearings, which ensures the concentricity of the inner and outer circles, reduces the friction generated by the rotation of the torsion shaft 74, thereby reducing the fatigue stress and increasing the service life of the torsion shaft 74. The function of the flexible bag 78 is to inject oil inside the pulse generator 7 to ensure that the internal and external pressures of the pulse generator 7 remain dynamically balanced under the action of mud. The small bearing 79 on the second bearing mounting section 745 is used to prevent the flexible bag 78 from deforming frequently due to the torsion of the torsion shaft and failing due to excessive fatigue stress.

[0043] Preferably, as Figure 4 shown, the limiting section 744 may include two limiting arms 747 radially extending outwardly from the opposite sides of the limiting section respectively. Limiting grooves (not shown in the figure) matching with the limiting arms 747 are formed on the inner surface of the motor housing 71 opposite to the limiting section 744, and the limiting arms 747 move within the range defined by the limiting grooves. The limiting arms 747 are used to limit the swinging amplitude of the torsion shaft 74 and prevent the torsion shaft 74 from breaking and failing due to excessive torsion.

[0044] In the preferred embodiment as Figure 2 and Figure 3 shown, three first set screws 70 evenly distributed at 120° may also be provided on the pulse tool drill collar 3 to fix and straighten the shear valve plate 76.

[0045] In the preferred embodiment as Figure 4 and as Figure 5 shown, the shear valve mounting section 746 may be configured as a special-shaped pentagonal structure, and its cross-sectional shape is a special-shaped 700 similar to a flower shape as Figure 5 shown. A special-shaped pentagonal hole 753 for cooperating with the special-shaped pentagonal structure is provided at the center of the shear valve 75 (as Figure 6(as shown). In this embodiment, the signal controls the electromagnet of the motor stator 72, thereby driving the rotation of the motor rotor 73, and further driving the rotation of the torsion shaft 74. The torsion shaft 74 undergoes torsion in the torsion section 742, and then drives the shear valve 75 to twist through the special-shaped pentagonal structure of the shear valve installation section 746, thereby changing the mud flow-through area, and further changing the mud pressure to generate a pulse signal. This special-shaped pentagonal structure can drive the shear valve 75 to swing with less energy consumption, and ensure that the fatigue stress under high-frequency swinging is not too large, reducing the risk of slipping teeth, thereby improving the service life of the torsion shaft 74.

[0046] In the preferred embodiment as Figure 6 and as Figure 7 shown, the shear valve 75 may include a valve body 751 and a plurality of valve leaves 752 formed on the outer periphery of one end face of the valve body 751. The special-shaped pentagonal hole 753 axially penetrates the center of the valve body 751. The shear valve 75 further includes a reinforcing rib 754 extending from the upper region of the valve leaf 752 towards the other end face of the valve body 751. A fillet 755 is formed in the region where the reinforcing rib 754 is connected to the valve leaf 752. The range of the outer diameter 756 of the shear valve is preferably: 95 - 115 mm. The range of the number of opening angles α is preferably: 6 - 8. The range of the fillet 755 is preferably: R10 - R50 mm. The range of the angle of the reinforcing rib 754 is preferably: 35° - 60°. The range of the thickness of the reinforcing rib 754 is preferably: 8 - 16 mm. The shear valve plate 76 includes a shear valve plate body and a plurality of valve plates 761 formed on the outer periphery of the shear valve plate body. An over-flow channel 762 is formed between adjacent valve plates 761. The range of the outer diameter 763 of the valve plate is preferably: 90 - 110 mm. The range of the number of opening angles β of the valve plate is preferably: 6 - 8.

[0047] In this embodiment, by optimizing the structures of the shear valve 75 and the shear valve plate 76, it can further meet the operation requirements of high displacement and high transmission rate, and at the same time improve the durability and stability of the large-size high-speed shear valve type mud pulse generator 100 under large-size conditions. Among them, the number and opening angle of the opening angles of the shear valve 75 and the shear valve plate 76 determine the flow-through area of the mud flowing through the shear valve, that is, determine the flow rate of the mud. Through the setting of the range of the number of the above-mentioned opening angles, the opening angle of the valve is appropriately increased, which can increase the flow-through area, reduce the mud flow rate, and reduce the erosion of the mud, thereby improving the service life of the shear valve 75 and the shear valve plate 76; at the same time, the number of the opening angles of the shear valve 75 and the shear valve plate 76 also determines the rotation amplitude of the torsion shaft 74. Through the above setting, appropriately increasing the number of opening angles can reduce the torsion amplitude of the torsion shaft 74 and extend the service life of the torsion shaft 74. Preferably, the number of the opening angle α of the shear valve 75 is preferably 3, and the number of the opening angle β of the valve plate 761 is preferably 3.

[0048] The outer diameter dimensions of the shear valve 75 and the shear valve plate 76 determine the flow area of the mud flowing through the shear valve 75 and the shear valve plate 76. By appropriately reducing the outer diameter dimensions of the shear valve 75 and the shear valve plate 76, the erosion of the mud on the shear valve 75 and the shear valve plate 76 can be reduced. However, at the same time, it will also bring the disadvantage that the mud signal fluctuation is not strong enough. Therefore, the above range of outer diameter dimensions is set in this application, which can reduce the erosion of the mud on the shear valve while increasing the degree of mud signal fluctuation.

[0049] The fillet 755 determines the size of the eddy current generated when the mud flows through. By setting the above range of the radius of the fillet 755, the radius of the fillet 755 is appropriately increased, making the mud flow velocity change smoothly, reducing the erosion of the mud, and increasing the service life of the shear valve 75.

[0050] The angle and thickness of the reinforcing rib 754 of the shear valve 75 determine the structural strength of the shear valve 75. By setting the above range of the angle and thickness of the reinforcing rib 754, the thickness is appropriately increased, which can improve the strength of the shear valve 75 and increase its service life.

[0051] In the preferred embodiment as Figure 8 shown, the difference from the embodiment as Figure 2 shown is that the pulse generator 7 may further include a micro-reducer 701 mounted on the first bearing mounting section 743 and located at the front end of the bearing group 77. The setting of the micro-reducer 701 is used to reduce the swing frequency of the torsion shaft 74, increase the swing torque of the torsion shaft 74, reduce the energy consumption, and reduce the output power of the motor. By introducing the micro-reducer 701 into the large-size high-speed shear valve type mud pulse generator 100, the driving efficiency and energy management of the torsion shaft 74 are optimized, enabling it to better adapt to the operation requirements of high displacement and high transmission rate.

[0052] As Figure 8 shown, the micro-reducer 701 may include a planet carrier 702 connected to the right half section of the first bearing mounting section 743, planet gears 703 connected to the planet carrier 702, a sun gear 705 connected to the left half section of the first bearing mounting section 743, the sun gear 705 meshing with the planet gears 703 on the outside, an internal gear ring 704 meshing with the outside of the planet gears 703, and the internal gear ring 704 is fixedly connected to the pulse generator drill collar 3.

[0053] As Figure 1As shown, the turbogenerator 11 may include a generator body connected to the upstream flow converter 9, a guide wheel fixedly connected to the generator body, and a turbine magnetically coupled to the generator body. The turbine is located behind the guide wheel. The high-speed mud flows towards the turbine under the guiding action of the guide wheel, causing the turbine to rotate. The rotation of the turbine converts the kinetic energy of the mud into the rotational energy of the motor rotor, thereby driving the generator body to generate electricity. The electricity generated by the generator body is transmitted to the instrument circuit through the three-phase wires on the upstream flow converter 9, and then transmitted to the lower instrument through the pulse generator 7 to supply power to the entire string of instruments. In this embodiment, the guide wheel is installed in front of the turbine, has a guiding effect on the mud fluid, controls the flow direction of the mud, and increases the rotational torque of the turbine, thereby increasing the output power of the generator.

[0054] Preferably, different turbines and stator-rotor combinations can be used according to different displacements to broaden the displacement range of the mud adapted by the instrument. This displacement range preferably can meet the requirements of small displacement (2.8~3.8 m 3 / min), medium displacement (3.8~4.8 m 3 / min), and high displacement (4.8~6 m 3 / min).

[0055] Also preferably, 3 second set screws can be installed near the guide wheel for supporting the guide wheel and for centering.

[0056] Under high-displacement mud flow rates, since the high-speed mud carries a large amount of solid particles and passes quickly through the guide wheel and the turbine, it will cause high erosion to the guide wheel and the turbine. Once the turbine and the guide wheel fail due to erosion damage, the generator will not be able to generate electricity and the instrument will not be able to operate. In view of this, in a preferred embodiment, the guide wheel and the generator body can be integrally formed, and the turbine can be integrally formed. The guide wheel and the generator body are preferably integrally formed by 3D printing. The outer surfaces of the guide wheel and the turbine can be sprayed with a strength reinforcement material. This strength reinforcement material can preferably be a nickel-based superalloy, such as Inconel 718 alloy.

[0057] In a specific embodiment, the turbine is machined from Inconel 718 alloy + surface electroplated coating process, and the guide wheel is formed by 3D printing of Inconel 718 alloy, which improves the erosion resistance of the turbine and the guide wheel and meets the operating requirements under high displacements.

[0058] Similarly, at high mud flow rates, if the upstream channel converter 9 and the downstream channel converter 10 fail due to erosion damage, it will cause the bus to be exposed or even broken, that is, the generator cannot generate electricity or the pulse generator 7 cannot generate pulse signals, and the communication between the wellhead and the downhole will be disconnected. In view of this, in a preferred embodiment, a strength reinforcement material can be sprayed on the inner surfaces of the upstream channel converter 9 and the downstream channel converter 10. The strength reinforcement material can preferably be a nickel-based superalloy, such as Inconel 718 alloy.

[0059] In a specific embodiment, the upstream channel converter 9 and the downstream channel converter 10 can be optimized and modeled through parametric fluid simulation to automatically generate an erosion-resistant channel structure. At the same time, a special process of supersonic spraying of cemented carbide is used on the surface to improve the erosion resistance, extend the service life of the instrument, and meet the operation requirements of the instrument at high discharge rates.

[0060] In such as Figure 1 and Figure 9 In the preferred embodiment shown, the circuit skeleton 6 can include a test section and a circuit board mounting section 14 connected in sequence. The test section is connected to the upstream channel converter 9, and the circuit board mounting section 14 is connected to the downstream channel converter 10. A circuit board is mounted on the circuit board mounting section 14, and a holding cylinder 13 is sleeved outside the circuit board. A circuit test port is opened in the area of the circuit drill collar 2 corresponding to the test section, as Figure 9 shown. A cover plate 102 is detachably connected to the circuit test port, and a sunken wear-resistant belt 101 is provided on the area of the circuit drill collar 2 near the cover plate 102 and / or on the outer peripheral wall of the holding cylinder 13.

[0061] In such as Figure 10 shown in the preferred embodiment, grooves 104 are opened on the area of the circuit drill collar 2 near the cover plate 102 and / or on the outer peripheral wall of the holding cylinder 13. The sunken wear-resistant belt 101 includes a plurality of wear-resistant layers connected in sequence from bottom to top and gradually decreasing in size in a stepped arrangement within the grooves 104, Figure 10 showing the first wear-resistant layer 1011, the second wear-resistant layer 1012, and the third wear-resistant layer 1013 arranged in a stepped manner. The lowermost first wear-resistant layer 1011 is filled and fixed within the entire groove 104, and its top is flush with the opening of the groove 104. The first wear-resistant layer 1011 can be fixed within the groove 104 through a laser cladding process, and adjacent wear-resistant layers can also be fixedly connected through a laser cladding process.

[0062] In this embodiment, since eddy currents are generated near the wear band under the condition of large displacement well conditions, the structure of the drill collar itself is damaged and its strength is reduced. The structural design of the sunken wear band 101 enables the downhole mud to wash not the drill collar itself but the sunken wear band 101. After the operation is completed, the sunken wear band 101 can be repaired, increasing the number of wells and the service life of the drill collar. At the same time, the mud flow field in the wellbore and the tool annulus is optimized, which not only protects the tool body but also extends the service life of the tool.

[0063] By designing the structure of the sunken wear band 101, that is, a certain depth (preferably 1 mm) of a sinking groove is dug at the position of the wear band of the drill collar, a wear band underlayer is laser-clad, and then a cemented carbide wear-resistant layer with a greater height (preferably 1.5 mm) is laser-clad. The hardness of the sunken wear band 101 after laser cladding is preferably not less than 40 HRC, the hardness of the insert is greater than 2000 HV, and the hardness of the working surface is greater than 55 HRC.

[0064] Preferably, as Figure 9 shown, the sunken wear band 101 formed on the gripper cylinder 13 can be formed into a spiral laser-clad wear band. The pitch of the spiral line can be preferably 2000 mm, the height is 445 mm, and the spiral direction is right-handed, conforming to the direction of the instrument drilling; considering that the gripper cylinder 13 will be deformed in the case of high-temperature cladding wear band, the wear band is designed to cover most of the position of the gripper cylinder 13, avoiding the sealing surface, improving the process, and reducing the influence of deformation.

[0065] Also preferably, as Figure 9 shown, in the sunken wear band 101 formed near the cover plate 102, the surface of the wear band after laser cladding is polished to reduce the surface roughness of the wear band and reduce the abrasion between the instrument and the wellbore during drilling.

[0066] In the preferred embodiment as Figure 1 shown, in combination with Figure 11 and Figure 12 shown, an upper flow deflector assembly 5 is also connected inside the vortex drill collar, and a lower flow deflector assembly 12 is also connected inside the pulsator drill collar 3, as Figure 11As shown, the upper deflector assembly 5 may include an upper deflector 51 and a TIP head 52 connected to the upper deflector 51. The lower deflector assembly 12 may include a lower deflector 121 and a hard connector 122 connected to the lower deflector 121. In this embodiment, to achieve the connection and signal transmission between instruments, the upper end of the unified standard instrument is a standard API female thread + TIP head 52, and the lower end of the instrument is a standard API male thread + hard connector 122; the instruments are connected through the mating of the API male and female threads, and the communication between the instruments is achieved through the insertion of the TIP head 52 and the hard connector 122. When the instrument communicates from top to bottom, the transmission signal is input from the TIP head 52 at the upper end of the instrument, transmitted through the bus of the vortex drill collar 1 to the circuit board on the circuit skeleton 6, and after being processed by the circuit board, it is transmitted through the bus of the pulser drill collar 3 to the hard connector 122 at the lower end of the instrument, and the signal is transmitted to the lower instrument through the insertion of the hard connector and the TIP head between the instruments. Similarly, when the instrument communicates from bottom to top, the transmission signal is input from the hard connector 122 at the lower part of the instrument, transmitted through the bus of the pulser drill collar 3 to the circuit board on the circuit skeleton 6, and after being processed by the circuit board, it is transmitted through the bus of the vortex drill collar 1 to the TIP head 52 at the upper end of the instrument, and the signal is transmitted to the upper instrument through the insertion of the hard connector and the TIP head between the instruments.

[0067] It should be noted that unless otherwise specified, the technical terms or scientific terms used in this application should have the ordinary meanings understood by those skilled in the art to which the present invention belongs.

[0068] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "length", "width", "thickness", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0069] In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the various embodiments of the present application, and they should all be covered within the scope of the claims and the specification of the present application. In particular, as long as there is no structural conflict, the various technical features mentioned in each embodiment can be combined in any way. The present invention is not limited to the specific embodiments disclosed in the text, but includes all technical solutions that fall within the scope of the claims.

Claims

1. A large-size high-speed shear valve mud pulser, characterized in that: include: A vortex drill collar, a circuit drill collar, a pulser drill collar and a hard-connected drill collar which are threadedly connected in sequence, the vortex drill collar has a built-in turbine generator, the circuit drill collar has a built-in instrument circuit, the pulser drill collar has a built-in pulse generator, the hard-connected drill collar has a built-in hard connection, the two ends of the circuit skeleton in the circuit drill collar are respectively fixedly connected with an upper flow channel converter and a lower flow channel converter, the upper flow channel converter is connected to the turbine generator, and the lower flow channel converter is connected to the pulse generator, wherein the pulse generator includes a motor housing connected to the lower flow channel converter, a motor stator fixed in the motor housing, a motor rotor coaxially arranged in the motor stator, a torsion shaft connected to the motor rotor, a shear valve connected to the torsion shaft, and a shear valve plate fixedly connected to the motor housing, the shear valve and the shear valve plate are arranged in parallel and spaced apart, and the torsion shaft includes at least a fixed The torsion shaft further comprises a first bearing mounting section and a second bearing mounting section connected between the torsion section and the shear valve mounting section, a torsion section and a shear valve mounting section, wherein the fixed section axially passes through the motor rotor and is fixedly connected to the motor housing, the torsion section axially penetrates into and is suspended in the motor rotor, and the shear valve mounting section is used to connect the shear valve; the torsion shaft further comprises a first bearing mounting section and a second bearing mounting section connected between the torsion section and the shear valve mounting section, and a limiting section located between the first bearing mounting section and the second bearing mounting section, the pulse generator further comprises a bearing group mounted on the first bearing mounting section, a small bearing mounted on the second bearing mounting section, and a bladder mounted between the motor housing and the small bearing, one end of the bladder is fixedly connected to the small bearing, and the other end is fixedly connected to an area of ​​the motor housing close to the limiting section, and an area of ​​the first bearing mounting section located between the torsion section and the bearing group is fixedly connected to the motor rotor.

2. The large-size high-speed shear valve type mud pulser according to claim 1 is characterized in that: The shear valve installation section is constructed as a special-shaped pentagonal structure, and a special-shaped pentagonal hole for matching with the special-shaped pentagonal structure is opened at the center of the shear valve.

3. The large-size high-speed shear valve type mud pulser according to claim 2 is characterized in that: The shear valve includes a valve body and a plurality of valve leaves formed on the outer periphery of one side end face of the valve body, the special-shaped pentagonal hole axially penetrates the center of the valve body, the shear valve also includes a reinforcing rib extending from the upper area of ​​the valve leaf toward the other side end face of the valve body, the area where the reinforcing rib is connected to the valve leaf is formed with a fillet, the outer diameter range of the shear valve is: 95-115mm, the number of opening angles range is: 6-8, the range of the fillet is: R10-R50mm, the angle range of the reinforcing rib is: 35°-60°, the thickness range of the reinforcing rib is: 8-16mm, the shear valve plate includes a shear valve plate body and a plurality of valve plates formed on the outer periphery of the shear valve plate body, a flow channel is formed between adjacent valve plates, the outer diameter range of the valve plate is: 90-110mm, and the number of opening angles range is: 6-8.

4. The large-size high-speed shear valve type mud pulser according to claim 1 is characterized in that: The pulse generator also includes a micro reducer mounted on the first bearing mounting section and located at the front end of the bearing group.

5. The large-size high-speed shear valve type mud pulser according to any one of claims 1 to 4, characterized in that: The turbine generator includes a generator body connected to the upper flow channel converter, a guide wheel fixedly connected to the generator body, and a turbine magnetically coupled to the generator body. The turbine is located behind the guide wheel. High-speed mud flows toward the turbine under the guidance of the guide wheel, causing the turbine to rotate, thereby driving the generator body to generate electricity.

6. The large-size high-speed shear valve type mud pulser according to claim 5, characterized in that: The guide wheel is integrally formed with the generator body, and the turbine is integrally formed.

7. The large-size high-speed shear valve type mud pulser according to claim 6, characterized in that: The outer surfaces of the guide wheel and the turbine, the inner surfaces of the upper flow channel converter and the lower flow channel converter are sprayed with strength reinforcement materials.

8. The large-size high-speed shear valve type mud pulser according to any one of claims 1 to 4, characterized in that: The circuit skeleton includes a test section and a circuit board installation section which are connected in sequence, the test section is connected to the upper flow channel converter, the circuit board installation section is connected to the lower flow channel converter, a circuit board is installed on the circuit board installation section, a holding tube is provided on the outer surface of the circuit board, a circuit test port is opened on the area of ​​the circuit drill collar corresponding to the test section, a cover plate is detachably connected to the circuit test port, and a sunken wear-resistant belt is provided on the area of ​​the circuit drill collar near the cover plate and / or the outer peripheral wall of the holding tube.

9. The large-size high-speed shear valve type mud pulser according to claim 8, characterized in that: The circuit drill bit is provided with grooves in the area near the cover plate and / or on the outer peripheral wall of the clamping tube. The sunken wear-resistant belt includes a plurality of wear-resistant layers which are connected in sequence from bottom to top in the groove and are arranged in steps with gradually decreasing sizes. The wear-resistant layer at the bottom is filled and fixed in the entire groove, and its top end is flush with the opening of the groove.

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