Semi-autonomous cutting element brazing system

Abstract

A method of bonding a cutting element to a downhole drilling tool includes orienting an induction coil relative to a cutting element pocket, and applying an energy input to the induction coil to heat the cutting element pocket to a braze temperature. The method also includes determining a pocket temperature of the cutting element pocket, and controlling energy input to the induction coil based on the pocket temperature to maintain the pocket temperature at a braze temperature for a braze period.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 477,610, filed on December 29, 2022, entitled “SEMI AUTONOMOUS CUTTING ELEMENT BRAZING SYSTEM,” the disclosure of which is incorporated herein by reference. Background Art

[0003] Wellbores can be drilled into a surface location or the seabed for various exploration or extraction purposes. For example, wellbores can be drilled to access fluids, such as liquid and gaseous hydrocarbons, stored in underground formations and to extract fluids from the formations. Wellbores for producing or extracting fluids can be formed in earthen formations using earth-boring tools, such as drill bits for drilling wellbores and reamers for expanding the diameter of the wellbore.

[0004] Earth-boring tools may include one or more cutting elements thereon. Typically, the tool includes one or more tool pockets on an outer surface of a tool body, and the cutting elements are secured within the pockets by brazing. The tool body and cutting elements are typically manufactured separately and may be formed from different materials. The high temperatures at which brazing occurs can alter the physical properties of the materials, which may result in cracking, joint failure, premature wear, etc. Furthermore, manual brazing can be labor-intensive and time-consuming, which can also lead to inconsistencies in the quality of the brazed joint, thereby adversely affecting structural integrity. Summary of the Invention

[0005] In some embodiments, a method of bonding a cutting element to a downhole drilling tool includes orienting an induction coil relative to a cutting element pocket, applying an energy input to the induction coil to heat the cutting element pocket to a brazing temperature, determining a pocket temperature of the cutting element pocket, and based on the pocket temperature, controlling the energy input to the induction coil to maintain the pocket temperature at the brazing temperature during brazing.

[0006] In some embodiments, a method of joining a cutting element to a downhole drilling tool includes applying a brazing material to a cutting element pocket, inserting a cutting element into the cutting element pocket, orienting a robotic arm relative to the cutting element pocket, the robotic arm including an induction coil, orienting the induction coil adjacent to the cutting element pocket, applying an energy input to the induction coil to heat the cutting element pocket to a brazing temperature, melting the brazing material while at the brazing temperature, and after melting the brazing material, pushing the cutting element into the cutting element pocket while maintaining the angular orientation of the cutting element.

[0007] In some embodiments, a brazing system includes a robotic arm having a working end, an induction heater coupled to the working end of the robotic arm, a drill body positioned relative to the robotic arm, and a thermal sensor oriented toward the brazing site.

[0008] This summary is provided to introduce a selection of concepts that are further described in the specific embodiments. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to help limit the scope of the claimed subject matter. Additional features and aspects of the embodiments of the present disclosure will be set forth herein and, in part, will be apparent from the description, or may be learned by practicing such embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] To describe the manner in which the above-described and other features of the present disclosure can be obtained, a more detailed description will be presented by reference to specific embodiments of the present disclosure illustrated in the accompanying drawings. For better understanding, like elements are represented by like reference numerals in the various drawings. Although some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. It should be understood that the drawings depict some example embodiments, and the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

[0010] Figure 1 is an example of a drilling system according to at least one embodiment of the present disclosure;

[0011] Figure 2 is a perspective view of a downhole end portion of an embodiment of a drill bit according to at least one embodiment of the present disclosure;

[0012] Figure 3 is a diagram of a brazing system according to at least one embodiment of the present disclosure;

[0013] Figure 4-1 is a perspective view of a brazing system according to at least one embodiment of the present disclosure;

[0014] Figure 4-2 yes Figure 4-1 A side cross-sectional view of a brazing system;

[0015] Figure 4-3 and 4-4 yes Figure 4-1 Front view of the brazing system;

[0016] Figure 5 is a perspective view of a brazing system according to at least one embodiment of the present disclosure;

[0017] Figure 6 is a flow chart of a method of using a brazing system according to at least one embodiment of the present disclosure; and

[0018] Figure 7 is a flow chart for implementing a control loop in conjunction with a brazing system, according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0019] The present disclosure generally relates to devices, systems, and methods for attaching abrasive elements to earth-boring tools. For example, a cutting element can be brazed to a drilling tool using a brazing system. In some embodiments, the brazing system can include an induction heater that generates a magnetic field to form a brazing zone within a portion of the drilling tool. The brazing system can guide the brazing zone at the cutting element and / or the cutting element pocket, thereby allowing the cutting element to be brazed to the cutting element pocket without damaging the cutting element and / or the cutting element pocket. For example, the brazing system can control the energy input to the induction heater to control the location and amplitude of the heating of the drilling tool. The brazing system can focus the brazing zone to a localized portion of the drilling tool. Controlling the energy input can reduce or eliminate damage to the cutting element pocket and / or the cutting element due to continuous heating or overheating. In some embodiments, the brazing system can be semi-autonomous and can braze the cutting element in 60 seconds or less. This can reduce the time and complexity of completing a drilling tool having one or more cutting elements. In this manner, the brazing system as described herein may have advantages over conventional methods of brazing cutting elements to drilling tools.

[0020] Figure 1 One example of a drilling system 100 is shown for drilling a formation 101 to form a wellbore 102. Drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 that extends downwardly into wellbore 102. Drilling tool assembly 104 may include a drill string 105, a bottom hole assembly ("BHA") 106, and a drill bit 110 attached to the downhole end of drill string 105.

[0021] The drill string 105 may include several joints of drill pipe 108 connected end-to-end by tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drilling rig 103 to the BHA 106. In some embodiments, the drill string 105 may also include additional downhole drilling tools and / or components, such as pup joints, short joints, etc. The drill pipe 108 provides hydraulic passages through which drilling fluid is pumped from the surface. The drilling fluid is discharged through nozzles, jets, or other orifices of selected sizes in the drill bit 110 for the purpose of cooling the drill bit 110 and the cutting structure on the drill bit 110, as well as for lifting drill cuttings out of the wellbore 102 during drilling.

[0022] The BHA 106 may include a drill bit 110, other downhole drilling tools, or other components. The exemplary BHA 106 may include additional or other downhole drilling tools or components (e.g., coupled between the drill string 105 and the drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (MWD) tools, logging-while-drilling (LWD) tools, downhole motors, reamers, profile cutters, hydraulic disconnects, jars, vibration or damping tools, other components, or combinations thereof. The BHA 106 may also include a rotary steerable system (RSS). The RSS may include directional drilling tools that change the direction of the drill bit 110 and, thereby, the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame (e.g., gravity, magnetic north, and / or true north). Using measurements obtained using the geostationary position, the RSS may position the drill bit 110, change the course of the drill bit 110, and guide the directional drilling tool along a projected trajectory.

[0023] Typically, the drilling system 100 may include other downhole drilling tools, components, and accessories, such as specialized valves (e.g., kelly plugs, blowout preventers, and safety valves). The additional components included in the drilling system 100 may be considered part of the drilling tool assembly 104, the drill string 105, or part of the BHA 106, depending on their location in the drilling system 100.

[0024] The drill bit 110 in the BHA 106 can be any type of drill bit suitable for degrading downhole materials. For example, the drill bit 110 can be a drill bit suitable for drilling the formation 101. Example types of drill bits used for drilling formations are fixed cutter or drag bits. In other embodiments, the drill bit 110 can be a milling cutter used to remove metal, composites, elastomers, other materials, or combinations thereof downhole. For example, the drill bit 110 can be used with a whipstock to mill into the casing 107 lining the wellbore 102. The drill bit 110 can also be a junk cutter used to mill out tools, plugs, cement, other materials, or combinations thereof within the wellbore 102. Chips or other cuttings formed by the use of the milling cutter can be lifted to the surface or allowed to fall downhole. The drill bit 110 can include one or more cutting elements used to degrade the formation 101. When the cutting elements are engaged in drilling, they can be subjected to various forces, pressures, impacts, etc. The cutting elements can be brazed to the drill bit 110 to form a brazed connection. The brazed connection may provide a secure connection of the cutting element to the drill bit 110 to withstand downhole environments.

[0025] Conventionally, brazing can be performed manually and can be labor-intensive and / or time-consuming. Conventional brazing can be imprecise and can cause damage to the cutting element and / or drill bit 110 due to overheating and / or prolonged heating. According to at least one embodiment of the present disclosure, the cutting element can be brazed to the drill bit 110 by a brazing system. In some embodiments, the brazing system can include an induction heater that can be positioned or moved by a robotic arm. The brazing system can heat the cutting element and / or drill bit 110 with the induction heater, thereby brazing the cutting element to the drill bit 110. In some embodiments, the brazing system can control the energy input to the induction heater and / or localize the heating of the induction heater, thereby avoiding damage to the cutting element and / or drill bit 110. In some embodiments, the brazing system can be semi-autonomous and can braze the cutting element in 60 seconds or less. In this way, the brazing system can braze the cutting element to the drill bit 110, having significant advantages over conventional methods.

[0026] Figure 2 is a perspective view of a downhole end of an embodiment of a drill bit 210. For example, the drill bit 210 may be a downhole drilling tool, such as that described herein. Figure 1 Any of the downhole drilling tools discussed herein. Drill bit 210 may include a drill bit body 212 from which a plurality of blades 214 may project. At least one of blades 214 may have a plurality of cutting elements 216 coupled thereto. In some embodiments, at least one of plurality of cutting elements 216 may be a planar cutting element, such as a shear cutting element. In other embodiments, at least one of plurality of cutting elements 216 may be a non-planar cutting element, such as a tapered cutting element, a ridged cutting element, or a shovel-shaped cutting element.

[0027] Cutting element 216 can be positioned and oriented to engage soil formations during underground drilling operations. Cutting element 216 may encounter objects and / or materials in the soil formation that may exhibit different levels of hardness, abrasiveness, toughness, elasticity, etc. Such operation may subject cutting element 216 to many temperatures, pressures, forces, torques, impacts, etc. that are different from those at the surface. These operating parameters may produce conditions and forces that may dislodge cutting element 216 from blade 214.

[0028] Blades 214 may have a plurality of cutting element pockets 217 formed into the body of blades 214. Drill bit body 212, including blades 214, may be formed from a matrix infiltrated with hard particles, such as tungsten carbide (WC) particles infiltrated with a metal binder. In some embodiments, drill bit body 212 (including blades 214) may be formed from steel. For example, drill bit body 212 and blades 214 may be machined from one or more steel billets. Furthermore, a composite drill bit may have components (e.g., blades, blade faceplates, blade covers) formed from a matrix material, and other components (e.g., drill bit body, blades) formed from a solid material (e.g., steel, aluminum). Cutting element pockets 217 may be formed in blades 214. Cutting elements 216 may be inserted into and secured to blades 214 at cutting element pockets 217. In some embodiments, cutting elements 216 may be secured to blades 214 via a brazing system, as described in further detail herein.

[0029] In some embodiments, cutting element 216 can be formed of a superhard portion 232 bonded or connected to a substrate 233. Superhard portion 232 can be located on the distal end of cutting element 216, or on the end of the cutting element opposite the end where cutting element 216 can be attached to cutting element pocket 217. The superhard portion can be any superhard or ultrahard material, such as polycrystalline diamond (PCD). Substrate 233 can be a sintered tungsten carbide or tungsten carbide metal matrix.

[0030] The cutting element 216 can be connected to the blade 214 by brazing the cutting element 216 in the cutting element pocket 217 (e.g., the cutting element 216 can be connected to the blade 214 by a brazing connection). During the brazing process, a filler material can be heated to bond with the cutting element 216 and the cutting element pocket 217. The filler material includes a brazing material and an optional flux material. The brazing material can be a metal or metal alloy that can bond with both the cutting element 216 and the cutting element pocket 217. The flux material can be an oxidation-resistant material that can coat the cutting element 216 and / or the cutting element pocket 217 to prevent oxidation of the material of the cutting element 216 and / or the cutting element pocket 217 during the heating period.

[0031] During brazing, the cutting element 216 and / or the cutting element pocket 217 (e.g., the material of the blade 214 surrounding the cutting element pocket 217) may be heated. The brazing material may be heated directly from the brazing system and / or indirectly from the heating of the cutting element 216 and the cutting element pocket 217. The brazing material may melt and flow between the cutting element 216 and the cutting element pocket 217 to fill the space between the cutting element 216 and the cutting element pocket 217. In some embodiments, the brazing material may flow through the space using capillary action. In some embodiments, the brazing material may flow through the space by any other mechanism.

[0032] The brazing material has a brazing temperature at which it melts and flows through the space. In some embodiments, the space between the cutting element 216 and the cutting element pocket 217 is an annular space. In some cases, the brazing material can be selected to have a brazing temperature that is lower than the melting temperature of the blade 214 and / or cutting element 216 or a temperature that would otherwise be harmful. For example, the brazing temperature can be approximately 1300°F. Overheating the materials comprising the drill bit body 212, blades 214, and / or cutting element 216 may change their material properties. For example, overheating the drill bit body 212, blades 214, and / or cutting element 216 may change their internal structure. In some cases, overheating may damage the drill bit body 212, blades 214, and / or cutting element 216. For example, overheating to a critical temperature of 1450°F or higher may cause damage to the drill bit body 212, blades 214, and / or cutting element 216. In some examples, heating of the metal matrix and / or superhard portion 232 of cutting element 216 may cause at least a portion of cutting element 216 to crack, become brittle, lose its wear resistance and / or abrasion resistance, or otherwise damage cutting element 216 .

[0033] Conventionally, brazing can be performed manually by a skilled operator who heats the blade 214 and / or cutting element 216 with an oxyacetylene torch and applies the brazing material to the space between the cutting element 216 and the cutting element pocket 217. Inconsistencies and / or human error can cause the blade 214 and / or cutting element 216 to reach or exceed a critical temperature, which can damage or reduce the effectiveness of these components. The flame temperature of the oxyacetylene torch or other torch used for brazing may exceed the critical temperature of the blade 214 and / or cutting element 216, making accurate heating of the blade 214 and / or cutting element 216 difficult. The intermittent application of the flame used for brazing can be complex and imprecise. It can be difficult to determine the internal temperature of the blade 214 and / or cutting element 216 during conventional brazing. For example, a skilled operator can identify specific metal colors, patterns, or visual characteristics to determine the approximate temperature of the blade 214. In some embodiments, the thermal sensor may be blinded or obscured by the flame from the oxyacetylene torch. As a result, it may be difficult or even impossible to accurately detect and control the temperature of the blade 214. This may result in damage to the blade 214, damage to the cutting element 216, reduced quality of the braze, other damage to the drill bit 210, and combinations thereof.

[0034] In some cases, brazing cutting elements 216 to blades 214 can be time-consuming and / or labor-intensive. For example, manually brazing a drill bit with multiple cutting elements using traditional brazing methods can take several hours. The brazing system described herein can significantly reduce the time and resources required to complete a drill bit. For example, the brazing system can include an induction heater that can be moved and controlled by a robotic arm. The brazing system can move the induction heater along a heating path corresponding to the geometry of the blade 214. The brazing system can control the energy input to the induction heater to braze one or more cutting elements 216 positioned along the heating path. In some embodiments, the brazing process for a single cutting element 216 can occur in less than 60 seconds. In some embodiments, the brazing system can be semi-autonomous and can braze multiple cutting elements 216 to the drill bit 210 by autonomously performing one or more functions, while an operator can manually perform one or more functions. In this way, the brazing system can quickly and efficiently braze one or more cutting elements 216 to the drill bit 110.

[0035] Figure 3An example of a brazing system 320 for joining or attaching a cutting element to a drill bit 310, in accordance with at least one embodiment of the present disclosure, is shown. The brazing system 320 can include a robotic arm 321 having a working end 322. The robotic arm 321 can move with three or more degrees of freedom, allowing it to move and / or manipulate the working end 322 in three-dimensional space. In some embodiments, the robotic arm 321 can be autonomous. For example, the robotic arm 321 can move and / or orient the working end 322 according to a preprogrammed path. In some embodiments, the robotic arm 321 can be non-autonomous. For example, the robotic arm 321 can be manipulated by an operator who controls the robotic arm 321. In some embodiments, the robotic arm 321 can be semi-autonomous. For example, the robotic arm can move and / or orient the working end 322 according to a preprogrammed path that is subject to input or control by an operator during one or more stages of operation of the robotic arm 321.

[0036] Brazing system 320 may include a drill bit support 311. Drill bit 310 may be connected to or supported by drill bit support 311. In some embodiments, a robotic arm 321 may be positioned relative to and associated with drill bit support 311 to allow robotic arm 321 to access drill bit 310. For example, drill bit support 311 and drill bit 310 may be stationary, and robotic arm 321 may move and / or orient a working end 322 relative to drill bit 310. In other words, working end 322 may be moved or positioned relative to drill bit 310. Brazing system 320 may include an induction heater 324. The induction heater 324 may be connected to the working end 322 of the robotic arm 321. The robotic arm 321 may move and / or manipulate the induction heater 324 based on movement and / or manipulation of the working end 322. For example, the robotic arm 321 may position and / or orient the induction heater 324 relative to the drill bit 310 connected to the drill bit support 311. In other words, the induction heater 324 can be moved or positioned relative to the drill head 310. This can allow the robotic arm 321 to move the induction heater 324 to any part of the drill head 310.

[0037] In some embodiments, the drill bit support 311 can be connected to a working end 322 of a robotic arm 321, and the robotic arm 321 can move and / or manipulate the drill bit support 311. The induction heater 324 can be in a fixed position, and the robotic arm 321 can move and / or orient the working end 322 holding the drill bit support 311 and the drill bit 310 relative to the induction heater 324. In other words, the robotic arm 321 can position and / or orient the drill bit 310 relative to the induction heater 324.

[0038] In some embodiments, the brazing system 320 may include multiple robotic arms 321. The drill bit support 311 may be connected to one of the robotic arms 321, and the induction heater 324 may be connected to another of the robotic arms 321. This may allow the drill bit support 311 and the induction heater 324 to move independently. This may help improve the flexibility and / or positionability of the drill bit support 311 and / or the induction heater 324 relative to each other.

[0039] Induction heater 324 may include an induction coil. When current is applied, induction heater 324 generates a magnetic field. The magnetic field generated by induction heater 324 can be modulated based on the electrical energy input to induction heater 324. For example, robotic arm 321 may position induction heater 324 adjacent to or in close proximity to drill bit 310, and the induction heater may generate a magnetic field oriented to pass through a portion of drill bit 310. In other words, robotic arm 321 may position induction heater 324 so that at least a portion of drill bit 310 is positioned within the magnetic field generated by induction heater 324. The magnetic field may induce a current in the portion of drill bit 310 within the magnetic field. Based on the conductivity and / or resistance of the material within the magnetic field and the strength of the magnetic field, this induced current may cause that portion of drill bit 310 to heat. In other words, the induced current (e.g., eddy current) within that portion of drill bit 310 caused by the magnetic field may cause that portion of drill bit 310 to heat due to resistive heating.

[0040] The magnetic field can cause the brazing zone in the portion of the drill bit 310 to experience heating from the induced current. Portions of the drill bit 310 located outside the brazing zone can experience reduced or no heating from the induced current. Portions of the drill bit 310 located outside the brazing zone can experience indirect heating, such as heat conduction from portions of the drill bit 310 located within the brazing zone. In this manner, the inductive heating effect of the applied magnetic field can be targeted, localized, or otherwise directed to a specific portion or brazing location of the drill bit 310. Localized heating can help reduce the amount of time that a portion of the drill bit 310 is at the brazing temperature, which can help reduce or prevent damage to the drill bit 310.

[0041] The strength of the magnetic field can be controlled by the electrical energy input to the induction heater 324. The strength of the magnetic field can correspond to the degree of heating experienced by an object within the magnetic field due to the induced current. For example, the induction heater 324 can inductively heat the brazing site to a first temperature, and varying the electrical energy input to the induction heater 324 can alter the magnetic field applied to the brazing site to inductively heat the brazing site to a second temperature different from the first temperature. Controlling the magnetic field applied to the brazing site controls the induced current flowing through the brazing site, thereby controlling the heating of the brazing site by the induced current. For example, increasing the strength or intensity of the magnetic field from the induction heater 324 can increase the rate at which the brazing site is heated and / or increase the size of the brazing site. The strength or intensity of the magnetic field (and thus the induced current) can be controlled by adjusting the frequency and amplitude of the alternating current supplied to the induction heater 324. In other words, the desired temperature of the brazing site can be achieved by controlling the electrical energy input to the induction heater 324. In this way, combined with the positioning of the induction heater 324, the temperature and position of the brazing site can be precisely controlled.

[0042] Brazing system 320 may include one or more thermal sensors 327. Thermal sensors 327 may be any type of thermal sensor, such as an infrared camera, a thermocouple, a thermistor, a resistance temperature detector (RTD), any other thermal sensor, and combinations thereof. Thermal sensor 327 may be oriented and / or pointed toward drill bit 310. Thermal sensor 327 may be oriented and / or pointed toward the brazing site. In this manner, thermal sensor 327 may be configured to determine the temperature of one or more portions of drill bit 310. In some embodiments, thermal sensor 327 may be oriented and / or pointed toward drill bit 310 and may determine the temperature of multiple portions of drill bit 310. For example, thermal sensor 327 may determine the temperature of at least a portion of the brazing site, a portion of drill bit 310 not within the brazing zone of the magnetic field, a cutting element of drill bit 310, a superhard portion of the cutting element of drill bit 310, a cutting element pocket of drill bit 310, induction heater 324, any other location, and combinations thereof. In some examples, the field of view of thermal sensor 327 may encompass the entirety of drill bit 310. For example, the sensor's field of view can capture the entire surface of drill bit 310 visible to the thermal sensor at a given orientation and / or angle of the thermal sensor relative to drill bit 310. In another example, the sensor's field of view can capture the entire leading edge and / or surface of the blade of drill bit 310. In some embodiments, thermal sensor 327 can be simultaneously oriented at multiple locations on drill bit 310. For example, multiple locations of drill bit 310 can be detectable within the same field of view, or sensor range, of thermal sensor 327. In another example, the thermal sensor can include multiple sensors at different orientations relative to drill bit 310, and the thermal sensor can capture a field of view that includes sensor input from any number of orientations and / or angles relative to drill bit 310.

[0043] In some embodiments, thermal sensor 327 can be oriented and / or pointed toward the brazing site and induction heater 324. For example, thermal sensor 327 can determine the surface temperature of one or more portions of drill bit 310 while also pointing toward and / or observing induction heater 324. Because induction heater 324 itself is not significantly heated by applied electrical energy and does not utilize a direct heat source (such as a flame), directing thermal sensor 327 toward and / or observing induction heater 324 while brazing the site can not affect the ability of thermal sensor 327 to detect the temperature of one or more portions of drill bit 310. This can help improve the accuracy of temperature control of the drill bit body, blades, cutting elements, or other components of drill bit 310. In this manner, induction heater 324 combined with thermal sensor 327 can help improve the speed and / or quality of the brazing process.

[0044] In some embodiments, the thermal sensor 327 and the induction heater 324 can each communicate with a brazing controller 329. For example, the brazing controller 329 can be a processor and memory that electronically communicates with the thermal sensor 327 and the induction heater 324. The brazing controller 329 can receive data from the thermal sensor 327. Using the data from the thermal sensor 327, the brazing controller 329 can control the electrical energy input to the induction heater 324. The brazing controller 329, the thermal sensor 327, and the induction heater 324 can form a control loop, and the heating effect of the induced current from the magnetic field can be monitored and regulated by the control loop. In this way, the control loop can help improve the speed and / or quality of the brazing process by accurately controlling the temperature of the drill bit 310.

[0045] In some embodiments, the brazing system 300 may include an indicator 323. The indicator 323 may include, but is not limited to, a graphic display, one or more lights, a speaker, or any combination thereof. The indicator may be coupled to the brazing controller 329 to provide the operator with an indication of one or more conditions of the brazing process. For example, the indicator 323 may be a temperature indicator, and may provide a temperature indication of a blade, a cutting element, a cutting element recess, a superhard portion of a cutting element, an induction heater, or any other component. In some embodiments, the indicator 323 may provide the operator with a signal indicating that the cutter recess is at a desired temperature for inserting a cutting element with brazing material. In some embodiments, the indicator 323 may provide the operator with a signal corresponding to the temperature of one or more positions of the drill bit 310. In addition, or in an alternative, the indicator 323 may provide the operator with a signal indicating that the robot arm 321 is moving or will move along the brazing path. The indicator 323 may indicate any other condition associated with the brazing process as described herein.

[0046] Figure 4-1 A perspective view of a brazing system 420 according to at least one embodiment of the present disclosure is shown. The brazing system 420 may include an induction heater 424, a blade 414, and a cutting element 416. The blade 414 may be any type of blade. For example, the blade 414 may be a blade on a drill bit, such as the blade 214 on the drill bit 210, as described herein in conjunction with Figure 2 As discussed. In some examples, blade 414 can be a blade on a reamer or stabilizer. In some examples, blade 414 can be a blade on a cannula cutter. In some examples, blade 414 can be a stand-alone blade. In some examples, blade 414 can be a test specimen or sample blade for testing. In some examples, blade 414 can be any other base or support to which a cutting element or other insert can be brazed. Blade 414 can include one or more cutting element pockets 417.

[0047] 4. The cutting element 416 can include a superhard portion 432. In the illustrated embodiment, the cutting element 416 is substantially cylindrical with a planar cutting face. However, it should be understood that the cutting element 416 can have any other geometric shape. The cutting element pocket 417 can be formed as a substantially cylindrical cavity in the body of the blade 414. In this manner, the cutting element pocket 417 can receive the cutting element 416 for attachment to the blade 414. In other words, a cutting element 416 having a base of a certain shape can be inserted into a cutting element pocket 417 having a complementary shape.

[0048] The blade 414 can have a first side 418 and a second side 419. The first side 418 can be the top side of the blade 414. For example, the first side 418 can be the side of the blade 414 associated with the exposed portion of the cutting element 416, such as Figure 4-1 As shown. The first side 418 can be adjacent to the second side 419. The second side 419 can be the back side of the blade 414. For example, the second side 419 can be the side of the blade opposite the superhard portion 432 of the cutting element 416, as shown. Figure 4-1 shown.

[0049] The induction heater 424 shown includes an induction coil 425. Figure 4-1In the embodiment shown in FIG, a coil axis 426 passing through the center of the induction coil 425 is substantially perpendicular to the first side 418 or at a 90° angle relative to the first side 418. In some embodiments, the coil axis 426 can be at an angle other than 90° relative to the first side 418. For example, the angle between the coil axis 426 and the first side 418 can be substantially 0°, such that the coil axis 426 is substantially parallel to the first side 418 and / or perpendicular to the second side 419. The coil axis 426 can be oriented at any other angle relative to the first side 418 and / or the second side 419.

[0050] As described herein, electrical energy passing through the induction coil 425 can generate a magnetic field that induces an electric current in the blade 414. At least a portion of the magnetic field extends through the induction coil 425 along the coil axis 426, such that the magnetic field extends through objects located near the induction coil 425 and the coil axis 426. The induction coil 425 can be coupled to a robotic arm, and the robotic arm can move and / or orient the induction coil 425 relative to the blade 414. In this manner, the brazing system 420 can orient the induction coil to target or be oriented at the brazing location and form a brazing zone. In some embodiments, the induction coil 425 can heat a localized portion of the blade 414. For example, the heating effect of the electric current induced by the magnetic field can be concentrated on portions of the first side 418 and / or the second side 419 corresponding to the cutting element pocket 417. In this manner, the heating effect of the electric current induced by the magnetic field can be concentrated on and localized to the cutting element pocket 417. Rather than heating the blade by applying an external heat source (i.e., a torch), the induction current generates heat via resistive heating within the blade 414 itself and / or the cutting element 416 itself. This can result in an increase in temperature of at least a portion of the cutting element pocket 417. Adjacent portions of the blade 414 and / or cutting element 416 outside the brazing zone can experience reduced or no heating by the induction heater 424.

[0051] The induction heater 424 can heat the cutting element pocket 417, the cutting element 416, and the brazing material to a brazing temperature. In some embodiments, the induction heater 424 indirectly heats the brazing material to the brazing temperature by heating the cutting element pocket 417 and / or the cutting element through an electric current induced by a magnetic field. The direct or indirect heating of the brazing material can cause the brazing material to melt, thereby entering the gap between the cutting element 416 and the cutting element pocket 417, for example, by capillary action. Upon cooling and solidification, the brazing material can secure the cutting element 416 to the cutting element pocket 417. In some embodiments, the brazing temperature can be within a range having an upper limit, a lower limit, or both, including any one of 800°F, 1000°F, 1200°F, 1400°F, 1600°F, 1800°F, 2000°F, or any value therebetween. For example, the brazing temperature can be greater than 800°F. In another example, the brazing temperature can be less than 2000°F. In other examples, the brazing temperature may be between 800° F. and 2000° F. In some embodiments, it may be critical that the brazing temperature be between 1300° F. and 1600° F. in order to bond the cutting element 416 to the cutting element pocket 417 via the brazing material without damaging the cutting element 416, the cutting element pocket 417, and / or the blade 414. In this manner, an induction heater may be used to heat the cutting element 416 and / or the cutting element pocket 417 to the brazing temperature.

[0052] In certain embodiments, brazing system 420 can be maintained at the temperature of cutting element 416 and / or blade 414 below critical temperature.Critical temperature can be the temperature that is higher than its blade 414 and / or cutting element 416 may damage.In certain embodiments, critical temperature can be in the scope of having and comprise 1300 ° F, 1400 ° F, 1500 ° F, 1600 ° F, 1700 ° F, 1800 ° F, 1900 ° F, 2000 ° F any one or any value therebetween upper limit value, lower limit value or upper limit value and lower limit value.For example, critical value can be greater than 1300 ° F.In another example, critical temperature can be less than 2000 ° F.In other examples, critical temperature can be between 1300 ° F and 2000 ° F. In some embodiments, a critical temperature between 1300°F and 1600°F may be critical to reduce or prevent damage to the superhard portion 432, cutting element 416, cutting element pocket 417, and / or blade 414 during the brazing process.

[0053] In some embodiments, the cutting element pocket 417 and / or the cutting element 416 may be heated to a preliminary temperature below the brazing temperature. The induction heater 424, the preheating system, or a combination thereof may heat the cutting pocket 417 and / or the cutting element 416 to the preliminary temperature. In some embodiments, the preliminary temperature may be above or below 1000°F. In some embodiments, the preliminary temperature may be within a range having an upper limit, a lower limit, or both, including any one of 500°F, 600°F, 700°F, 800°F, 900°F, 1000°F, 1100°F, 1200°F, 1300°F, or any value therebetween. For example, the preliminary temperature may be greater than 500°F. In another example, the preliminary temperature may be less than 1300°F. In yet another example, the preliminary temperature may be between 500°F and 1300°F. In some embodiments, a preliminary temperature between 800°F and 1000°F may be critical in order to adequately braze the cutting element 416 to the cutting element pocket 417 using the brazing system 420 as discussed herein.

[0054] In some embodiments, the induction heater 424 may heat the cutting element pocket 417 and / or the cutting element 416 to the brazing temperature during a heating period. The heating period may be for each cutting element pocket 417 of the blade 414 or a subset of the cutting element pockets 417. In some embodiments, the heating period may be greater than or less than 30 seconds. In some embodiments, the heating period may be within a range having an upper limit, lower limit, or upper and lower limits including any one of 10 seconds, 30 seconds, 60 seconds, 90 seconds, 120 seconds, 150 seconds, or 180 seconds or any value therebetween. For example, the heating period may be greater than 10 seconds. In another example, the heating period may be less than 180 seconds. In yet other examples, the heating period may be any value within a range between 10 seconds and 180 seconds. In some embodiments, it may be critical that the heating period be between 20 seconds and 40 seconds to increase the speed and / or reduce the cost of brazing the blade 414.

[0055] In some embodiments, the induction heater 424 can maintain the brazing temperature for a brazing period. The brazing period can be for each cutting element pocket 417 of the blade or a subset of the cutting element pocket 417. In some embodiments, the brazing period can be greater than or less than 30 seconds. In some embodiments, the brazing period can be in the range of an upper limit, a lower limit, or an upper limit and a lower limit with any one or any value therebetween of 10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds, 60 seconds. For example, the brazing period can be greater than 10 seconds. In another example, the brazing period can be less than 60 seconds. In other examples, the brazing period can be any value in the range between 10 seconds and 60 seconds. In some embodiments, it may be critical that the brazing period is between 20 seconds and 40 seconds to produce high-quality brazing.

[0056] In some embodiments, the brazing zone of the induction heater 424 may be positioned within the cutting element pocket 417 such that the adjacent cutting element pocket may be located outside the brazing zone. A temperature gradient may exist between the temperature of the cutting element pocket 417 and the temperature of the adjacent cutting element pocket 417-1. In some embodiments, the temperature gradient may be within a range having an upper limit, a lower limit, or both of any one of 100°F, 200°F, 300°F, 400°F, 500°F, 600°F, 700°F, 800°F, 900°F, 1000°F, or any value therebetween. For example, the temperature gradient may be a difference greater than 100°F. In another example, the temperature gradient may be a difference less than 1000°F. In yet another example, the temperature gradient may be a difference between 100°F and 1000°F. In some embodiments, it may be critical that the temperature gradient is the difference between 500°F and 1000°F so that the heating effect of the induction heater is limited to the cutting element pocket 417 and / or that the adjacent cutting element pocket 417-1 is preheated using the brazing system described herein, thereby reducing the heating period of the adjacent cutting element pocket 417-1.

[0057] Figure 4-2 yes Figure 4-1FIG4 is a cross-sectional view of a brazing system 420. As can be seen, the brazing system 420 can include a brazing material 413. The brazing material 413 can be located at the base of the cutting element pocket 417 between the cutting element 416 and the base of the cutting element pocket 417. In some embodiments, the brazing material 413 can be inserted into the cutting element pocket 417 before the cutting element 416 is inserted into the cutting element pocket 417. In some embodiments, the brazing material can include one or more filler metals, such as copper, nickel, silver, aluminum, gold, manganese, or any other metal and / or rare earth element suitable for bonding the cutting element 416 to the cutting element pocket 417. In some embodiments, the brazing material 413 can be in a solid form, such as a brazing disk, sheet, ring, wire, block, washer, or any other suitable solid form of the brazing material 413. In this way, the brazing material 413 can be placed or inserted into the cutting element pocket 417 in a solid form before the cutting element 416 is inserted into the cutting element pocket 417. In some embodiments, the brazing material 413 can be in a non-solid form, such as atomized into a powder or granules, a paste, or a liquid. In this manner, the cutting element pocket 417 can be at least partially filled with the brazing material 413 before the cutting element 416 is inserted. In some embodiments, the brazing material 413 can be applied to (i.e., coated or applied to) the cutting element pocket 417 and / or the cutting element 416 before the cutting element 416 is inserted into the cutting element pocket 417. In some embodiments, the brazing material 413 can be applied to the joint between the cutting element 416 and the cutting element pocket 417 after the cutting element 416 is inserted into the cutting element pocket 417. For example, the brazing material 413 can be applied to the joint after the cutting element pocket 417 and / or the cutting element 416 are heated (e.g., heated to a brazing temperature).

[0058] During brazing, oxides or impurities may form on one or more surfaces of the cutting element 416 and / or the cutting element pocket 417. This may weaken the bond created between the cutting element 416 and the cutting element pocket 417. Heating of the cutting element 416 and / or the cutting element pocket 417 may increase or accelerate the formation of oxides. To this end, conventional methods typically introduce flux material into the mating surfaces of the cutting element 416 and / or the cutting element pocket 417 to protect these surfaces from the formation of oxides. In some embodiments, the brazing material 413 may include a flux material. In some embodiments, the brazing material 413 may not include a flux material, so that the flux material (if used) can be used alone or applied separately from the brazing material 413.

[0059] Conventionally, brazing an entire blade 414 or drill bit may take several hours. A long-lasting flux material (sometimes referred to as a high-temperature flux material), such as "brown flux," can be used to provide a long-lasting shield against oxide formation during conventional brazing methods. In some embodiments, the long-lasting flux material can be a high-temperature flux material. As discussed herein, the brazing process of the present invention can be performed during a brazing period that can be shorter than the brazing duration of conventional brazing methods, such as less than 60 seconds. In some embodiments, the brazing system 420 as discussed herein can use a non-persistent flux material. In some embodiments, the flux material can be a medium- to high-temperature flux material, "white flux," or a water-based flux. In some embodiments, brazing according to the brazing system 420 as discussed herein can be performed without a flux material. In some embodiments, the brazing system 420 can include a vacuum system so that one or more of the functions of the brazing system 420 can be performed in a vacuum or at substantially zero atmospheric pressure.

[0060] When brazing is completed, the long-term continuous flux material may leave residual flux material in the joint. This residual material can weaken the combination between the cutting element 416 and the cutting element recess 417. The flux material of shorter duration can leave less residue or no residue. In the case of using a long-term continuous flux material, after the brazing material 413 has melted, some residual materials can be removed from the brazed connection by spinning or rotating the angular orientation of the cutting element 416 in the cutting element recess 417. This can be before the brazing material cools and hardens or before the brazing is completed to remove the residual flux material from the joint. In some embodiments, the brazing system 420 as described herein can braze the cutting element 416 to the cutting element recess 417 without spinning or rotating the angular orientation of the cutting element 416 in the cutting element recess 417. In other words, the angular orientation of the cutting element 416 can be maintained or unchanged throughout the brazing process. This may be because the flux of short duration may leave little or even no residual material in the joint. This may help strengthen the braze and increase contact of the braze material 413 with the body of the cutting element 416 and blade 414 .

[0061] In some embodiments, the cutting element 416 can be pushed or placed in the cutting element pocket 417 after the brazing material 413 has melted but before it has hardened. As discussed herein, the placement of the cutting element 416 in the cutting element pocket 417 can be performed without spinning or rotating the cutting element 416 in the cutting element pocket 417. In other words, the cutting element 416 can be placed or pushed into the cutting element pocket 417 while maintaining the angular orientation of the cutting element 416. This can help to simplify the brazing process while maintaining a strong bond between the cutting element 416 and the cutting element pocket 417. In some embodiments, the cutting element 416 can be manually placed by an operator. In some embodiments, the brazing system 420 can autonomously place the cutting element 416, for example, using a robotic arm.

[0062] The push-out load is understood to be the amount of force required to push the cutting element 416 out of the cutting element pocket 417. This can correspond to the strength of the braze or the strength of the connection created between the cutting element 416 and the cutting element pocket 417. In some embodiments, the braze performed by the brazing system 420 can be a full-strength braze. This can correspond to a strength or push-out load comparable to that achieved by conventional methods, according to the brazing system described herein.

[0063] Figure 4-3 and 4-4 yes Figure 4-1 4. As discussed herein, the induction heater 424 can be positioned and / or movable relative to the blade 414. The induction heater 424 can be movable along a heating path 428. In some embodiments, the heating path 428 can correspond to a drill bit (such as that described herein in conjunction with Figure 2 The heating path 428 and the brazing system 420 can be adapted to the geometry of any downhole tool including the cutting element 416 brazed to the blade 414. In some embodiments, the heating path 428 can be a predetermined heating path 428. For example, the heating path 428 can be determined by an operator input to the brazing system 420. In some embodiments, the operator can manually determine the heating path 428 and the brazing system can be programmed to follow the determined heating path 428. In another example, the heating path can be determined autonomously by the brazing system 420. In some embodiments, the brazing system 420 can scan the geometry of the downhole tool, including the specific geometry of the blade 414, and the computing device can determine the heating path 428 based on the geometry of the downhole tool.

[0064] In some embodiments, the heating path 428 can have a first end 429 and a second end 430. The heating path 428 can follow a series of adjacent cutting element pockets 417. In this manner, discrete locations along the heating path 428 can correspond to the induction heater 424 being positioned adjacent to, proximate to, or relative to one or more cutting element pockets 417. The heating path can define an offset distance 427 between the induction heater 424 and the blade 414. For example, the offset distance 427 can be the distance between the induction coil 425 and the first side 418 of the blade. In this manner, the induction coil 425 can be offset, or can be out of direct contact with the blade 414.

[0065] In some embodiments, the offset distance 427 may be a constant distance throughout the entire heating path 428. For example, Figure 4-3 and 4-4 , the heating path 428 can be substantially parallel to the first side 418 of the blade 414, and the induction coil 425 can be positioned at a constant distance from the blade 414 throughout the movement of the induction heater 424 along the heating path 428. In some embodiments, the offset distance 427 can be non-constant. For example, the brazing system 420 can move the induction coil 425 closer to and / or further away from the blade 414 one or more times throughout the movement of the induction heater 424 along the heating path 428. In some embodiments, the offset distance 427 can be varied to accommodate the geometry of the drill bit. In some embodiments, the offset distance 427 can be varied to control the heating effect of the induction heater 424, as will be discussed herein.

[0066] As discussed herein, the induction heater 424 can move along the heating path 428. In some embodiments, the induction heater can move at a constant speed along the heating path 428. For example, the induction heater 424 can preheat one or more portions of the blade 414 by traveling along the heating path at a constant speed. In some embodiments, the induction heater 424 can change speed one or more times as it moves along the heating path 428. For example, the induction heater 424 can speed up as it leaves one cutting element pocket 417 and slow down as it approaches another cutting element pocket 417. In this manner, the movement of the induction heater 424 along the heating path can be dynamic.

[0067] Heating path 428 in Figure 4-3 and 4-4 However, it should be understood that the heating path 428 can be non-linear, and one or more portions of the heating path 428 can follow a path of non-linear shape. For example, in some embodiments, the blade 414 can include one or more portions that are substantially non-linear, such as Figure 24. Thus, one or more portions of the heating path 428 can similarly define a nonlinear path to accommodate the nonlinear geometry of the blade 414. In another example, the heating path 428 can follow one or more shapes and / or patterns, such as a circle, an ellipse, a figure-eight, a rectangle, any other shape and / or pattern, and combinations thereof. The pattern and / or shape of the heating path 428 can help control the heating effect of the induction heater and / or apply heat at a desired location. In this manner, the heating path can follow any number of linear and / or nonlinear paths to apply the heating effect of the induction heater 424 to any number of drill bit geometries.

[0068] As discussed herein, the induction heater 424 can generate a magnetic field, thereby causing a heating effect to be applied to the blade 414. The heating effect can be localized to the brazing zone 415. In some embodiments, one or more parameters of the brazing system can be adjusted to control the brazing zone. For example, moving the induction heater 424 along the heating path 428 can correspondingly move the brazing zone along the blade 414 relative to the heating path 428. In another example, moving the induction heater 424 in a patterned motion along the heating path 428 can target the brazing zone at various locations on the blade 414. In another example, varying the offset distance 427 can affect the application of the brazing zone 415 to the blade 414. In yet another example, adjusting the energy input (e.g., frequency, amplitude) to the induction coil can affect the application of the brazing zone 415 to the blade 414. As a result of adjusting one or more of the parameters just mentioned, the brazing zone 415 can be adjusted and altered in various ways. For example, adjusting one or more parameters can change the depth to which the brazing zone 415 penetrates into the blade 414. In another example, adjusting one or more parameters can change the width or cross-sectional area encompassed by the brazing zone 415. In another example, adjusting one or more parameters can change the strength of the generated magnetic field, which can cause the brazing zone 415 to produce a more rapid increase in the temperature of the blade 414. In this manner, the brazing zone can be tailored to produce a desired heating effect as described herein.

[0069] In some embodiments, the induction heater 424 can travel at least a portion of the heating path 428 when no electrical energy is supplied to the induction heater 424 or when a magnetic field is not generated. In other words, the induction heater 424 can travel at least a portion of the path without applying the heating effect of the induction heater 424 to the blade 414. When electrical energy is supplied to the induction heater 424 or when a magnetic field is generated, the induction heater 424 can travel at least a portion of the heating path. In other words, the induction heater 424 can travel at least a portion of the heating path while applying the heating effect of the induction heater 424 to the blade 414. As the induction heater 424 moves along the heating path 428, electrical energy can be directed through the induction coil 425 in a phased manner, allowing the induction heater 424 to precisely control the location and duration of the induced current in the blade 414 to heat the blade 414. In this manner, the induction heater 424 can be moved along the heating path 428 and positioned relative to the blade 414 while the heating effect of the induction heater 424 can be selectively applied to the blade 414.

[0070] In accordance with at least one embodiment of the present disclosure, the induction heater 424 can be initially positioned at the first end 429. The induction heater 424 can travel along the heating path 428 toward the second end 430. The induction heater 424 can slow down or stop at a first position 423-1 along the heating path 428. The first position 423-1 can correspond to the induction heater 424 being positioned adjacent to or relative to the first cutting element pocket 417-1 positioned along the heating path 428. The first position 423-1 can also correspond to the brazing zone 415 being directed toward the first cutting element pocket 417-1. When the induction heater 424 is at the first position 423-1, as discussed herein, the induction heater 424 can heat the first cutting element pocket 417-1, the first cutting element 416-1, and / or the brazing material to bond the first cutting element 416-1 to the first cutting element pocket 417-1.

[0071] After the brazing of the first cutting element 416-1 is completed, the induction heater can then resume advancing along the heating path 428, for example, toward the second end 430. In some embodiments, the resumption of the induction heater 424 advancing along the heating path 428 can be based on operator input, for example, an operator input indicating that the brazing of the first cutting element 416-1 is complete. For example, the operator can input an indication that the first cutting element 416-1, the first cutting element recess 417-1, and / or the brazing material have reached the brazing temperature and the first cutting element 416-1 is placed in the first cutting element recess 417-1. In another example, the operator can input an indication that the brazing period has passed. In some embodiments, the operator input can be based on an indication received from an indicator connected to the brazing system. For example, the operator can utilize an indicator to monitor one or more conditions of the brazing process, and the operator can input one or more inputs to the brazing system based on one or more of the observed conditions to advance the brazing process.

[0072] In some embodiments, the induction heater 424 can be automated by the brazing system 420 to resume advancing along the heating path 428. For example, the brazing system 420 can determine that the first cutting element pocket 417-1, the first cutting element 416-1, and / or the brazing material have reached the brazing temperature, and that the first cutting element 416-1 is seated in the first cutting element pocket 417-1. In another example, the brazing system 420 can determine that the brazing period has elapsed. In this manner, the induction heater 424 can bond the first cutting element 416-1 to the first cutting element pocket 417-1, and once brazing of the first cutting element 416-1 has been achieved, the induction heater 424 can advance along the heating path 428.

[0073] exist Figure 4-4In the illustrated embodiment, the induction heater 424 can advance from a first position 423-1 along the heating path 428 and stop at a second position 423-2. The second position 423-2 can be located further along the heating path 428 than the first position 423-1. The second position 423-2 can correspond to the induction heater 424 being positioned adjacent to a second cutting element pocket 417-2 located along the heating path 428. The second position 423-2 can also correspond to the brazing zone 415 being directed toward the second cutting element pocket 417-2. As discussed herein, the second cutting element 416-2 can be brazed to the second cutting element pocket 417-2 corresponding to the second position 423-2, and the induction heater 424 can advance from the second position 423-2 along the heating path 428. The induction heater can continue in this manner for any number of cutting element pockets 417 located along the heating path 428. In some embodiments, the induction heater 424 can stop at some positions 423 for longer durations. For example, brazing the first cutting element 416-1 to the first cutting element pocket 417-2 may correspond to the blade 414 being "cold" or not preheated. As a result, the induction heater 424 may require a longer time to heat the various elements to the brazing temperature. As the induction heater travels to a later cutting element pocket 417 in the series of cutting element pockets 417, the later cutting element pocket 417 may be warmer or slightly preheated due to heat conduction through the blade 414 from the brazing of the previous cutting element pocket 417. Thus, the induction heater may stop at a later cutting element pocket 417 for a shorter duration as needed to braze the later cutting element 416 to the cutting element pocket 417. In this manner, the induction heater 424 can braze one or more cutting elements 416 to one or more cutting element pockets 417 positioned along the heating path 428 by moving along the heating path 428.

[0074] As discussed herein, in some embodiments, the induction heater 424 can be used to heat one or more of the cutting element pockets 417, the cutting element 416, and / or the brazing material 413 to a preliminary temperature, such as 800°F. For example, before heating one or more of the cutting element pockets 417, the cutting element 416, and / or the brazing material 413 to the brazing temperature, or before brazing the cutting element 416 to the cutting element pockets 417, the induction heater 424 can make a preliminary pass through the heating path 428 to heat one or more of the cutting element pockets 417, the cutting element 416, and / or the brazing material 413 to the preliminary temperature. In some embodiments, the preliminary pass can follow a different path than the path of the heating path 428. In this manner, one or more of the blade 414 and / or the cutting element pockets 417, the cutting element 416, and / or the brazing material 413 can be preheated or heated to a preliminary temperature below the brazing temperature prior to brazing. In some embodiments, such preheating can help reduce the brazing time period. In some embodiments, this may help reduce the amount of oxides or impurities that may form on one or more surfaces of the cutting element 416 and / or the cutting element pocket 417 during the brazing process.

[0075] In some embodiments, the induction heater 424 can make a preliminary pass from the first end 429 to the second end 430 at a constant speed to preheat the blade 414 substantially to a preliminary temperature along the cutting element pocket 417. The brazing system 420 can then continue to heat and / or braze the individual cutting element pockets and / or cutting elements as discussed herein. In some embodiments, the induction heater 424 can make a preliminary pass through the heating path 428 and can make one or more stops along the heating path 428 to preheat the cutting element pocket 417 to a preliminary temperature individually along the heating path 428. The brazing system 420 can then continue to heat and / or braze the individual cutting element pockets and / or cutting elements as discussed herein. In some embodiments, the induction heater 424 can make multiple preliminary passes along the heating path 428 to heat the cutting element pocket 417 to a preliminary temperature. In some embodiments, the induction heater 424 may heat one or more cutting elements 416 and / or cutting element pockets 417 without making a preliminary pass through the heating path 428, and the temperature gradient as discussed herein may preheat adjacent cutting element pockets.

[0076] In some embodiments, the brazing system 420 can be fully autonomous. For example, the brazing system 420 can perform all functions discussed herein without the assistance or input of an operator, such as: initially positioning the blade 414 relative to the robotic arm, inserting the cutting element 416 and / or brazing material 413 into the cutting element recess 417, determining the heating path 428, applying and / or controlling the energy input to the induction heater 424, moving and / or advancing the induction heater 424 along the heating path 428, placing the cutting element 416, any other functions and combinations thereof. In some embodiments, the brazing system 420 can be at least partially operated by an operator. For example, the brazing system 420 can be semi-autonomous, and at least a portion of the functions discussed herein of the brazing system 420 can be performed by an operator, or with the assistance or input of an operator. In some embodiments, an operator can perform various tasks as part of the initial setup process. For example, an operator can initially insert or position the blade 414 relative to the robotic arm of the brazing system 420, as discussed herein. In some examples, an operator can insert the cutting element 416, the brazing material 413, and / or the flux material into the cutting element pocket 417. As discussed herein, in some examples, the operator can determine a heating path 428 and can input the heating path 428 or program the brazing system 420 to follow the heating path 428.

[0077] In some embodiments, the operator can perform various tasks during the brazing process or as a part of the brazing process. For example, the operator can manually control the movement of the induction heater 424, such as by controlling the robot arm as discussed herein. In some examples, the operator can apply and / or control the energy input to the induction heater 424. In some examples, the brazing system 420 can move the induction heater 424 along the heating path 428 according to the operator input, such as when the operator determines to advance the induction heater 424 to another cutting element recess 417 along the heating path, when to apply, adjust or stop the energy input to the induction heater 424, when to stop the induction heater 424 at the position along the heating path 428, and their combination. In some examples, the operator can manually push or place the cutting element 416 in the cutting element recess 417, as discussed herein. In this way, the brazing system 420 can be semi-autonomous, which can simplify the brazing process and eliminate the need to partially automate the brazing process, which may be troublesome or difficult to complete for a fully autonomous system.

[0078] Figure 5is a perspective view of a brazing system 520 according to at least one embodiment of the present disclosure. As described herein, the brazing system can include a blade 514 having one or more cutting elements 516 and one or more cutting element pockets 517. The blade 514 can have a first side 518 and a second side 519. The brazing system 520 can include an induction heater 524 positionable relative to the blade 514. In some embodiments, the induction heater 524 can include a plurality of induction coils. For example, the induction heater can include a first induction coil 525-1 and a second induction coil 525-2. Figure 5 In the illustrated embodiment, a first coil axis 526-1 passing through the center of the first induction coil 525-1 and a second coil axis 526-2 passing through the center of the second induction coil 525-2 may define an angle of substantially 90°. In other words, the first induction coil 525-1 and the second induction coil 525-2 may be substantially perpendicular to each other. In some embodiments, the first coil axis 526-1 and the second coil axis 526-2 may define an angle other than 90°. For example, the angle between the first coil axis 526-1 and the second coil axis 526-2 may be substantially 180°, which may correspond to the first coil axis 526-1 and the second coil axis 526-2 coinciding. The angle between the first coil axis 526-1 and the second coil axis 526-2 may be any other angle, such as any angle between 0° and 180°. In some embodiments, no angle may be defined between the first coil axis 526-1 and the second coil axis 526-2. For example, first coil axis 526-1 and second coil axis 526-2 can be substantially parallel, which can correspond to first induction coil 525-1 and second induction coil 525-2 being substantially side-by-side. In this manner, first induction coil 525-1 and second induction coil 525-2 can be oriented relative to each other.

[0079] In some embodiments, the first induction coil 525-1 and the second induction coil 525-2 can be electrically coupled such that they are both part of the same circuit. For example, the energy input to the first induction coil 525-1 can be the same energy input as the energy input to the second induction coil 525-2. In this way, the first induction coil 525-1 and the second induction coil 525-2 can be controlled together. In some embodiments, the first induction coil 525-1 and the second induction coil 525-2 can be separate parts of the same circuit. For example, the energy input to the first induction coil 525-1 can be different energy input than the energy input to the second induction coil 525-2. In this way, the first induction coil 525-1 and the second induction coil 525-2 can be controlled separately and independently of each other. In some embodiments, the first induction coil 525-1 and the second induction coil 525-2 can have different energy outputs or generate magnetic fields of different strengths. The separately controlled induction coils can generate differential magnetic fields with different induced currents, which can be used for resistive heating of portions of the blade 514. For example, the second induction coil 525-2 can generate a wider and / or more intense second magnetic field to produce a second brazing zone within the blade 514 that is larger and / or deeper than the first magnetic field generated by the first induction coil 525-1. This can help produce a desired intensity and / or heating zone relative to the cutting element 516 and / or the cutting element pocket 517. In this way, the energy output of the induction heater 524 can be customized for a specific application.

[0080] In some embodiments, the first induction coil 525-1 and the second induction coil 525-2 may be physically coupled together. This may correspond to the first induction coil 525-1 and the second induction coil 525-2 being movable together. For example, the first induction coil 525-1 and the second induction coil 525-2 may each be connected to a working end of a robotic arm as discussed herein. The robotic arm may move and / or orient the first induction coil 525-1 and the second induction coil 525-2 together as a single, integral unit. In some embodiments, the first induction coil 525-1 and the second induction coil 525-2 may not be physically coupled together. This may correspond to the first induction coil 525-1 and the second induction coil 525-2 being movable independently. For example, the first induction coil 525-1 and the second induction coil 525-2 may each be connected to a working end of a separate robotic arm as discussed herein. The robotic arm may move and / or orient each of the first induction coil 525-1 and the second induction coil 525-2 independently. In this manner, first induction coil 525 - 1 and second induction coil 525 - 2 may be movable and oriented relative to blade 514 .

[0081] As described herein, the first induction coil 525-1 and the second induction coil 525-2 can each generate a separate magnetic field. In some embodiments, the first induction coil 525-1 can generate a first magnetic field, and the second induction coil 525-2 can generate a second magnetic field that is independent of the first magnetic field. Figure 5 In the embodiment shown in , the first induction coil 525-1 and the second induction coil 525-2 can be positioned adjacent to or in close proximity to each other. The adjacent orientation can cause the first magnetic field and the second magnetic field to interact with each other. In this way, the first induction coil 525-1 and the second induction coil 525-2 can work together to generate a single magnetic field. Figure 5 As shown, the first induction coil 525-1 and the second induction coil 525-2 can be oriented to generate a magnetic field facing the brazing location or oriented at the brazing location and generate a brazing zone via the induced current. In this way, the first induction coil 525-1 and the second induction coil 525-2 can cooperate to heat a localized portion of the blade 514. For example, the heating effect of the current induced by the magnetic field can be substantially concentrated on a portion of the first side 518 and the second side 519 corresponding to the cutting element pocket 517. In this way, the heating effect of the current induced by the magnetic field can be concentrated on and localized to the cutting element pocket 517. In some embodiments, the current induced by the magnetic field can cause the temperature of at least a portion of the cutting element pocket 517 to increase. The temperature of the cutting element 516 can be increased directly due to the current induced by the magnetic field, or indirectly due to heat conduction from the cutting element pocket 517, which is itself heated by the current induced by the magnetic field. In this manner, the induction heater may heat the cutting element pocket 517 and / or the cutting element 516 by generating a magnetic field.

[0082] Figure 6 Flowchart showing a method 640 or series of actions for using a brazing system as discussed herein, in accordance with at least one embodiment of the present disclosure. Figure 6 Actions according to one embodiment are shown, but alternative embodiments may omit, add to, reorder, and / or modify Figure 6 Any action shown in .

[0083] Method 640 may include orienting the induction coil relative to the cutting element pocket at 641. For example, the brazing system may orient the robotic arm, and the robotic arm may include an induction coil on its working end. In some embodiments, the brazing system may orient the robotic arm by moving the induction coil along the heating path. In some embodiments, the heating path may be determined by the brazing system. For example, the brazing system may scan the geometry of the tool body and determine the heating path based on the geometry of the tool body. In some embodiments, the heating path may be determined by an operator of the brazing system. For example, the operator may manually determine the heating path based on the geometry of the tool body, and may input the heating path into the brazing system. In some embodiments, the heating path may be offset corresponding to an offset distance by which the induction heater is positioned so that it does not contact the tool body. In this way, the brazing system may orient the induction heater relative to the cutting element pocket at 641 in order to perform the functions discussed herein.

[0084] In at least one embodiment of the present disclosure, method 640 may include inserting a cutting element into a cutting element pocket. At 641a. In some embodiments, the cutting element may include a superhard portion. As discussed herein, a brazing system may braze the cutting element to the cutting element pocket. In some embodiments, the brazing system may be used to determine the temperature of one or more components of the brazing system at 643. For example, the brazing system may determine the temperature of the cutting element, the cutting element pocket, the brazing material, the superhard portion, or any other component as described herein. Controlling the induction heater as discussed herein may be based at least in part on the determined temperature. For example, the brazing system may maintain the temperature (i.e., the superhard portion temperature) below a critical temperature. In some embodiments, the brazing material may be applied to the cutting element pocket. For example, the brazing material may be applied to the cutting element pocket before the cutting element is inserted into the cutting element pocket at 641a and / or before energy input is applied to the induction coil at 642.

[0085] The brazing system can apply energy input to the induction coil at 642. In some embodiments, applying the energy input to the induction coil can heat the cutting element pocket to a brazing temperature. In some embodiments, applying the energy input to the induction coil can heat the cutting element pocket to a brazing temperature within a heating period of 60 seconds or less. The brazing system can melt the brazing material while at the brazing temperature. In some embodiments, the system can braze the cutting element to the blade without the use of a flux material. In some embodiments, the brazing system can apply the heating effect of the induction heater in a concentrated or localized manner. For example, the heating effect of the induction heater can be confined to the brazing zone, as discussed herein.

[0086] The method may include determining the temperature of one or more components of the brazing system at 643. For example, the brazing system may determine the temperature of the cutting element, the cutting element pocket, the brazing material, the superhard portion, or any other component as described herein. For example, the brazing system may determine the pocket temperature at a portion of the metal matrix or steel surrounding the cutting element pocket. In another example, the brazing system may determine the temperature at the base of the cutting element. The brazing system may determine the temperature of one or more components of the brazing system using an infrared camera directed at the brazing system. As described above, one or more thermal sensors may be used to determine the temperature of multiple components of the brazing system simultaneously or sequentially.

[0087] Method 640 may include controlling a brazing zone of the induction heater at 644. In some embodiments, the brazing system may control the brazing zone by adjusting one or more parameters of the brazing system. For example, the brazing zone may be controlled by controlling the energy input to the induction coil, moving the induction coil along the heating path, adjusting the offset distance of the heating path, adjusting any other parameters of the brazing system, and combinations thereof. According to at least one embodiment of the present disclosure, the brazing system may control the brazing zone of the induction heater to maintain a temperature (i.e., the temperature at 643) at a brazing temperature during the brazing period. The brazing system may control the brazing zone based on the temperature determined at 643. For example, if the temperature is determined to be below the brazing temperature, the brazing system may maintain and / or increase the energy input to the induction coil. In another example, if the temperature is determined to be at the brazing temperature, the brazing system may maintain and / or reduce the energy input to the induction coil. In other examples, if the temperature is determined to be above the brazing temperature, the brazing system may reduce and / or stop the energy input to the induction coil. In some embodiments, controlling the brazing zone of the induction heater can include controlling electrical energy input to the induction coil, which in turn controls the magnetic field from the induction coil and the current induced in the cutting element pockets and / or the cutting element base. The brazing zone can be controlled at 644 to maintain a first temperature (e.g., a brazing temperature) in one or more locations without exceeding a second temperature (e.g., a critical temperature) in another location, such as a superhard layer or webbing between cutter pockets in or near the brazing zone.

[0088] In some embodiments, method 640 may include placing (e.g., pushing) the cutting element into the cutting element pocket at 645. For example, a robotic arm of the brazing system may place the cutting element into the cutting element pocket after the brazing material is melted or after the brazing period. In another example, an operator may place the cutting element into the cutting element pocket after the brazing material is melted or after the brazing period. In some embodiments, the cutting element may be placed into the cutting element pocket without rotating the cutting element. For example, the angular orientation of the cutting element relative to the cutting element pocket may be maintained as the cutting element is pushed into the cutting element pocket.

[0089] In some embodiments, the cutting element pocket can be a first cutting element pocket, the temperature can be a first pocket temperature, and the second cutting element pocket can be positioned along a heating path. As discussed herein, method 640 can also include orienting an induction coil relative to the second cutting element pocket; applying an energy input to the induction coil to heat the second cutting element pocket to the brazing temperature; determining a second temperature of the second component; and / or controlling one of the brazing induction heaters to maintain the second temperature at the brazing temperature for the brazing period. The brazing system can be used to control the brazing zone based on the determined second temperature. In some embodiments, the brazing system can control the brazing zone of the induction heater to heat one or more components to a preliminary temperature that is lower than the brazing temperature. For example, the brazing system can heat the first cutting element pocket and the second cutting element pocket to a preliminary temperature before heating the first cutting element pocket to the brazing temperature.

[0090] In some embodiments, the induction coil is a first induction coil, and the brazing system can orient the first induction coil to be adjacent to a first side of the cutting element pocket. The brazing system can orient the second induction coil to be adjacent to a second side of the cutting element pocket. In some embodiments, the brazing system can apply energy input to the first induction coil and the second induction coil to heat the cutting element pocket to a brazing temperature. As discussed herein, the brazing system can control the energy input to the first induction coil and the second induction coil to maintain the temperature of the cutting element pocket at the brazing temperature during the brazing period. For example, the brazing system can control the energy input to the first induction coil and the second induction coil based on a determined temperature of the cutting element pocket or another component of the brazing system.

[0091] As discussed herein, method 640 may include inserting a cutting element into a cutting element pocket at 641a, and the cutting element may include a superhard portion at a distal end of the cutting element. In some embodiments, the distal end may be an end of the cutting element oriented toward a third side (i.e., front) of the cutting element pocket, opposite the first side (i.e., rear). In some embodiments, the brazing system may apply energy input to the first and second induction coils to heat the cutting element pocket from both the first side (i.e., rear) and the second side (i.e., top). For example, the magnetic field generated by the first and second induction coils may generate a heating effect originating within the blade containing the cutting element pocket. The heating effect may be concentrated and / or localized to the first and second sides, such that the distal end and / or superhard portion of the cutting element do not receive the heating effect, or receive the heating effect to a lesser extent. In this manner, the brazing system may generate a more precise and localized heating effect than conventional methods (e.g., torch heating), thereby more effectively brazing the cutting element to the cutting element pocket through one or more acts of method 640.

[0092] Figure 7 A flow chart illustrating a method 740 or series of actions for using a brazing system as discussed herein is shown in accordance with at least one embodiment of the present disclosure. Figure 7 Actions according to one embodiment are shown, but alternative embodiments may omit, add to, reorder, and / or modify Figure 7 Any action shown in .

[0093] Method 740 may include, at 745, applying energy input to the induction heater to heat the cutting element pocket. As discussed herein, the brazing system may employ a control loop for controlling the energy input and the heating effect of the induction heater on a target object (i.e., a drill bit) within the magnetic field generated by the induction heater. For example, method 740 may include determining, at 746, whether the target object is at a brazing temperature. The target object may be, for example, a cutting element pocket, a cutting element, and / or a brazing material, as discussed herein, and the brazing system may determine, at 746, whether one or more of these objects is at a brazing temperature. If it is determined that the target object is not at a brazing temperature, method 740 may loop back to 745. This loop between applying energy to the induction heater and determining whether the target object is at a brazing temperature may continue until it is determined that the target object is at a brazing temperature. In this manner, the brazing system may include a control loop, as discussed herein, to control the heating effect of the induction coil to heat the target object to a brazing temperature.

[0094] When it is determined that the target object (e.g., the cutting element pocket, the cutting element, and / or the brazing material) is at the brazing temperature, the brazing system can control the energy input to the induction heater at 747 to maintain the target object at the brazing temperature for the brazing period. As discussed herein, the brazing period can be between 10 seconds and 60 seconds. In some embodiments, the brazing period can be 30 seconds. After the brazing period, at 748, the brazing system can advance the induction heater along the heating path. For example, the brazing system can advance the induction heater along the heating path from one target object to another (e.g., from one cutting element pocket to another). In some embodiments, the brazing system can return to applying energy to the induction heater at 745 to heat another target object. In other words, the brazing system can restart method 740 with another target object positioned along the heating path. In this way, the brazing system can be used to implement one or more actions of method 740 in conjunction with any number of target objects (e.g., brazing multiple cutting elements to a series of cutting element pockets).

[0095] Embodiments of the brazing system have been described primarily with reference to wellbore drilling operations; the brazing systems described herein can be used in applications other than wellbore drilling. In other embodiments, the brazing systems according to the present disclosure can be used outside of a wellbore or other downhole environment used to explore for or produce natural resources. For example, the brazing system of the present disclosure can be used in a borehole used to place a utility line. Therefore, the terms "wellbore," "borehole," and the like should not be construed to limit the tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0096] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed technology. In addition, in order to provide a concise description of these embodiments, not all features of the actual embodiments may be described in the specification. It should be understood that in the development of any such actual embodiments, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developer's specific goals, such as meeting system-related and business-related constraints, which may vary from one embodiment to another. In addition, it should be understood that such development efforts may be complex and time-consuming, but are still routine tasks of design, fabrication, and manufacturing for those of ordinary skill in the art who benefit from this disclosure.

[0097] In addition, it should be understood that reference to "one embodiment" or "an embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also include the described features. For example, any element described with respect to the embodiments herein can be combined with any element of any other embodiment described herein. The numerals, percentages, ratios or other values ​​described herein are intended to include that value, as well as other values ​​of "about" or "approximately" the value, as will be understood by those of ordinary skill in the art encompassed by the embodiments of the present disclosure. Therefore, the values ​​should be interpreted broadly enough to encompass values ​​that are at least close enough to the values ​​to perform the desired function or achieve the desired result. The values ​​include at least the variations expected in a suitable manufacturing or production process, and may include values ​​within 5%, within 1%, within 0.1% or within 0.01% of the values.

[0098] In view of this disclosure, those skilled in the art will recognize that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional "means-plus-function" clauses, are intended to cover structures described herein as performing the functions described, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. Except for those claims where the phrase "means for..." appears together with the associated function, it is the express intention of the applicant not to invoke means-plus-function or other functional claims in any claim. Every addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims will be covered by the claims.

[0099] As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount, is within standard manufacturing or process tolerances, or that still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within less than 5%, less than 1%, less than 0.1%, and less than 0.01% of a stated amount. Furthermore, it should be understood that any directions or reference frames in the foregoing descriptions are merely relative directions or movements. For example, any reference to "up" and "down," or "above," or "below," is merely a description of the relative position or movement of the relevant elements.

[0100] The present disclosure may be implemented in other specific forms without departing from the spirit or characteristics of the present disclosure. The described embodiments are to be considered illustrative rather than restrictive. Therefore, the scope of the present disclosure is indicated by the appended claims rather than the preceding description. Changes that fall within the meaning and scope of equivalents of the claims are to be included within the scope of the claims.

Claims

1. A method of incorporating a cutting element into a downhole drilling tool, comprising: orienting the induction coil relative to the cutting element dimple; applying an energy input to the induction coil to heat the cutting element pocket to a brazing temperature; determining a dimple temperature of the cutting element dimple; and Based on the dimple temperature, energy input to the induction coil is controlled to maintain the dimple temperature at a brazing temperature for a brazing period. 2 . The method of claim 1 , wherein orienting the induction coil comprises orienting a robotic arm, and wherein the robotic arm comprises the induction coil on a working end thereof. 3 . The method of claim 2 , further comprising determining a heating path based on a geometry of a drill body, wherein orienting the robotic arm comprises moving the induction coil along the heating path.

4. The method of claim 3, wherein the cutting element pocket is a first cutting element pocket, and the pocket temperature is a first pocket temperature, and wherein a second cutting element pocket is located along the heating path, the method further comprising: orienting the induction coil relative to the second cutting element pocket; applying an energy input to the induction coil to heat the second cutting element pocket to a brazing temperature; determining a second dimple temperature of the second cutting element dimple; and Based on the second dimple temperature, energy input to the induction coil is controlled to maintain the second dimple temperature at a brazing temperature for the brazing period.

5. The method of claim 1, wherein determining the dimple temperature comprises determining the dimple temperature of the cutting element dimple using an infrared camera directed toward the cutting element dimple and the induction coil.

6. The method of claim 1, wherein applying the energy input comprises applying the energy input to the induction coil to heat the cutting element dimple to a brazing temperature in 60 seconds or less. 7 . The method of claim 1 , wherein controlling the energy input to the induction coil comprises reducing the electrical energy input to the induction coil to maintain the dimple temperature at the brazing temperature.

8. The method of claim 1 , wherein the cutting element pocket is a first cutting element pocket and the downhole drilling tool includes a second cutting element pocket, the method further comprising applying energy input to the induction coil to heat the first cutting element pocket and the second cutting element pocket to a preliminary temperature below the brazing temperature before heating the first cutting element pocket to the brazing temperature.

9. The method of claim 1 , further comprising inserting a cutting element into the cutting element pocket, the cutting element comprising a superhard portion, and wherein the method further comprises: determining a superhard portion temperature of the superhard portion; and Energy input to the induction coil was controlled to maintain the superhard portion temperature below 1600°F.

10. The method of claim 1 , further comprising applying a brazing material to the cutting element pocket and inserting a cutting element into the cutting element pocket, wherein applying the energy input to the induction coil further comprises applying the energy input to the induction coil to heat the cutting element pocket and the brazing material to a brazing temperature without using a flux material. The method according to claim 10 , wherein the brazing temperature is below the critical temperature of 1600° C.

12. The method of claim 1 , wherein the induction coil is a first induction coil, the method further comprising: orienting a first induction coil adjacent a first side of the cutting element pocket; orienting a second induction coil adjacent a second side of the cutting element pocket; applying energy input to the first induction coil and the second induction coil to heat the cutting element pocket to a brazing temperature; and Based on the dimple temperature, energy input to the first induction coil and the second induction coil is controlled to maintain the dimple temperature at a brazing temperature for the brazing period.

13. The method of claim 12 further comprising inserting a cutting element into the cutting element pocket, the cutting element comprising a superhard portion on a distal end of the cutting element, the distal end oriented adjacent a third side of the cutting element pocket opposite the first side, the method further comprising applying energy input to the first induction coil and the second induction coil to heat the cutting element pocket from the first side and the second side.

14. A method of incorporating a cutting element into a downhole drilling tool, comprising: applying a brazing material to the cutting element pocket; inserting a cutting element into the cutting element recess; orienting a robotic arm relative to the cutting element pocket, the robotic arm comprising an induction coil; orienting the induction coil adjacent the cutting element pocket; applying an energy input to the induction coil to heat the cutting element pocket to a brazing temperature; When at the brazing temperature, melting the brazing material; and After melting the brazing material, the cutting element is positioned into the cutting element pocket while maintaining the angular orientation of the cutting element.

15. The method of claim 14, wherein orienting the induction coil further comprises moving the induction coil along a predetermined heating path relative to the cutting element pocket.

16. A brazing system comprising: a support member configured to support a drill bit including a plurality of cutting element pockets; a robotic arm having a working end movable relative to the support; an induction heater connected to a working end of the robotic arm; and A thermal sensor is oriented toward the support.

17. The brazing system of claim 16, wherein the thermal sensor is oriented at the support and the induction heater thermal sensor.

18. The brazing system of claim 16, wherein the thermal sensor comprises an infrared camera.

19. The brazing system of claim 18, wherein the field of view of the infrared camera is configured to capture the entire surface of the drill bit.

20. The brazing system of claim 16, wherein the induction heater comprises a plurality of induction coils.

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