System method and apparatus for instrumentally joining elements

Abstract

An instrument assembly includes an electronics housing disposed in a body of a downhole tool; and a bonding element assembly, the bonding element assembly being connected to the electronic device housing. The instrument assembly includes an engagement sensor positioned at a base of an engagement element assembly and configured to make a measurement corresponding to an engagement of the engagement element assembly and a borehole. The instrumentation assembly includes an electronics housing seal configured to isolate at least a portion of the electronics housing from downhole pressure.

Description

Cross Reference to Related Applications

[0001] This disclosure claims priority to U.S. Provisional Application No. 63 / 502,129, filed May 15, 2023, which is incorporated by reference herein in its entirety. BACKGROUND

[0002] Wellbores can be drilled into subterranean locations or seafloors for various exploration or production purposes. For example, wellbores can be drilled to access fluids (such as liquid and gaseous hydrocarbons) stored in subterranean formations and extract the fluids from the formations. Wellbores for producing or extracting fluids can be formed in the formations using earth-boring tools, such as drill bits for drilling the wellbores and reamers for enlarging the diameters of the wellbores.

[0003] Wellbores can extend deep into the ground, often several kilometers. Accurate detection and mapping of geological formations is important for identifying sources of oil, gas, geothermal, or other valuable resources, but is often difficult. For example, conventional techniques often implement imaging tools to measure various parameters of the surrounding rock, implement tools to collect and remove samples of the formations for analysis at the surface, and implement tools to detect various downhole dynamics of the drilling system.

[0004] The operating costs of some conventional tools can be high, in part because they are often only usable when the well is not being actively drilled. Some conventional tools can be part of the drilling tool assembly and / or implemented while drilling. However, these tools are often located a substantial distance uphole from the downhole tool that is actively engaging or cutting into the formation. As a result, the measurements of some conventional tools can be of limited use, for example, it can be difficult to determine or characterize downhole dynamics as the downhole (engaging) tool interacts with the formation and / or to make measurements close to the point of engagement of the downhole (engaging) tool. Additionally, the measurements (or images) of some conventional tools can have limited precision and / or resolution, limiting their usefulness and / or ability to detect and / or characterize geological features and / or downhole dynamics.

[0005] Accordingly, improved methods, systems, and apparatuses for imaging and / or mapping formations of a wellbore while drilling and for detecting downhole dynamics have significant advantages over conventional techniques. SUMMARY

[0006] In some embodiments, an instrument assembly includes an electronics housing disposed in a body of a downhole tool and a bonding element assembly connected to the electronics housing. The instrument assembly includes a bonding sensor positioned at a base of the bonding element assembly and configured to make a measurement corresponding to bonding of the bonding element assembly and a borehole. The instrument assembly includes an electronics housing seal configured to isolate at least a portion of the electronics housing from downhole pressure.

[0007] In other embodiments, a bonding element assembly includes a bonding element having a distal end and a base. A bonding sensor is positioned at the base of the bonding element. The bonding element assembly includes a connector configured to hold the bonding element in a bonding element pocket in a body of a downhole tool such that a force exerted on the distal end of the bonding element is transferred to the base of the bonding element. The bonding element assembly includes a seal configured to seal pressure of the bonding element pocket.

[0008] In other embodiments, a method of using a bonding element assembly includes bonding a downhole formation with a bonding element of a bonding element assembly. The method includes transferring a force from the bonding element to a bonding sensor. The force is associated with the bonding element bonding the downhole formation. The bonding sensor is positioned at a base of the bonding element and the bonding element is axially fixed. The method includes receiving a bonding measurement from the bonding sensor with a processor positioned in an electronics housing.

[0009] This Summary is provided to introduce a selection of concepts that are further described below in the. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0010] Additional features and advantages of the embodiments of the present disclosure will be set forth in the description that follows, and in part will be apparent from the description, or can be learned by practice of such embodiments. The features and advantages of the embodiments can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or can be learned by the practice of such embodiments as set forth hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0011] In order to describe the manner in which the above-recited and other features of the present disclosure can be obtained, a more particular description will be rendered by reference to specific implementations thereof, which are illustrated in the appended drawings. For better understanding, identical elements are denoted by the same reference numbers throughout the various drawings. While some of the drawings can be schematic or exaggerated representations of concepts, at least some of the drawings can be drawn to scale. Understanding that the drawings depict some example implementations, the implementations will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: Figure 1 One implementation of a drilling system for drilling a subterranean formation is shown in accordance with at least one implementation of the present disclosure; Figure 2 is a bottom view of a downhole end of an implementation of a drill bit in accordance with at least one implementation of the present disclosure; Figure 3 is a perspective cutaway view of a drill bit in accordance with at least one implementation of the present disclosure; Figure 4-1 is a perspective cutaway view of a drill bit in accordance with at least one implementation of the present disclosure; Figure 4-2 and Figure 4-3 is Figure 4-1 is a partial cutaway view of a drill bit of Figure 5 is a schematic view of a sensor engagement element and a cutting guide element engaged with a borehole in accordance with at least one implementation of the present disclosure; Figure 6 is a side view of a drill bit in accordance with at least one implementation of the present disclosure; Figure 7 is an exploded partial view of an engagement element assembly in accordance with at least one implementation of the present disclosure; Figure 8 is an exploded partial view of an engagement element assembly in accordance with at least one implementation of the present disclosure; Figure 9 is an exploded partial view of an engagement element assembly in accordance with at least one implementation of the present disclosure; Figure 10 is an exploded partial view of an engagement element assembly in accordance with at least one implementation of the present disclosure; Figure 11 is a side cutaway view of an engagement element housing in accordance with at least one implementation of the present disclosure; Figure 12 is a side cutaway view of an engagement element housing in accordance with at least one implementation of the present disclosure; Figure 13 is a side cutaway view of an engagement element housing in accordance with at least one implementation of the present disclosure; Figure 14is a side cross-sectional view of a junction element housing according to at least one embodiment of the present disclosure; Figure 15 is a side cross-sectional view of a junction element housing according to at least one embodiment of the present disclosure; Figure 16 is a side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool according to at least one embodiment of the present disclosure; Figure 17-1 is an exploded side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool according to at least one embodiment of the present disclosure; Figure 17-2 is Figure 17-1 is an assembled side cross-sectional view of the electronics housing system shown; Figure 18 is a side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool according to at least one embodiment of the present disclosure; Figure 19 is a side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool according to at least one embodiment of the present disclosure; Figure 20 shows a flowchart of a method or series of actions for using a junction element assembly according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0012] The present disclosure relates generally to apparatuses, systems, and methods for instrumented junction elements. For example, a drilling system can implement one or more tools to engage a borehole. An instrumented junction element can be used in conjunction with one or more downhole tools and can engage a borehole. The instrumented junction element can include one or more sensors for making downhole measurements associated with the engagement of the junction element with the borehole, such as engagement (e.g., force) measurements. In at least one embodiment described herein, observed downhole measurements (or, more specifically, changes in observed downhole measurements) can be used to determine and / or map one or more features of a borehole. For example, mapping borehole features can aid in the identification of subsurface resources, such as oil, gas, and geothermal, as well as structural determinations of a formation. For example, mapping borehole features can aid in the identification of subsurface resources, such as oil, gas, and geothermal, as well as structural determinations of a formation.

[0013] Electronics, such as processors and / or power sources, can be associated with the sensors. These electronics can be located on or housed within the downhole tool. For example, an instrumented junction element can be connected to the downhole tool at a junction element pocket. An electronics housing can be connected to and / or can extend from and / or can house electronics within the junction element pocket. In this way, the sensors of the instrumented junction element can be connected to the electronics. In another example, the electronics housing can be included in a location different from the junction element pocket, such as in a bore of the downhole tool. The electronics housing system can include a cable conduit for guiding a cable from the sensors through the tool body to the bore. An adapter can connect the cable conduit to the electronics housing, and in this way, the sensors can be connected to the electronics.

[0014] In at least one embodiment, the instrumented junction element helps protect the sensors and / or electronics from damage. For example, the instrumented junction element can seal the opening of the junction element pocket and / or the electronics housing such that downhole pressure and / or drilling fluid does not seep into the electronics housing. In another embodiment, the instrumented junction element is disposed in a junction element housing, and the junction element housing can seal the junction element pocket and / or the electronics housing. In at least one embodiment, the instrumented junction element forms a seal in this way that helps protect the electronics from being exposed to one or more aspects of the downhole drilling environment that can damage the electronics.

[0015] The junction element housing can include one or more sensors in place of or in addition to the junction sensors. For example, the junction element housing can include a force sensor, a pressure sensor, a strain sensor, or a temperature sensor. In some embodiments, the junction element assembly will not include an instrumented junction element and / or junction sensors. In this way, at least one embodiment of the junction element housing can be configured in any number of ways in order to make any number of relevant downhole measurements.

[0016] Figure 1 One embodiment of a drilling system 100 for drilling a wellbore 102 into a formation 101 (e.g., a downhole formation) is shown. The drilling system 100 includes a rig 103 for rotating a drilling tool assembly 104 that extends downhole into the wellbore 102. The drilling tool assembly 104 can include a drill string 105, a bottom hole assembly (“BHA”) 106, a drill bit 110 attached to a downhole end of the drill string 105.

[0017] Drill string 105 can include several joints of drill pipe 108 connected end-to-end by tool joints 109. Drill string 105 can convey drilling fluid through a central bore and can transmit rotational power from rig 103 to BHA 106. Rotational power can also be transmitted by one or more mud motors located in wellbore 102. In some embodiments, drill string 105 also includes additional components, such as short subs, short drill pipes, and the like. Drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid is expelled through nozzles, jets, or other orifices of selected size in drill bit 110 for cooling drill bit 110 and cutting structures thereon, and for lifting cuttings out of wellbore 102 as it is being drilled.

[0018] BHA 106 can include drill bit 110 or other components. Exemplary BHA 106 can include additional or other components (e.g., coupled between drill string 105 and drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, under-reamers, casing shoes, hydraulic slip joints, jars, vibration or shock absorption tools, other components, or combinations of the foregoing. BHA 106 can also include a rotary steerable system (RSS). The RSS can include a directional drilling tool that changes the direction of drill bit 110, thereby changing the trajectory of wellbore 102. At least a portion of the RSS can maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, and / or true north. Using measurements obtained through the geostationary position, the RSS can position drill bit 110, change the course of drill bit 110, and guide the directional drilling tool on a projected trajectory.

[0019] In general, drilling system 100 can include other drilling components and accessories, such as special-purpose valves (e.g., kelly bushings, blowout preventers, and safety valves). Additional components included in drilling system 100 can be considered part of drilling tool assembly 104, drill string 105, or part of BHA 106, depending on their location in drilling system 100.

[0020] 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 into the surface formation 101. An example type of drill bit for drilling into a formation is a fixed-cutter or drag bit. In other embodiments, the drill bit 110 can be a mill shoe for removing metal, composite materials, elastomers, other downhole materials, or combinations thereof. For example, the drill bit 110 can be used with a whipstock to mill into a casing 107 that is run over the wellbore 102. The drill bit 110 can also be a flat mill shoe for milling out tools, plugs, cement, other materials, or combinations thereof within the wellbore 102. Cuttings or other drillings formed by use of the mill shoe can be transported to the surface or can be allowed to fall downhole.

[0021] The drilling system 100 can include one or more instrument assemblies 119. The instrument assembly 119 can be implemented in a downhole tool of the drilling system 100, such as in the drill bit 110. The instrument assembly 119 can include one or more sensors, for example, for making measurements (such as forces) based on the engagement of one or more components of the instrument assembly with the borehole.

[0022] Figure 2 is a bottom view of a downhole end of an embodiment of a drill bit 210 according to at least one embodiment of the present disclosure. The drill bit 210 can include a drill bit body 211 from which a plurality of blades 212 can protrude. At least one blade 212 can have a plurality of cutting elements 213 connected thereto. In some embodiments, at least one of the cutting elements is a planar cutting element, such as a shear cutting element. In other embodiments, at least one cutting element is a non-planar cutting element, such as a conical cutting element (e.g., a stingray cutting element) and / or a ridged cutting element.

[0023] In some embodiments, the drill bit 210 includes an instrument assembly 219. The instrument assembly 219 can include instrumentation for making one or more downhole measurements with the drill bit 210. For example, the instrument assembly 219 can include one or more sensors for measuring forces, strains, pressures, temperatures, or combinations thereof.

[0024] According to at least one embodiment of the present disclosure, the instrument assembly 219 includes an engagement element and an engagement sensor for measuring engagement of the engagement element with the borehole. A power source can provide power to the engagement sensor, and a processor and memory can receive and / or record engagement measurements from the engagement sensor. In this way, the engagement element can engage the borehole, and the instrument assembly can make corresponding measurements (e.g., axial force and / or other measurements) of the engagement element. The engagement measurements can be helpful in creating or generating one or more of a graph, plot, image, or map of parameters experienced by the drill bit 210 in order to illustrate one or more properties and / or characteristics of the material encountered by the drill bit 210 as it drills the borehole.

[0025] Figure 3 is a perspective cutaway view of a drill bit 310 according to at least one embodiment of the present disclosure. As just mentioned, in some embodiments, the drill bit 310 includes an instrument assembly 319. The instrument assembly 319 can include an electronics housing 314. The electronics housing 314 can be disposed in the drill bit body 311 of the drill bit 310. The electronics housing 314 can define a volume within the drill bit 310 to, for example, house electronics of the instrument assembly 319 as will be discussed herein.

[0026] In some embodiments, the instrument assembly 319 includes an engagement element assembly 320. The engagement element assembly 320 can be connected to the drill bit 310 by connection to the electronics housing 314. For example, the electronics housing 314 can include or define (e.g., can be formed) an engagement element pocket, and the engagement element assembly 320 can be connected to the engagement element pocket. The engagement element assembly 320 can be connected to the electronics housing 314 by a sealed connection. For example, the instrument assembly 319 can include a seal 322. The seal 322 can be positioned between the electronics housing 314 and the engagement element assembly 320 to seal the electronics housing 314. For example, the electronics housing 314 can be sealed with pressure (e.g., atmospheric pressure), and the seal 322 can maintain pressure within the electronics housing 314. In some embodiments, fluid (e.g., drilling fluid) is present in the borehole, and the seal 322 prevents the fluid from seeping into the electronics housing 314. In this way, the engagement element assembly 320 can be connected to the electronics housing 314 to form a sealed volume to, for example, protect electronics housed in the electronics housing 314.

[0027] In some embodiments, the instrument assembly 319 includes a sensor 323. The sensor 323 can be an engagement sensor for making one or more measurements associated with the engagement of the engagement element assembly 320 with the borehole. For example, the engagement sensor can be a force sensor. In some embodiments, the sensor 323 is positioned at the base of the engagement element assembly 320 and can make measurements, for example, based on the force exerted on the engagement element assembly 320. For example, the electronics housing 314 can have one or more internal structural features for holding and / or supporting the sensor 323 and / or the engagement element assembly 320. In this way, the force exerted on the engagement element assembly 320 can correspond to the measurements made by the sensor 323.

[0028] Figure 4-1 is a perspective cutaway view of a drill bit 410 in accordance with at least one embodiment of the present disclosure. In some embodiments, the drill bit 410 includes an instrument assembly 419. The instrument assembly can include an engagement element assembly 420 connected to an electronics housing 414. In some embodiments, the engagement element assembly 420 is removably connected to the electronics housing 414. In other words, the engagement element assembly 420 can not be permanently attached to the drill bit 410 by brazing the engagement element assembly 420 to the drill bit 410 as in conventional methods. In this way, the engagement element assembly 420 can be selectively connected to and / or removed from the drill bit 410. In at least one embodiment, this can facilitate the incorporation of electronics 425 and / or sensors 423 into the drill bit 410. For example, the electronics 425 can be installed into the electronics housing 414 and connected to the sensors 423, after which the engagement element assembly 420 can be connected to the electronics housing 414, completing the installation of the instrument assembly 419. In at least one embodiment, this can facilitate the implementation and / or replacement of sensing and / or measuring devices, such as those included in the instrument assembly 419, by significantly simplifying the implementation of such devices in downhole tools, such as the drill bit 410.

[0029] In some embodiments, the junction element assembly 420 includes a sensor junction element 421. The sensor junction element 421 can be a planar junction element, a non-planar (e.g., conical, hemispherical, bullet-shaped, etc.) junction element (such as a stingray junction element), or any other junction element. The sensor junction element 421 can be a junction element, or can be configured to engage with a borehole. For example, the sensor junction element 421 can be at least partially composed of an ultra-hard material, such as a polycrystalline diamond compact (PCD). As used herein, the term "ultra-hard" should be understood to refer to those materials known in the art having a grain hardness of approximately 1,500 HV (Vickers Hardness, units of kg / mm2) or greater. Such ultra-hard materials can include, but are not limited to, diamond or polycrystalline diamond, sapphire, carbyne, Lonsdaleite; cubic boron nitride (cBN); polycrystalline cubic boron nitride (PcBN); Q-carbon; binderless PcBN; diamond-like carbon; low-oxidized boron; aluminum-manganese-boronide; metal borides; carbon-boron-nitrogen-oxide systems showing hardness values above 1,500 HV, and combinations of the above. In some embodiments, the ultra-hard material has a hardness value above 3,000 HV. In other embodiments, the ultra-hard material has a hardness value above 4,000 HV. In yet other embodiments, the ultra-hard material has a hardness value greater than 80 HRa (Rockwell Hardness A). In some examples, the sensor junction element 421 is formed of any other material, including metals, metal alloys, ceramic materials, any other material, and combinations thereof.

[0030] The junction element assembly 420 can be connected to the electronics housing 414 such that the sensor junction element 421 extends at least partially beyond the outer surface 470 of the drill bit 410. For example, the sensor junction element 421 can extend from the drill bit 410 such that the sensor junction element 421 can engage with a borehole while the drill bit 410 is being used to drill a well. The sensor junction element 421 can extend in a substantially vertical direction (e.g., extend in a substantially downhole direction). This can facilitate engagement of the sensor junction element 421 with a borehole.

[0031] In some embodiments, the instrument assembly includes a sensor 423. The sensor 423 can be an engagement sensor and can make measurements associated with the engagement of the sensor engagement element 421 with the borehole. The sensor 423 can be positioned at the base of the engagement element assembly 420. The sensor 423 can be positioned at the base of the sensor engagement element 421. For example, the conduit 415 and / or the engagement element assembly 420 can have one or more structural features for holding and / or supporting the sensor 423 relative to the sensor engagement element 421. When the sensor engagement element 421 is engaged with the borehole, forces exerted on the engagement element 421 can be transmitted through the base of the sensor engagement element 421 to the sensor 423. In some embodiments, the forces are axial forces. In this way, the sensor 423 can make measurements based on the forces of the sensor engagement element 421. This can facilitate making measurements of the formation encountered by the sensor engagement element 421. For example, materials in the formation (e.g., geological materials) can exhibit different material properties, such as hardness, which can correspond to different measurements (e.g., forces) sensed by the sensor engagement element 421. In another example, features in the formation, such as fractures or veins, can correspond to different measurements (e.g., forces) sensed by the sensor engagement element 421. The sensor 423 can measure these changes and, in this way, detect features and / or properties of the formation.

[0032] In this way, the sensor 423 can make measurements associated with the engagement of the sensor engagement element 421 with the borehole. For example, the sensor 423 can measure strain, stress, displacement, pressure, deformation, deflection, or any other parameter associated with the engagement of the sensor engagement element 421 with the borehole. These measurements can facilitate calculating or determining forces on the sensor engagement element 421 or determining any other dynamics associated with the engagement of the sensor engagement element 421 with the borehole. The sensor 423 can include a strain gauge, a Hall effect sensor, a magnet, a capacitive sensor, a spring sensor, any other sensor, or combinations thereof.

[0033] As mentioned above, the instrument assembly 419 includes an electronics housing 414 disposed in the bit body 411. In some embodiments, the electronics housing includes or defines a conduit 415 that extends into the bit body 411. The conduit 415 can have an elongated shape. For example, the conduit 415 can be substantially cylindrical. The conduit 415 can take any other shape according to the shapes disclosed herein. The conduit 415 can extend into the bit 410 such that a volume is defined within the bit body 411.

[0034] In some embodiments, the instrument assembly 419 includes a seal 422. The seal 422 can be positioned between the engagement element assembly 420 and the electronics housing 414. For example, the seal 422 can be an O-ring seal, such as a metal, rubber, or plastic O-ring seal. The seal 422 can be a gasket seal. The seal 422 can be a face seal. For example, the electronics housing 414 and the engagement element assembly 420 each have a sealing surface, and the sealing surfaces abut to form the seal 422. The seal 422 can function to seal an interior volume of the electronics housing 414. For example, the electronics housing 414 can be sealed to maintain an internal pressure of the electronics housing 414. The electronics housing 414 can be sealed to prevent fluid from seeping into the electronics housing 414. This can facilitate the use and / or protection of the electronics within the sealed portion of the electronics housing 414.

[0035] The volume of the electronics housing 414 can be sized and / or shaped to accommodate electronics 425. For example, the electronics 425 can include a processor 425-1 and / or a battery 425-2. The electronics 425 can include one or more additional components, such as a memory, a communication device, etc. The electronics 425 can be coupled to and / or associated with the sensor 423. For example, the battery 425-2 can power some function of the sensor 423. The processor 425-1 can receive and / or record one or more measurements of the sensor 423 (e.g., process and / or save to a memory). The electronics 425 can be positioned within the sealed portion of the electronics housing 414. In some embodiments, the sensor 423 is positioned in the sealed portion of the electronics housing 414, which can facilitate the connection of the sensor 423 to the electronics 425 (e.g., through a wired connection). In this way, the electronics housing 414 can facilitate the implementation of one or more electronics into the drill bit 410, such as a processor for receiving downhole measurements from the sensor 423.

[0036] The electronics housing 414 can have an opening 416. The opening 416 can be positioned at an outer surface of the drill bit body 411. In some embodiments, the engagement element assembly 420 is connected to the electronics housing 414 at the opening 416. For example, a portion of the electronics housing 414 proximate or adjacent to the opening 416 can be an engagement element pocket 417. The engagement element pocket 417 can be a portion of the electronics housing 414 that is configured for connection to and / or retention of the engagement element assembly 420. In some embodiments, the engagement element pocket 417 is separate from the conduit 415. For example, the engagement element pocket 417 can be located at a different location on the drill bit 410 than the conduit. The engagement element pocket 417 can form or define a separate cavity from a cavity of the conduit 415. In this way, the electronics 425 can be housed at a different location than the engagement element assembly 420 and / or the sensor 423.

[0037] According to at least one embodiment of the present disclosure, the opening 416 can be located at a distal (e.g., downhole) end of the conduit 415. The opening can be located at an outer surface 470 of the drill bit body 411 and can provide access to the electronics housing 414, for example, to insert and / or connect the electronics 425. The engagement element pocket 417 can be a portion of the conduit 415 proximate or proximal to the opening 416. In this way, the engagement element pocket 417 and the conduit 415 can be positioned or formed in the same cavity of the drill bit body 411. This can facilitate and / or simplify installation and / or connection of one or more of the electronics 425, the engagement element assembly 420, and the sensor 423. The opening 416 (and in this example, the engagement element pocket 417) can be located on an outer surface of the drill bit body 411 that is a downhole end of the drill bit 410. This positioning can facilitate extension of the engagement element assembly 420 and / or the sensor engagement element 421 from the outer surface of the drill bit body 411.

[0038] In some embodiments, the conduit 415 includes a sleeve 415-1. For example, the sleeve 415-1 can be substantially the same shape as the conduit 415, and can be hollow or can have an internal bore. In some embodiments, the sleeve 415-1 is substantially a hollow cylinder. The sleeve 415-1 and / or the conduit 415 can be any shape suitable for housing the electronics 425 described herein. In some embodiments, the sleeve 415-1 is disposed within and / or connected to the conduit 415. For example, the sleeve 415-1 can be brazed into the conduit 415. The sleeve 415-1 can be glued, pressed, or screwed into the conduit, or any other suitable connection means for connecting the sleeve 415-1 to the conduit 415. The sleeve 415-1 can span the entire length of the conduit 415, such that the sleeve 415-1 substantially constitutes the entire portion of the conduit 415. For example, one or more of the features of the conduit 415 described herein (e.g., a sealing feature, a connection to the junction element assembly, etc.) can be included as part of the sleeve 415-1. In some embodiments, the sleeve 415-1 spans or encompasses only a portion of the conduit 415. For example, the sleeve 415-1 can define or be associated with a sealed portion of the electronics housing 414. For example, the sleeve 415-1 can not include or be associated with the connection of the junction element assembly 420 to the electronics housing 414.

[0039] The sleeve 415-1 can at least partially define or form a sealed volume of the electronics housing 414. The sleeve 415-1 can be configured to withstand a pressure differential between the sealed volume and an exterior of the drill bit 410. For example, the sleeve 415-1 has a wall thickness selected to prevent collapse under the pressure differential.

[0040] In some cases, the material properties of the metal matrix of the drill bit body 411 make it difficult to incorporate one or more features of the conduit 415 discussed herein. The sleeve 415-1 can be more easily machined or manufactured to facilitate the incorporation of one or more of these features. In some embodiments, the sleeve 415-1 is manufactured prior to being installed into the drill bit 410. In some embodiments, the sleeve 415-1 is installed into the drill bit 410, and one or more features of the electronics housing 414 are machined or manufactured into the sleeve 415-1 after installation. In this way, the electronics housing 414 can include the sleeve 415-1 to facilitate the inclusion of one or more features of the instrument assembly 419.

[0041] In some embodiments, the guide tube 415 is oriented longitudinally relative to the drill bit 410. For example, the longitudinal axis of the guide tube 415 may be oriented such that it is parallel to the longitudinal axis of the drill bit 410. The longitudinal axis of the drill bit 410 may be the axis of rotation of the drill bit 410. In this way, the guide tube 415 may be oriented substantially vertically, for example, during downhole drilling activities of the drill bit 410. This can facilitate the substantially vertical extension (e.g., downhole) of the engagement element assembly 420 and / or engagement element 421 from the drill bit 410.

[0042] Although Figure 4-1 One or more components of the instrument assembly 419 shown are substantially vertical or substantially located within the longitudinal plane of the drill bit 410; however, it should be understood that one or more components of the instrument assembly 419 may be oriented at an angle, for example, relative to the longitudinal plane of the drill bit 410. In fact, one or more components of the instrument assembly 419 may be included in the drill bit 410 in any orientation, provided that the orientation is suitable for drilling and / or measuring as described herein. For example, one or more of the conduit 415, the engagement element assembly 420, and the engagement element cavity 417 may be horizontally oriented, as if the engagement element... Figure 6 This is under discussion. In another example, one or more of the conduit 415, engagement element assembly 420, and engagement element cavity 417 may be oriented diagonally relative to the longitudinal plane or at any other angle. This can facilitate the implementation of instrument assembly 419 into various drilling tools.

[0043] In some embodiments, the electronic housing 414 (more specifically, the engagement element cavity 417) is positioned within the drill body 411 such that the engagement element assembly 420 and / or the sensor engagement element 421 are adjacent to the engagement elements of the drill 410 (such as...). Figure 2 The sensor engagement element 421 extends from the drill bit 410 behind the engagement element (e.g., the engagement element 213). For example, during drilling operations, the drill bit 410 can rotate such that the engagement element follows a rotation path. The sensor engagement element 421 can be positioned such that it follows the same rotation path as one of the engagement elements of the drill bit 410. In other words, the radius of the rotation path of the sensor engagement element 421 can be substantially the same as the radius of the rotation path of the cutting element of the drill bit 410. In this way, the sensor engagement element 421 can follow the rotation path of the cutting guide element 475. Although Figure 4-2 The cutting guide element 475 is shown as an engagement element of the drill bit 410, which is adjacent to and / or located in front of the sensor engagement element 421 in terms of steering. However, it should be understood that the cutting guide element 475 can be positioned at any location on the drill bit 410 (as discussed below) and / or can be any of the engagement elements of the drill bit 410.

[0044] The sensor engagement element 421 can follow the rotational path of the cutting guide element 475 by being positioned at an offset angle from the cutting guide element 475. For example, the offset angle can be an angle between the cutting guide element 475 and the sensor engagement element 421 measured about the rotational axis of the drill bit 410 (e.g., measured in the rotational direction and in the plane of the drill bit 410). In this way, the offset angle can correspond to an angle between a point of engagement of the cutting guide element 475 with the formation and a point of engagement of the sensor engagement element 421 with the formation.

[0045] In some embodiments, the sensor engagement element 421 is positioned substantially adjacent or proximate to the cutting guide element 475. For example, the offset angle can be small, such as 1°, and the sensor engagement element 421 can be positioned immediately (in a turning sense) behind the cutting guide element 475. In another example, the offset angle can be large, and the sensor engagement element 421 can be positioned immediately (in a turning sense) in front of the cutting guide element 475. In some embodiments, the adjacent or proximate position of the sensor engagement element 421 to the cutting guide element 475 can correspond to the sensor engagement element 421 and the cutting guide element 475 being positioned on the same blade of the drill bit 410.

[0046] In some embodiments, the sensor engagement element 421 is not positioned adjacent or proximate to the cutting guide element 475. For example, the offset angle can be any angle between 1° and 359°, such as 45°, 90°, 180°, 270°, or any other angle. In some embodiments, the sensor engagement element 421 and the cutting guide element 475 are positioned in the same blade of the drill bit 410. In some embodiments, this corresponds to the sensor engagement element 421 being positioned in a different blade (or not in a blade) than the cutting guide element 475. In this way, the sensor engagement element 421 can be positioned at any offset angle relative to the cutting guide element 475 such that the sensor engagement element 421 and the sensor cutting guide element 475 follow substantially the same rotational path. In some embodiments, the sensor engagement element 421 and / or the cutting guide element 475 are each positioned in a blade of the drill bit 410. In some embodiments, the sensor engagement element 421 and / or the cutting guide element 475 are each not positioned in a blade of the drill bit 210.

[0047] Figure 4-2 and 4-3 are schematic illustrations showing engagement of the sensor engagement element 421 and the cutting guide element 475. It should be understood that Figure 4-2The positioning of the sensor engagement element 421 and the cutting guide element 475 is shown adjacent, near, or substantially side-by-side for illustrative purposes only. The position and / or spacing of the sensor engagement element 421 and the cutting guide element 475 can correspond to any of the offset angles described above. In this way, Figure 4-2 The sensor engagement element 421 and the cutting guide element 475 are shown relative to the rotation 480 of the drill bit 410, not necessarily relative to the actual or physical position on the drill bit 410. Similarly, it should be understood that, Figure 4-3 The sensor engagement element 421 and the cutting guide element 475 are not necessarily shown relative to a positioning in, for example, each of the drill bit 410. Rather, Figure 4-3 The sensor engagement element 421 and the cutting guide element 475 are illustrative cases of engagement of the sensor engagement element 421 and the cutting guide element 475 with the formation 401.

[0048] As discussed herein, the sensor engagement element 421 engages the formation 401 in order to take one or more corresponding measurements. In some embodiments, the sensor engagement element 421 engages the formation 401 by contacting the formation 401 and / or extending into the formation. This can be characterized by an engagement distance 473. For example, the cutting guide element 475 can engage the formation and can cut and / or plow out a guide slot 476. The sensor cutting element 473 can extend into the formation 401 at or in the guide slot 476 (e.g., as Figure 4-3 shown) and can create a trailing slot 477. The engagement distance 473 can be the difference between the farthest extent of the guide slot 476 (e.g., downhole) and the trailing slot 477. In this way, the engagement distance 473 can correspond to the distance or farthest extent that the sensor engagement element 421 extends into the formation 401 when engaged.

[0049] In some embodiments, the engagement distance 473 can be 1 mm. The engagement distance 473 can be a range having an upper value, a lower value, or an upper value and a lower value including 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 10 mm, or any value in between. For example, the engagement distance 473 can be less than 10 mm. In another example, the engagement distance can be greater than 0.1 mm. In yet another example, the engagement distance 473 can be between 0.1 mm and 10 mm. In some embodiments, the offset distance 473 is less than 1 mm to ensure that the sensor engagement element 421 has a substantially sufficient engagement with the formation 401 to be able to take one or more measurements accurately while minimizing noise in the measurements.

[0050] The sensor engagement element 421 can extend axially (e.g., downhole) a sensor axial distance 471. The cutting guide element 475 can extend axially (e.g., downhole) a cutting axial distance 472. The sensor axial distance 471 and the cutting axial distance 472 can each be a distance measured between a point of engagement of the sensor engagement element 421 and the cutting guide element 475 (respectively) with the formation 401 and a reference point 474, such as at a base of a blade of the drill bit 410. The reference point 474 can be any reference point used to measure the sensor axial distance 471 and the cutting axial distance 472 relative to the engagement of the sensor engagement element 421 and the cutting guide element 475 with the formation 401. For example, the sensor engagement element 421 can be mounted in a downhole tool that engages with a well wall (e.g., rather than engaging with a well bottom), the sensor axial distance 471 and the cutting axial distance 472 can be measured radially outward from the reference point 474 to where the sensor engagement element 421 and the cutting guide element 475 engage with the well wall, respectively. In this way, the sensor engagement element 421 can follow the same rotational path as the cutting guide element 475 (e.g., behind it in terms of rotation), while still engaging the borehole within the groove or channel cut by the cutting guide element 475, as discussed in connection with Figure 5 The sensor axial distance and / or the cutting axial distance 471 can be determined or configured so that the sensor engagement element 421 engages the formation 401 with the engagement distance 472, as discussed above.

[0051] In some embodiments, the sensor axial distance 471 can be greater than the cutting axial distance 472. In other words, the sensor engagement element 421 can extend axially (e.g., downhole) farther than the cutting guide element 475. This can correspond to the sensor engagement element 421 being positioned with a smaller offset angle, such as less than 180°. In this way, after the cutting guide element 475 cuts out the guide groove 476, the sensor engagement element 421 can extend axially and engage the formation.

[0052] In some embodiments, the sensor axial distance 471 can be substantially the same as or even less than the cutting axial distance 472. This can correspond to the sensor engaging element 421 being positioned at a large offset angle, such as greater than 180°. For example, while some of the figures herein have shown the formation as having a face that is substantially horizontal or substantially parallel with respect to the drill bit 410 and / or the various engaging elements of the drill bit 410, due to the rotation of the drill bit 410 and the drill bit’s advancement downhole through the formation 401 while rotating, in some cases, the face of the formation 401 can have a helical or spiral-like nature such that the face of the formation can be represented as being inclined or non-parallel with respect to the drill bit 410. In this manner, after the cutting pilot element 475 has cut out the pilot groove 476, the sensor engaging element 421 can extend axially and engage the formation, even if the sensor engaging element 421 can not extend axially further than the cutting pilot element 475. In this manner, the configuration of the sensor axial distance 471 and / or the cutting axial distance 472 can be based on or dependent on the offset angle as discussed above.

[0053] In some embodiments, the one or more sensors are connected to one or more other components of the BHA. In some embodiments, the one or more sensors include a transmitter for transmitting sensor data. For example, the transmitter can transmit the sensor data to other components of the BHA. In another example, the transmitter can transmit the sensor data to the surface.

[0054] As discussed herein, the sensor engaging element 421 can follow the same (or similar) rotational path as the cutting pilot element 475. This can correspond to the sensor engaging element 421 engaging the formation 401 within the pilot groove 476 that is cut or plowed out by the cutting pilot element 475. The sensor engaging element 421 can be positioned and / or oriented such that the width of the trailing groove 477 never exceeds the width of the pilot groove 476 when the sensor engaging element 421 follows behind the cutting pilot element 475 in the turn. For example, the sensor engaging element 421 can engage the formation 401 at the center of the pilot groove 476. In another example, the sensor engaging element 421 can engage the borehole at another location of the pilot groove 476 that is non-central. The sensor engaging element 421 can engage the formation 401 within the pilot groove 476 at an angle (e.g., with respect to a longitudinal axis of the sensor engaging element 421), such as a right angle or perpendicular angle, or any other angle.

[0055] The sensor engagement element 421 can follow behind the cutting guide element 475 in this manner to facilitate measuring and / or calculating the force on the sensor engagement element 421, or any other parameter associated with the engagement of the sensor engagement element 421 with the borehole. For example, the sensor engagement element 421 can engage the formation 401 in substantially the same manner regardless of the depth of cut and / or rate of penetration of the drill bit. For a given geometry of rock or material being removed, the force on the engagement element (e.g., the cutter) can be proportional to the area of rock being cut or removed. The sensor engagement element 421 can engage the formation 401 within the guide slot 476 so as to maintain a substantially uniform geometry (more specifically, area) of rock being removed by the sensor engagement element 421. This can result in the sensor engagement element 421 engaging with the formation 401 substantially uniformly at all depths of cut and / or rates of penetration of the cutting guide element 475 and / or the downhole tool implementing the cutting guide element 475 and the sensor engagement element 421. By contrast, if the sensor engagement element 421 does not follow directly behind the cutting guide element 475 and / or does not engage the formation 401 within the guide slot 476, the area of rock engaged (e.g., removed) by the sensor engagement element 421 can vary based on the depth of cut of the cutting guide element 475, thereby significantly complicating the calculation of the force (or other parameter) on the sensor engagement element 421. In this manner, variations in the force (or other parameter) measured on the sensor engagement element 421 can be due to variations or features of the formation 401 (e.g., variations in material, variations in hardness, veins or fractures in the formation, etc.) rather than variations in the geometry of the cut by the sensor engagement element 421 (e.g., due to variations in the depth of cut of the cutting guide element).

[0056] Figure 5This is a side view of a drill bit 510 according to at least one embodiment of the present disclosure. In some embodiments, the drill bit 510 includes an electronics housing 514, which is at least partially defined by a conduit 515. A engagement element recess 517 may be connected to and / or associated with the conduit 515 to retain an engagement element assembly 520. A seal 522 may be positioned between the engagement element assembly 520 and the engagement element recess 517 to seal the engagement element recess 517 and / or the conduit 515. In some embodiments, the conduit 515 and / or the engagement element recess 517 are not oriented in a longitudinal direction and / or are not oriented parallel to the axis of rotation of the drill bit 510. In some embodiments, the conduit 515 and / or the engagement element recess 517 are substantially horizontally oriented and / or substantially tangential to the rotational trajectory of the drill bit 510. In this way, the engagement element assembly 520 and / or the sensor engagement element 521 do not extend vertically or axially from the drill bit 510, but may extend in the rotational or radial direction of the drill bit 510. In some embodiments, the conduit 515 and the engagement element cavity 517 are connected as part of the same cavity in the drill bit 510. In this way, the sensor 523 and / or the electronics associated with the sensor 523 can be positioned adjacent to and / or behind the engagement element assembly 520. The sensor 523 and / or the electronics associated with the sensor 523 can be located within a sealed portion of the electronics housing 514. In some embodiments, the engagement element cavity 517 is positioned in the drill bit 510 as shown, and the conduit 515 is positioned at a separate location in the drill bit 510. In this way, the sensor 523 and / or the electronics associated with the sensor 523 can be positioned at a different location than the engagement element assembly 520 (e.g., the sensor 523 can be connected to the engagement element assembly 520 via a linkage).

[0057] Sensor engagement element 521 may be included in drill bit 510 as one of the engagement elements for cutting (e.g., active cutting) drilling (e.g., ... Figure 2 (The sensor engagement element 521 may be subjected to forces in the horizontal or rotational direction, and the sensor 523 can measure these forces. Forces measured in this way can help determine the rotational force applied to the engagement element and / or the torque applied to the drill bit 510. As discussed herein, variations in the measured forces can also help identify features in the formation. The horizontal or rotational forces acting on the sensor engagement element 521 can help acquire and / or measure one or more parameters other than force, such as strain, stress, pressure, deformation, deflection, etc.

[0058] Although Figure 5The junction element assembly 520, the conduit 515, and the junction element pocket 517 shown in FIG. 6 are substantially horizontal or substantially within a radial plane of the drill bit 510, but it should be understood that one or more of the junction element assembly 520, the conduit 515, and the junction element pocket 517 can be oriented at an angle, for example, relative to a radial plane of the drill bit 510. Indeed, one or more of the junction element assembly 520, the conduit 515, and the junction element pocket 517 can be included in the drill bit 510 in any orientation so long as the orientation is consistent with drilling a borehole and / or taking measurements as described herein.

[0059] Figure 6 is a side cross-sectional view of an instrument assembly 619 according to at least one embodiment of the present disclosure. The instrument assembly 619 can include an electronics housing 614 formed in a body 611 of a drill bit 610. The instrument assembly 619 can include a junction element assembly 620. For example, the junction element assembly 620 can be connected to the electronics housing 614, for example, at a junction element pocket of the electronics housing 614. The junction element assembly 620 can include a sensor junction element for engaging a formation. The junction element assembly 620 can include a junction element housing for connecting the junction element to the electronics housing, or the junction element assembly can be directly connected to the electronics housing without a junction element housing.

[0060] In some embodiments, the instrument assembly 619 can include a membrane. The membrane can be integrally formed in the body 611 of the drill bit 610. For example, the electronics housing 614 can be formed and / or defined by a proximal cavity 614a and a distal cavity 614b, the proximal cavity penetrating and / or extending into the drill bit body 611 from a proximal side 629 of the drill bit body 611, and the distal cavity penetrating and / or extending into the drill bit body 611 from a distal side of the drill bit body 611. The proximal cavity 614a and the distal cavity 614b can not meet or converge such that there is no through hole in the drill bit body 611, but a small portion and / or thin portion of the drill bit body 611 can remain and / or separate the proximal cavity 614a and the distal cavity 614b to form the membrane 636. The proximal cavity 614a and the distal cavity 614b can each be included as part of the electronics housing 614 (e.g., the proximal cavity 614a and the distal cavity 614b can define the electronics housing 614). The distal cavity can be a junction element pocket of the electronics housing 614, such as Figure 4-1 the junction element pocket 417 in FIG. 6.

[0061] The instrument assembly 619 can be configured such that the diaphragm 636 is positioned at the base of the engagement element assembly 620. In this way, forces can be transmitted to the diaphragm 636 by the engagement element assembly. Based on the forces transmitted by the engagement element assembly, the diaphragm 636 can experience one or more dynamic changes (or changes in dynamics), such as forces, stresses, strains, pressures, deflections, deformations, displacements, or any other dynamics resulting therefrom (and combinations thereof). For example, the diaphragm can be configured to at least to some extent deflect and / or deform based on the forces transmitted to the diaphragm from the engagement element assembly 620. The diaphragm can be configured to support the engagement element assembly 620 and / or withstand forces from the engagement element assembly 620 without breaking, deforming, or otherwise plastically deforming. In some embodiments, the instrument assembly 619 can include a strain gauge 637. For example, the strain gauge 637 can be positioned on the diaphragm, such as in the proximal cavity 614a of the electronics housing 614. The strain gauge can sense or measure one or more of the dynamics (or changes in dynamics) of the diaphragm (e.g., based on deformations and / or deflections of the diaphragm). In this way, the strain gauge 637 and the diaphragm 636 can form a sensor 623. The sensor 623 can sense engagement of the engagement element assembly 620 with the formation and / or make measurements corresponding to the engagement. In some embodiments, the engagement element assembly 620 can substantially remain axially fixed in response to the forces experienced by the engagement element assembly 620. In this way, the sensor 623 can make measurements based on elastic deformations and / or measurable changes in at least one dimension of at least a portion of the diaphragm (e.g., as opposed to axial movement or displacement of the engagement element assembly 620).

[0062] In some embodiments, the diaphragm 636 can form (or can be) the seal 622. For example, due to the diaphragm 636’s integration with the bit body 611, the diaphragm 636 can isolate the proximal cavity 614a from the distal cavity 614b and / or from the exterior of the drill bit 610. The diaphragm 636 and / or the seal 622 can isolate the proximal cavity 614a from external pressures (e.g., downhole pressures) and / or can prevent pressure and / or fluid from seeping into and / or out of the proximal cavity 614a. This can help to protect the strain gauge 637 (and associated electronics positioned in the proximal cavity 614a) from exposure to one or more properties of the downhole environment that can damage these components. In this way, the diaphragm 636 can be the seal 622 and can seal at least a portion of the electronics housing (e.g., isolate from downhole pressure and / or fluid seepage). In some embodiments, the diaphragm 636 can be the seal 322. Figure 3

[0063] Figure 7 ​is an exploded view of a junction element assembly 720 according to at least one embodiment of the present disclosure. In some embodiments, the junction element assembly 720 includes a sensor junction element 721. The sensor junction element 721 can be connected to the drill bit 710 via a junction element recess 717. As discussed herein, the junction element recess 717 can be part of or connected to the electronics housing conduit, or can be included in the drill bit 710 as a separate component from the electronics housing conduit.

[0064] In some embodiments, the sensor junction element 721 is connected to or held in the junction element recess 717 by direct engagement with the junction element recess 717. For example, the sensor junction element 721 can be connected to the junction element recess by a connector. The connector can be a thread 726. In this way, the sensor junction element 721 can be screwed into and tightened into the junction element recess 717 in order to secure the sensor junction element 721 to the drill bit 710.

[0065] In some embodiments, the junction element assembly 720 includes a seal 722. The seal 722 can be positioned between the sensor junction element 721 and the junction element recess 717. In this way, the seal 722 can seal the junction element recess 717, for example, from the environment outside of the drill bit 710. In some embodiments, the electronics housing conduit is connected to the junction element recess 717, and the seal 722 seals the electronics housing conduit. In some embodiments, the seal prevents fluid from seeping into the junction element recess 717. In some embodiments, the seal maintains pressure within the junction element recess. This can protect the electronics and / or sensors 723 from harsh downhole environments, thereby facilitating the inclusion of these components into the drill bit 710.

[0066] In some embodiments, the seal 722 is an O-ring seal. For example, the sensor engagement element 721 can include an outer groove around its exterior. The seal 722 can be seated in the groove and maintain its position in this way between the sensor engagement element 721 and the engagement element recess 717. In some embodiments, the seal 722 is contained within the engagement element recess 717 (e.g., by an inner groove around the interior of the engagement element recess 717). In some embodiments, the seal 722 is a gasket seal. For example, the sensor engagement element 721 can include a flange, and a gasket seal can be positioned between the flange of the sensor engagement element 721 and an upper surface of the engagement element recess 717, which can seal the engagement element recess 717 when tightened. In some embodiments, the seal 722 is formed by sealing the surfaces of the sensor engagement element 721 and the engagement element recess 717 without an O-ring, gasket, or other dedicated sealing component. For example, the sealing surfaces can be tightened against one another such that the seal 722 is formed. In this way, the engagement element recess 717 (and / or the electronics housing conduit) can be isolated from one or more aspects of the downhole environment.

[0067] As mentioned above, the junction element assembly 720 can include a sensor 723. The sensor 723 can be a junction sensor configured to make a measurement corresponding to the junction of the sensor junction element 721 with a borehole. The sensor 723 can be a force sensor. For example, the sensor 723 can be a force transducer, a load cell, a strain gauge, or a combination thereof, and can make one or more force measurements. The sensor 723 can be any other type of sensor for making any other downhole measurement, as described herein. The sensor 723 can be inserted into the junction element pocket 717 below and / or before the sensor junction element 721. The sensor 723 can be positioned in the sealed portion of the junction element pocket 717 and in this way protected from the drilling environment. The sensor can be positioned at the base of the sensor junction element 721. As discussed herein, the sensor junction element 721 can engage a downhole formation, which can exert a force on the sensor junction element 721. This force can be transmitted through the sensor junction element 721 to the sensor 723. For example, one or more features (e.g., in the junction element pocket 717) can support the sensor 723, and the sensor junction element 721 can press against or exert a force on the sensor 723. In this way, the sensor 723 can make a junction measurement corresponding to the junction of the sensor junction element 721 with a borehole, such as a force measurement corresponding to an axial force exerted on the sensor junction element 721. In some embodiments, the sensor is connected to or included on the sensor junction element 721. For example, the sensor 723 can be a strain gauge and can be connected to the base of the sensor junction element 721, such as will be discussed in connection with FIGS. 8-10. Figure 11 to Figure 15 are discussed.

[0068] The sensor engagement element 721 can be fixed relative to the engagement element pocket 717. For example, the sensor engagement element 721 can be fixed such that forces exerted on the sensor engagement element 721 do not cause the sensor engagement element 721 to move, e.g., axially relative to the engagement element pocket 717. The sensor engagement element 721 can exert a force on the sensor 723 without the sensor engagement element moving axially relative to the sensor 723. For example, the sensor 723 can include a strain gauge, and the sensor 723 can sense a parameter associated with the force (e.g., force, deformation, pressure, deflection, displacement, etc.) by sensing a strain caused by the sensor engagement element 721. This can be in contrast to a sensor that employs a mechanical device, such as a spring and / or linkage, to sense a force associated with movement of the sensor engagement element 721, for example. In this way, the sensor engagement element 721 can be axially fixed relative to the engagement element pocket 717 in order to securely hold the sensor engagement element 721. In some embodiments, the sensor engagement element 721 is not axially fixed relative to the engagement element pocket 717. For example, the sensor 723 can include a mechanical device for making a measurement (e.g., a spring to measure a force), and the sensor engagement element 721 can be free to move axially within the engagement element pocket 717 at least to some extent. In this way, the sensor 723 can make a measurement associated with the sensor engagement element 721 based on movement of the sensor engagement element 721. In some embodiments, one or more sensors are connected to one or more other components of the BHA. In some embodiments, one or more sensors include a transmitter for transmitting sensor data. For example, the transmitter can transmit sensor data to other components of the BHA. In another example, the transmitter can transmit sensor data to the surface.

[0069] Figure 8 is an exploded view of an engagement element assembly 820 according to at least one embodiment of the disclosure. In some embodiments, the engagement element assembly 820 includes a sensor engagement element 821. The sensor engagement element 821 can be connected to the drill bit 810 via an engagement element pocket 817. As discussed herein, the engagement element pocket 817 can be part of or connected to an electronics housing conduit, or can be included in the drill bit 810 as a separate component from the electronics housing conduit.

[0070] In some embodiments, the sensor engagement element 821 is connected to or retained in the engagement element recess 817 by direct engagement with the engagement element recess 817. For example, the sensor engagement element 821 can be directly inserted into the engagement element recess 817, and can be connected to the engagement element recess 817 by a connector. The connector can be a snap ring 827. For example, the engagement element recess 817 can include an internal groove, and the snap ring 827 can be inserted into the internal groove by compressing the snap ring 827. The inner diameter of the snap ring 827 seated in the internal groove can be smaller than the outer diameter of the sensor engagement element 821. In this way, the snap ring 827 can be inserted into the engagement element recess 817 on top of or behind the sensor engagement element 821 to retain the sensor engagement element 821 in the engagement element recess 817. In some embodiments, the sensor engagement element 821 is axially fixed relative to the engagement element recess 817, such as discussed above in connection with Figure 7 .

[0071] In some embodiments, the engagement element assembly 820 includes a seal 822. The seal 822 can be a seal 722, and / or can include one or more features of a seal 722, as discussed above in connection with Figure 7 . Figure 7 The seal 822 can be positioned between the sensor engagement element 821 and the engagement element recess 817, and in this way can isolate the engagement element recess 817 from the environment outside of the drill bit 810. In some embodiments, the engagement element assembly 820 includes a sensor 823, such as the sensor 723 discussed above in connection with Figure 7 .

[0072] Figure 9 is an exploded view of an engagement element assembly 920 according to at least one embodiment of the present disclosure. In some embodiments, the engagement element assembly 920 includes a sensor engagement element 921. The sensor engagement element 921 can be connected to the drill bit 910 via an engagement element recess 917. As discussed herein, the engagement element recess 917 can be part of or connected to an electronics housing conduit, or can be included in the drill bit 910 as a separate component from the electronics housing conduit.

[0073] In some embodiments, the sensor engagement element 921 is connected to or retained in the engagement element recess 917 by indirect engagement with the engagement element recess 917. For example, the sensor engagement element 921 can be connected to or contained in an engagement element housing 924, and the engagement element housing 924 can be connected to the engagement element recess 917. This will be discussed herein in connection with Figure 11 to Figure 15The junction element housing 924 is discussed in detail. In some embodiments, the junction element housing 924 is connected to the junction element pocket 917 by a connector. The connector can be a screw thread 926. In this way, the junction element housing 924 can be screwed into and tightened into the junction element pocket 917 in order to secure the sensor junction element 921 to the drill bit 910. The sensor junction element 921 can be connected to the junction element housing 924 by any suitable means, including permanent (or semi-permanent) connection means. For example, the sensor junction element 921 can be brazed, glued, pressed, screwed, or fastened into the junction element housing 924. In some embodiments, the sensor junction element 921 is axially fixed relative to the junction element pocket 917, such as discussed above in connection with Figure 7 .

[0074] In some embodiments, the junction element assembly 920 includes a seal 922. The seal 922 can include one or more features of the seal 722 discussed above in connection with Figure 7 . In some embodiments, the junction element assembly 920 includes a sensor 923, such as the sensor 723 discussed above in connection with Figure 7 .

[0075] Figure 10 is an exploded view of a junction element assembly 1020 according to at least one embodiment of the present disclosure. In some embodiments, the junction element assembly 1020 includes a sensor junction element 1021. The sensor junction element 1021 can be connected to the drill bit 1010 via a junction element pocket 1017. As discussed herein, the junction element pocket 1017 can be part of or connected to an electronics housing conduit, or can be included in the drill bit 1010 as a separate component from the electronics housing conduit.

[0076] In some embodiments, the sensor junction element 1021 is connected to or held in the junction element pocket 1017 by indirect engagement with the junction element pocket 1017. For example, the sensor junction element 1021 can be connected to or contained in a junction element housing 1024, and the junction element housing 1024 can be connected to the junction element pocket 1017. The junction element housing can include one or more features of the junction element housing 924 discussed above in connection with Figure 9 . In some embodiments, the junction element assembly 1020 includes a sensor 1023, such as the sensor 723 discussed above in connection with Figure 11 to Figure 15The various embodiments of the sensor engagement element described in connection with Figure 8 may be removably connected to the engagement element recess by a mechanical connection. This can facilitate the inclusion and / or replacement of the sensor engagement element and / or electronics associated with the sensor engagement element. For example, the electronics can be inserted into the engagement element recess (e.g., into an electronics housing conduit connected to the engagement element recess), and then the engagement element assembly can be installed into the engagement element recess. In another example, the electronics can be housed in another location, and wires of the electronics can extend into the engagement element recess, where they can be connected to the sensor of the engagement element assembly, and then the assembly can be installed into the engagement element recess. In this way, the electronics can receive downhole measurements from the sensor. The removable connection of the engagement element assembly can also facilitate the inclusion of electronics, such as the sensor, into the engagement element assembly (e.g., into the electronics housing) without the need to expose the electronics to temperatures that can damage the electronics (such as by brazing the engagement element). Figure 7

[0077] In some embodiments, the engagement element assembly 1020 includes a seal 1022. The seal 1022 can include one or more features of the seal 722 described in connection with Figure 7 . The seal 1022 can be positioned between the engagement element housing 1024 and the engagement element recess 1017 and in this way can isolate the engagement element recess 1017 from the environment outside of the drill bit 1010. In some embodiments, the engagement element assembly 1020 includes a sensor 1023, such as the seal 723 described in connection with Figure 7 above.

[0078] In this way, the various embodiments of the sensor engagement element described in connection with Figure 7 to Figure 10 may be removably connected to the engagement element recess by a mechanical connection. This can facilitate the inclusion and / or replacement of the sensor engagement element and / or electronics associated with the sensor engagement element. For example, the electronics can be inserted into the engagement element recess (e.g., into an electronics housing conduit connected to the engagement element recess), and then the engagement element assembly can be installed into the engagement element recess. In another example, the electronics can be housed in another location, and wires of the electronics can extend into the engagement element recess, where they can be connected to the sensor of the engagement element assembly, and then the assembly can be installed into the engagement element recess. In this way, the electronics can receive downhole measurements from the sensor. The removable connection of the engagement element assembly can also facilitate the inclusion of electronics, such as the sensor, into the engagement element assembly (e.g., into the electronics housing) without the need to expose the electronics to temperatures that can damage the electronics (such as by brazing the engagement element).

[0079] Figure 11 ​is a side cutaway view of an instrument housing or engagement element housing 1124 according to at least one embodiment of the present disclosure. The engagement element housing 1124 includes a housing body configured to connect to an engagement element pocket 1117 of a downhole tool. The housing can have a distal end 1128 and a proximal end 1129. The proximal end 1129 can be inserted into and / or engaged with the engagement element pocket 1117. The housing body can be connected to the engagement element pocket 1117 such that the distal end 1128 is positioned at an outer surface of the downhole tool. The distal end 1128 positioned on the outer surface of the downhole tool can facilitate measurements by one or more sensors associated with the engagement element housing 1124.

[0080] In some embodiments, the housing body is removably connected to the engagement element pocket 1117. For example, the housing body can include threads 1126. The threads 1126 can be external threads on an outer surface of the housing body. The threads 1126 can be screwed into or onto internal threads on an inner surface of the engagement element pocket 1117. In another example, the housing body can be removably connected to the engagement element pocket 1117 by a snap ring, such as the kind described in connection with Figure 7 to Figure 10 In some embodiments, the housing body is removably connected to the engagement element pocket 1117. For example, the housing body can include threads 1126. The threads 1126 can be external threads on an outer surface of the housing body. The threads 1126 can be screwed into or onto internal threads on an inner surface of the engagement element pocket 1117. In another example, the housing body can be removably connected to the engagement element pocket 1117 by a snap ring, such as the kind described in connection with

[0081] In some embodiments, the engagement element housing 1124 has a seal 1122. The seal 1122 can be positioned on the exterior of the housing body such that the seal 1122 is positioned between the housing body and the engagement element recess 1117 (e.g., when the engagement element housing 1124 is connected to the engagement element recess 1117). The seal 1122 can help seal a portion of the engagement element recess 1117 (and / or the electronics housing conduit). For example, the seal 1122 can seal the pressure in the engagement element recess 1117, and / or can prevent fluid or other matter from seeping into the engagement element recess 1117. In some embodiments, such as shown in the figures, the seal 1122 is an O-ring seal. The O-ring can be seated in a groove or channel on the exterior of the housing body. In some embodiments, the O-ring is seated in a groove or channel on the interior of the engagement element recess 1117. In this way, the O-ring can be positioned between the housing body and the engagement element recess 1117 to seal the engagement element recess 1117. In some embodiments, the seal 1122 is a gasket. For example, the gasket can be disposed on a flange. In some embodiments, the gasket is disposed on a mating surface of the engagement element recess 1117. The gasket can be positioned between the flange and the surface of the engagement element recess 1117 to seal the engagement element recess 1117. In some embodiments, the seal 1122 is formed without a separate or dedicated sealing element. For example, the mating surfaces of the housing body and the engagement element recess 1117 can interface to form the seal 1122 (e.g., the flange and the surface of the engagement element recess 1117). In this way, the engagement element housing 1124 can form a removable connection with the drill bit, and can also seal, for example, the electronics housing conduit of the drill bit.

[0082] In some embodiments, the engagement element housing 1124 includes a measurement recess 1131. The measurement recess 1131 can be formed in the housing body. The measurement recess 1131 can define a cavity or conduit in the housing body. For example, the measurement recess 1131 can have a recess base 1132 and a recess opening 1133. The recess base 1132 and the recess opening 1133 can be located on opposite ends of the measurement recess 1131. In some embodiments, the recess opening 1133 is located on the distal end 1128 of the housing body. In some embodiments, the recess opening 1133 is located on the proximal end 1129 of the housing body. The measurement recess 1131 can be configured to house one or more sensors to make one or more downhole measurements. For example, the recess base 1132 can include or can define a diaphragm 1136. A strain gauge can be connected to the recess base 1132 at the diaphragm 1136. For example, the strain gauge and / or the diaphragm 1136 can facilitate a measurement of a force and / or a pressure associated with the operation of the drill bit. For example, the diaphragm 1136 can experience or exhibit a strain as a result of a pressure or force acting on the diaphragm 1136. The strain gauge can measure the corresponding strain. In this way, the downhole measurements can include force measurements and / or pressure measurements. In another example, a temperature sensor can be positioned in the measurement recess for measuring a temperature associated with the drill bit (e.g., making temperature measurements). In this way, the engagement element recess 1117 can facilitate the inclusion of instrumentation into the drill bit for making one or more downhole measurements, including force measurements, pressure measurements, temperature measurements, and the like.

[0083] The engagement element housing 1124 can be at least partially made of one or more wear-resistant materials. For example, the engagement element housing 1124 can include tungsten carbide, polycrystalline diamond compact (PDC), high speed steel, ceramic, nickel alloy, any other suitable wear-resistant material, and combinations thereof. In some embodiments, one or more portions of the engagement element housing 1124 are made of or coated with a wear-resistant material. The wear-resistant properties of the engagement element housing 1124 can facilitate exposure of at least a portion of the engagement element housing 1124 to conditions of a borehole (e.g., at an outer surface of the drill bit). In this way, the engagement element housing 1124 can withstand harsh downhole drilling environments, such that the engagement element housing 1124 can be incorporated in any number of downhole locations and can be used with any number of downhole tools.

[0084] Figure 12is a side cross-sectional view of an engagement element housing 1224 according to at least one embodiment of the present disclosure. In some embodiments, a sensor engagement element 1221 is disposed or retained in the engagement element housing 1224. The engagement element housing 1224 can include a housing body 1230 having a distal end 1228 and a proximal end 1229. The sensor engagement element 1221 can be any type of engagement element, such as a planar engagement element, a non-planar (e.g., conical, hemispherical, bullet-shaped, etc.) engagement element (such as a stingray engagement element), a rolling engagement element, or any other engagement element. The sensor engagement element 1221 can be an engagement element, or an element that is not configured for cutting or whose primary purpose is not cutting, such as a steering pad or a stabilizing pad. The sensor engagement element 1221 can be positioned in a measurement pocket 1231. For example, the sensor engagement element 1221 can be at least partially inserted into a cavity defined by the measurement pocket 1231. The sensor engagement element 1221 can extend out of a pocket opening 1233. The pocket opening 1233 can be positioned on the distal end 1228 of the housing body 1230 such that the sensor engagement element 1221 extends outward from an outer surface of a downhole tool, such as a drill bit. In this way, the sensor engagement element 1221 can be configured to extend from the drill bit in order to engage a borehole.

[0085] The sensor engagement element 1221 can be connected to or retained in the measurement pocket 1231. For example, the sensor engagement element 1221 and / or the measurement pocket 1231 can each have a slot or channel. For example, upon installation of the sensor engagement element 1221, a retainer (e.g., a snap ring) can be positioned in the corresponding slot to retain the sensor engagement element 1221 in the measurement pocket 1231. The sensor engagement element 1221 can be connected to or retained in the measurement pocket 1231 by any other suitable means. For example, the sensor engagement element 1221 can be glued, brazed, pressed, screwed, or fastened into the measurement pocket 1231. In this way, the sensor engagement element 1221 can be removably connected to the housing body 1230.

[0086] The sensor engagement element 1221 can be retained in the measurement pocket 1231 such that the sensor engagement element 1221 is axially fixed. For example, the sensor engagement element 1221 can be fixed such that the sensor engagement element 1221 does not move relative to its longitudinal axis during engagement with a borehole. As discussed herein, this can facilitate the transmission of forces through the sensor engagement element 1221 to the sensor 1223. In some embodiments, the sensor engagement element 1221 is axially fixed but can be free to turn or rotate within the measurement pocket 1231. This can help to continuously expose different portions of a rotating cutting face in order to reduce wear of the sensor engagement element 1221.

[0087] In some embodiments, the base 1232 of the measurement cavity 1231 includes or defines a diaphragm 1236. The diaphragm 1236 can be positioned at the base of the sensor engagement element 1221. When the sensor engagement element 1221 engages a bore, a force (e.g., an axial force) can be transmitted through the sensor engagement element 1221 to the diaphragm 1236. For example, in some embodiments, the sensor engagement element 1221 is held in the measurement cavity 1231 such that a force exerted on the sensor engagement element 1221 is not distributed throughout the housing body 1230. Rather, in some embodiments, the sensor engagement element 1221 is held in the measurement cavity such that a force exerted on the sensor engagement element 1221 is directed and / or transmitted through the base of the sensor engagement element 1221 to the diaphragm 1236. The diaphragm 1236 can experience or exhibit a strain corresponding to at least a portion of the force (e.g., an axial force).

[0088] The strain of the diaphragm 1236 can be due to the material compliance of the diaphragm 1236. In some embodiments, the diaphragm thickness of the diaphragm 1236 is 10 mm. In some embodiments, the diaphragm thickness is in a range having an upper value, a lower value, or an upper value and a lower value including 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, or any value in between. For example, the diaphragm thickness can be less than 20 mm. In another example, the diaphragm thickness can be greater than 1 mm. In yet another example, the diaphragm thickness can be between 1 mm and 20 mm. In some embodiments, it is critical that the diaphragm thickness be between 3 mm and 6 mm to ensure that the diaphragm 1236 exhibits a measurable level of strain while preventing the diaphragm 1236 from plastically deforming due to the axial force.

[0089] In some embodiments, a sensor 1223 is housed by the measurement recess 1231. For example, a strain gauge 1237 can be disposed on the diaphragm 1236. The strain gauge 1237 can measure a strain exhibited by the diaphragm 1236, for example, based on a force exerted on the sensor engagement element 1221. In this way, the sensor engagement element 1221, the diaphragm 1236, and the strain gauge 1237 can form the sensor 1223 (e.g., a bonded sensor). In some embodiments, the strain gauge 1237 is disposed on an opposite side of the diaphragm 1236 from the sensor engagement element 1221. In this way, the strain gauge 1237 can be positioned in the sealed portion of the engagement element recess (and / or electronics housing conduit). This can facilitate incorporation of the strain gauge 1237 and / or associated electronics into the drill bit, as any cable path from the sealed portion of the engagement element recess to the unsealed portion of the engagement element recess is not needed.

[0090] Figure 13 is a side view cross-section of an engagement element housing 1324 according to at least one embodiment of the present disclosure. In some embodiments, the engagement element housing 1324 includes a housing body 1330 having a measurement recess 1331. In some embodiments, a recess opening 1333 is positioned on a proximal end 1329 of the housing body 1330. In this way, the measurement recess 1331 can open into or face the sealed portion of the engagement element recess, such as Figure 11 is an engagement element recess 1117. The sensor 1323 can be housed by the measurement recess 1331 in a manner that extends directly out from the sealed portion of the engagement element recess (e.g., a cable extends out from the sealed portion). This can facilitate connection of the sensor 1323 to electronics (e.g., a processor and / or power source) housed in the engagement element recess (and / or electronics housing conduit) for receiving downhole measurements from the sensor.

[0091] In some embodiments, the sensor 1323 is a temperature sensor, such as a thermocouple. A recess base 1332 can be positioned at a distal end 1328 of the housing body 1330. In this way, the sensor 1323 can be positioned or extend directly below the distal end 1328 of the housing body 1330, facing the borehole. The recess base 1332 oriented in this way can facilitate accurate measurements by the sensor 1323 (e.g., temperature sensor) at the exterior surface of the drill bit, while still being protected in the engagement element recess (such as, Figure 11seal portion. For example, heat experienced by the drill bit can be transferred through the recess base 1332 to the sensor 1323. The recess base 1332 can be thick enough to resist wear and protect the sensor 1323, but thin enough to effectively transfer heat to the sensor 1323. In this way, the recess base 1332 can be a membrane 1336 for transferring heat. In some embodiments, the recess base 1332 and / or the membrane 1336 are partially or entirely made of a material with high thermal conductivity. For example, the recess base 1332 can include a diamond disc. In some embodiments, a thermally conductive paste is disposed in the measurement recess 1331 to help conduct heat to the sensor 1323. In this way, the recess base 1332 and / or the membrane 1336 can resist wear while effectively conducting heat to the sensor 1323.

[0092] In some embodiments, the measurement recess 1331 is formed in a side portion or sidewall of the housing body 1330 (such as shown in FIG. 13B). This can be in addition to or in lieu of the measurement recess 1331 being formed in another portion (e.g., a central portion) of the housing body 1330. In this way, the measurement recess 1331 can extend at least partially along and / or parallel to an additional measurement recess 1331 in another portion of the housing body 1330. In this way, any number of techniques for incorporating a gauge joint housing in a drill bit can be combined to include any number of sensors for making downhole measurements associated with the drill bit and / or the formation. Figure 15

[0093] Figure 14 is a side cutaway view of a joint housing 1424 according to at least one embodiment of the present disclosure. In some embodiments, the joint housing 1424 can include a housing body 1430 having a proximal end 1429 and a distal end 1428. In some embodiments, the joint housing 1424 includes a measurement recess 1431-1 for housing one or more sensors. In some embodiments, the measurement recess 1431-1 is formed in a sensor joint element 1421. In some embodiments, this is in addition to a measurement recess 1431 formed in a housing body 1430 of the joint housing 1424 into which the sensor joint element 1421 is inserted. A recess opening 1433-1 can be located at the proximal end 1429 of the sensor joint element 1421 and can face a joint recess (such as the joint recess 1117 shown in FIG. 11A) in the drill bit. Figure 11 ​The measurement cavity 1431-1 can be configured such that the sensor 1423-1 is positioned adjacent to or toward the distal end 1428 of the sensor engagement element 1421 so that the sensor 1423-1 can measure the temperature at or near the point of engagement of the sensor engagement element 1421 with the borehole. In this way, the sensor 1423-1 can take an accurate reading of the temperature experienced and / or exhibited by the sensor engagement element 1421.

[0094] In some embodiments, the sensor engagement element 1421 extends through a membrane 1436 of the housing body 1430. For example, the membrane 1436 can include an inner bore, and the shaft of the sensor engagement element 1421 can extend through the inner bore of the membrane 1436. This can facilitate the measurement cavity 1431-1 being connected to or open to the sealed portion of the engagement element cavity. To this end, the sensor engagement element 1421 and / or the housing body 1430 can include one or more additional seals 1422. These seals 1422 can seal the inner bore of the membrane 1436 so as to seal the engagement element cavity as described herein. In some embodiments, the engagement element housing 1424 includes a strain gauge 1437. The strain gauge 1437 can include two or more strain gauges positioned around the inner bore of the membrane 1436. In some embodiments, the strain gauge 1437 includes a strain gauge that is at least partially annular or circular, and the strain gauge 1437 can be positioned at least partially (or entirely) around the inner bore of the membrane 1436.

[0095] Figure 15is a side cross-sectional view of a junction element housing 1524 according to one or more embodiments of the present disclosure. In some embodiments, the junction element housing 1524 can include a housing body 1530 having a distal end 1528 and a proximal end 1529. In some embodiments, the junction element housing 1524 includes a measurement recess 1531. In some embodiments, the measurement recess 1531 will not include a sensor junction element housed therein. This can be in addition to or in lieu of the measurement recess 1531 housing a sensor junction element. The recess base 1532 and diaphragm 1536 of the measurement recess 1531 can be positioned at the proximal end 1529 of the housing body 1530. The recess opening 1533 can be positioned at the distal end 1528, opening to the exterior of the drill bit or borehole. In this way, the diaphragm 1536 (including the strain gauge 1537 positioned on the diaphragm 1536) can form a sensor 1523 (e.g., a pressure sensor). For example, in some cases, fluid (e.g., air, drilling fluid, etc.) present in the borehole can enter the measurement recess 1531 and can exert pressure on the diaphragm 1536. As a result, the diaphragm 1536 can experience and / or exhibit strain, which can be measured by the strain gauge 1537. This can facilitate measuring the pressure present in the borehole and / or experienced by the drill bit.

[0096] In some embodiments, a mud filter 1538 is positioned in the measurement recess 1531. The mud filter 1538 can prevent the measurement recess 1531 from becoming clogged with, for example, drilling mud or any other particulate matter present in the borehole. For example, the mud filter 1538 can span the recess opening 1533 and can include one or more eyelets. The eyelets can allow fluid and smaller particles to flow into and / or out of the measurement recess 1531, but can prevent mud and / or larger particles from entering the measurement recess 1531. In this way, the mud filter 1538 can prevent particulate matter from building up above the sensor 1523 (e.g., above the diaphragm 1536). This can ensure that the sensor 1523 is able to accurately measure downhole pressure.

[0097] The present disclosure is directed to systems and methods for measuring downhole pressure. Figure 11 to Figure 15The various embodiments of the junction element housing described can include any number of measurement cavities with sensors therein. In some embodiments, the junction element housing includes 1, 2, 3, 4, 5, or more measurement cavities with sensors for making any number of downhole measurements. For example, the junction element housing can include one or more measurement cavities with distal cavity openings, such as for measuring forces or pressures described herein, and / or can also include one or more measurement cavities with proximal cavity openings, such as for measuring temperatures described herein. One or more sensors can also be implemented in conjunction with the junction element housing with measurement cavities described herein in addition to the sensors described above. For example, in addition to temperature sensors, pressure sensors, and axial force sensors, the junction element housing can also include gyroscopes, accelerometers, 2-axis and 3-axis force sensors, light sensors, sound sensors, sensors for measuring electrical properties, any other sensors for making measurements related to drilling and / or boreholes, and combinations thereof. In this way, the techniques described herein in conjunction with the various embodiments of the junction element housing described herein can be combined in any number of combinations, incorporating any number of instrument configurations in a drill bit for making downhole measurements. In some embodiments, one or more sensors are connected to one or more other components of the BHA. In some embodiments, one or more sensors include a transmitter for transmitting sensor data. For example, the transmitter can transmit sensor data to other components of the BHA. In another example, the transmitter can transmit sensor data to the surface.

[0098] Figure 16 is a side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool 1639 according to at least one embodiment of the present disclosure. In some embodiments, the downhole tool 1639 is a downhole drill bit for extending a borehole. In some embodiments, the electronics housing system is implemented in conjunction with any other downhole tool discussed herein.

[0099] In some embodiments, the electronics housing system includes an electronics housing 1642. The electronics housing 1642 can be positioned within the downhole tool 1639. For example, the electronics housing 1642 can be positioned at least partially inside the interior bore 1641 of the downhole tool 1639. The electronics housing can be positioned at any other location and in any other portion of the downhole tool 1639. The electronics housing 1642 can house electronics associated with sensors of the downhole tool 1639, such as instrumented junction element assemblies as discussed herein, for example.

[0100] In some embodiments, the electronics housing system includes a cable conduit 1644. The cable conduit 1644 can help to route or guide one or more cables. For example, the downhole tool 1639 can include one or more sensors, and the cable conduit 1644 can route cables from the sensors at least partially through the body of the downhole tool 1639. This can help to connect electronics in the electronics housing 1642 to the one or more sensors.

[0101] In some embodiments, the electronics housing system includes an electronics housing adapter or adapter 1646. The adapter 1646 can be positioned within the inner bore 1641. The adapter 1646 can be connected to the electronics housing 1642 and / or the cable conduit 1644. In this way, the adapter 1646 can help to connect the cable conduit 1644 and the electronics housing 1642, for example, in order to route one or more cables from the cable conduit 1644 to the electronics housing 1642. The adapter can form one or more sealed connections with the electronics housing 1642 and / or the cable conduit 1644. In this way, the adapter 1646 can help to connect and seal the cable path, preventing pressure and / or fluid infiltration.

[0102] Figure 17-1 is an exploded side cross-sectional view of an electronics housing system implemented in conjunction with a downhole tool 1739 according to at least one embodiment of the present disclosure and Figure 17-2 is an assembled side cross-sectional view thereof.

[0103] In some embodiments, the electronics housing system 1740 includes an electronics housing 1742. The electronics housing 1742 can be a conduit configured to house electronics, such as Figure 4-1electronics housing 1742 can be a synaptiform housing of the downhole tool (e.g., modified to engage with the adapter 1746, as will be described in detail herein). In some embodiments, the electronics housing 1742 has an elongated shape. For example, the electronics housing 1742 can be substantially cylindrical in shape. This can facilitate positioning the electronics housing 1742 within the inner bore 1741. In another example, the electronics housing 1742 can be polygonal in cross-section. This can facilitate a desired orientation in the inner bore 1741. In some embodiments, the electronics housing 1742 is oriented along a longitudinal direction of the downhole tool 1739. For example, the electronics housing 1742 can be substantially parallel to a longitudinal axis and / or a rotational axis of the downhole tool 1739. In some embodiments, the electronics housing 1742 is positioned at a center of the downhole tool 1739. For example, the electronics housing 1742 can be concentric with the downhole tool 1739, and / or a longitudinal axis of the electronics housing 1742 can be positioned along a longitudinal axis of the downhole tool 1739. This can facilitate balancing rotation of the downhole tool 1739. This can also facilitate fluid flow through the inner bore 1741, as will be described herein.

[0104] The electronics housing 1742 can include an opening 1743. The opening 1743 can facilitate insertion and / or connection of electronics housed in the electronics housing 1742 (e.g., as discussed herein in connection with the conduit 415). For example, one or more cables can pass through the opening 1743 in order to connect the electronics to one or more sensors. According to at least one embodiment of the present disclosure, the opening 1743 can be oriented along a downhole direction and / or can face a downhole end of the downhole tool 1739. This can facilitate implementing sensors at or near an outer surface at the downhole end of the downhole tool 1739. Figure 4-1

[0105] ​In some embodiments, the electronics housing 1742 is positioned or positionable at least partially within an inner bore 1741 of the downhole tool 1739. For example, the inner bore 1741 can be a fluid passageway. In some cases, drilling fluid flows continuously or periodically through the inner bore 1741 to facilitate one or more functions of the downhole tool 1739. The electronics housing 1742 can be sealed so as to prevent drilling fluid from seeping into the electronics housing 1742. For example, the opening 1743 can connect and seal with one or more components (as will be described herein) so as to seal the electronics housing 1742. In some embodiments, the electronics housing 1742 is configured to withstand pressures within the inner bore 1741. For example, in some cases, the flow of drilling fluid is pressurized (e.g., pressurized fluid is provided to one or more nozzles of the drilling tool). In some cases, due to downhole conditions, the downhole tool 1739 and / or the inner bore 1741 experiences and / or exhibits increased atmospheric pressure. The electronics housing 1742 can be configured to withstand these pressures, for example, without collapsing and / or failing. The electronics housing 1742 can be sealed (e.g., at the opening 1743) so as to prevent loss of pressure within the electronics housing 1742. For example, the electronics housing 1742 can be sealed with surface atmospheric pressure, and the electronics housing 1742 (and the opening 1743) can seal the surface pressure within the electronics housing 1742. In this way, the electronics housing 1742 positioned within the inner bore 1741 can be exposed to fluids and / or pressures associated with drilling activities, and the electronics within the electronics housing 1742 can be protected from exposure to these fluids and / or pressures.

[0106] In some embodiments, the electronics housing 1742 is connected to and / or included as part of the downhole tool 1739. In some embodiments, the electronics are connected to and / or included as part of a second downhole tool 1739-2 and / or are positionable within the inner bore 1741 of the downhole tool 1739, for example, through a connection of the downhole tool 1739 to the second downhole tool 1739-2. For example, the second downhole tool 1739-2 can be positioned above or uphole of the downhole tool 1739 and can be connected directly or indirectly (e.g., through one or more additional downhole tools and / or drilling components) to the downhole tool 1739 such that the electronics housing 1742 is positioned at least partially within (or positionable within) the downhole tool 1739 (e.g., in the inner bore 1741). By including the electronics housing 1742 within existing tools and / or components of a drilling system, this can facilitate implementation of the electronics housing 1742. In some embodiments, the second downhole tool 1739-2 is a section of drill pipe. The second downhole tool 1739-2 can be any other downhole tool or component of a drilling system described herein.

[0107] In some embodiments, the downhole tool 1739 includes one or more sensors 1745 for making one or more downhole measurements. For example, the sensors 1745 can be instrumented junction element assemblies as described herein. The sensors 1745 can be junction sensors, force sensors, pressure sensors, temperature sensors, gyroscopes, accelerometers, light sensors, velocity sensors, depth sensors, sound sensors, sensors for measuring electrical properties, any other sensors for making relevant downhole measurements, and combinations thereof. In some embodiments, the sensors 1745 are implemented at or near an outer surface of the downhole tool 1739. The sensors 1745 can be implemented at or near a downhole end of the downhole tool 1739. The sensors 1745 can be connected to a junction element pocket 1747 of the downhole tool 1739, such as the junction element pockets 1747 described herein. The sensors 1745 can be connected to the junction element pocket 1747. For example, the sensors 1745 can be removably connected to the junction element pocket 1747, as described herein. The sensors 1745 can be connected to the junction element pocket 1747 by a sealed connection. For example, the sealed connection of the junction element pocket 1747 can prevent pressure and / or fluid from seeping through the sealed connection and / or into (or out of) the junction element pocket.

[0108] As mentioned above, the electronics housing system 1740 includes a cable conduit 1744. The cable conduit 1744 can be a channel or path for guiding one or more cables associated with the sensors 1745. The cable conduit 1744 can extend at least partially through a body of the downhole tool 1739. For example, the cable conduit 1744 can be connected to the junction element pocket 1747 at a first end, and / or can be connected to the inner bore 1741 at a second end. In this way, the cable conduit 1744 can provide a cable path for one or more sensor cables from the junction element pocket 1747 to the inner bore 1741 and to the electronics housing 1742 as will be described herein. This can facilitate including electronics associated with the sensors 1745 in the downhole tool 1739 and / or drilling system at a location different from the sensors 1745.

[0109] As mentioned above, the electronics housing system 1740 includes an adapter 1746. The adapter 1746 can include an adapter body 1748. The adapter body 1748 can be configured to connect to the downhole tool 1739. For example, the adapter body 1748 can connect to an interior portion of the downhole tool 1739 or at the inner bore 1741. The adapter body 1748 can connect to the downhole tool 1739 by a removable connection. For example, the adapter body 1748 can connect to the downhole tool by way of bolts, screws, threads, or press-in, or by any other suitable connection. According to at least one embodiment of the present disclosure, the adapter body 1748 can be configured to connect to a head 1778 of the downhole tool 1739. For example, the downhole tool 1739 can be a drill bit, and the adapter body 1748 can connect to the head 1778 of the drill bit. The adapter body 1748 can connect to the head 1778 at an interior portion or inner bore of the head 1778. The head 1778 can be located at a downhole portion of the drill bit. In some embodiments, the downhole tool 1739 includes a shank 1779. For example, the shank 1779 can connect to the head 1778, such as to connect the downhole tool 1739 to a drill string (or additional downhole tools). The adapter body 1748 can be positioned between the head 1778 and the shank 1779 of the downhole tool 1739. For example, the adapter body 1748 can connect to the head 1778 of the drill bit between the connection of the head 1778 and the shank 1779. Positioning the adapter 1746 in this manner can facilitate assembling the downhole tool 1739 with the electronics housing system 1740 implemented therein, as will be discussed herein.

[0110] In some embodiments, the adapter body 1748 can connect with any downhole tool. For example, the adapter body 1748 can connect to the downhole tool 1739 by features already included or common to existing downhole tools. In another example, the adapter body 1748 can connect to the downhole tool 1739 by slight modification to an existing downhole tool. In this manner, the adapter 1746 can be implemented and / or retrofitted into existing downhole tools without the need to purchase, create, or manufacture specialized downhole tools to implement the adapter 1746. This can facilitate connecting the electronics housing system 1740 with any downhole tool.

[0111] The adapter body 1748 can be connected to the downhole tool 1739 and can at least partially span the inner bore 1741 (e.g., an inner diameter of the inner bore 1741). In some embodiments, the adapter body 1748 includes one or more apertures and / or fluid passages. For example, the adapter body 1748 (e.g., when connected to the downhole tool 1739) can at least partially cover or block one or more fluid conduits of the downhole tool 1739. Fluid passages in the adapter body 1748 can allow fluid passage to the fluid conduits of the downhole tool 1739, for example, to provide a fluid flow to one or more nozzles (e.g., at an outer surface of the downhole tool 1739). One or more features can be included to orient the adapter body 1748 so as to align the fluid passages of the adapter body 1748 (and / or to align the connection of the adapter body 1748 with the electronics housing 1742 and / or the cable conduit 1744, as will be described herein). For example, the adapter body 1748 and / or the downhole tool 1739 can include one or more alignment pins, pegs, slots, notches, or markings to facilitate proper alignment of the adapter body 1748 in the inner bore 1741. An adapter body 1748 having fluid passages can facilitate implementation of the adapter with existing downhole tools (e.g., as a retrofit) without the need to alter or change the downhole tool.

[0112] In some embodiments, the adapter 1746 includes a first connector 1749-1. The first connector 1749-1 can be a connector configured for connection with the electronics housing 1742. For example, the first connector 1749-1 can be connected at the opening 1743 of the electronics housing 1742. In this way, the adapter 1746 can be connected to the electronics housing 1742 to form a first connection. The first connection can be a first sealed connection. For example, the electronics housing 1742 (e.g., the opening 1743) and / or the first connector 1749-1 can include and / or form a seal. The seal can be an O-ring seal, a gasket seal, a sealing surface, or a combination thereof. The first sealed connection can prevent pressure penetration and / or escape from the electronics housing 1742. The first sealed connection can prevent fluid penetration into the electronics housing 1742. For example, drilling fluid in the inner bore 1741 can not penetrate into the electronics housing 1742 through the first sealed connection. In some embodiments, the first sealed connection is a removable connection. In this way, the adapter 1746 can facilitate formation of a sealed volume in the electronics housing 1742.

[0113] In some embodiments, the adapter 1746 includes a second connector 1749-2. The second connector 1749-2 can be a connector configured to connect to the cable conduit 1744. For example, the second connector 1749-2 can connect to the cable conduit 1744 at a location where the cable conduit 1744 extends into the bore 1741. In this way, the adapter 1746 can connect to the cable conduit 1744 to form a second connection. The second connection can be a second sealed connection. For example, the cable conduit 1744 and / or the second connector 1749-2 can include and / or form a seal. The seal can be an O-ring seal, a gasket seal, a sealing surface, or a combination thereof. The second sealed connection can prevent pressure infiltration and / or escape from the cable conduit 1744. The second sealed connection can prevent fluid infiltration into the cable conduit 1744. In some embodiments, the second sealed connection is a removable connection. For example, drilling fluid in the bore 1741 can not infiltrate the cable conduit 1744 through the second sealed connection.

[0114] In some embodiments, the adapter 1746 has a cable passage 1750. For example, the cable passage 1750 can be a hole or eyelet that passes through the adapter body 1748, for example, from the first connector 1749-1 to the second connector 1749-2. The cable passage 1750 can connect the cable conduit 1744 to the electronics housing 1742. In this way, one or more cables from the sensor 1745 can pass through the cable conduit 1744, through the adapter 1746, and to the electronics housing 1742. As described herein, the adapter 1746 can form a sealed connection with the cable conduit 1744 and the electronics housing 1742. In this way, the engagement element pocket 1747, the cable conduit 1744, the adapter 1746 (e.g., the cable passage 1750), and the electronics housing 1742 can all be connected and sealed. This can form a continuous sealed volume from the engagement element pocket 1747 to the electronics housing 1742. This can facilitate including the sensor 1745 and electronics in the drilling system and / or the downhole tool 1739 by protecting them from fluids and / or pressures that can damage them. In this way, implementing the adapter 1746 can facilitate including the electronics housing 1742 and / or electronics in the electronics housing 1742 in a location that is different from the sensor 1745 (e.g., the electronics housing 1742 is not directly connected to the engagement element pocket 1747 and / or the sensor 1745).

[0115] This can facilitate implementing multiple sensors 1745 at multiple locations of the downhole tool 1739 and / or drilling system, while only requiring one central electronics housing 1742. For example, multiple cable conduits 1744 can be connected with an adapter 1746 to implement the multiple sensors 1745 and / or engagement element pockets 1747. The adapter 1746 can be configured to connect to the multiple electronics housing 1742. Separating the electronics housing 1742 from the sensors 1745 can facilitate different configurations for the sensors 1745. For example, the configuration, location, or orientation of the sensors 1745 can be designed such that it can be difficult to position or house companion electronics adjacent to or proximate to the sensors 1745.

[0116] As mentioned above, one or more components of the electronics housing system 1740 can be removably connected or removably connected to one or more other components. This can facilitate assembly of the downhole tool 1739 that implements the electronics housing system 1740. For example, assembly of the downhole tool 1739 can include first installing and / or connecting the adapter 1746 into (e.g., in an inner bore of) the head 1778 of the downhole tool 1739. A seal such as an O-ring can be added before installation to form a seal between the adapter 1746 and the cable conduit 1744. The adapter 1746 can be installed and / or connected by aligning one or more alignment features such as a locating pin to align the fluid passage and / or the cable passage of the adapter 1746. The shank 1779 of the downhole tool 1739 can then be installed and / or connected to the head 1778. The shank 1779 can be connected with the head 1778 by a threaded connection, and the threaded connection can be torqued. This threaded connection can at least partially help connect or maintain the connection of the adapter 1746 with the downhole tool 1739. A cable can be fed from the sensor 1745 through the bond element pocket 1747, the cable conduit 1744, the adapter 1746, and into the electronics housing 1742. In some embodiments, the cable (e.g., from the sensor 1745) is fed through the electronics housing. For example, the electronics housing can have an end cap at an end opposite the opening 1743, and the cable can be fed (e.g., temporarily) through the entire electronics housing to facilitate installation and / or assembly. The sensor can then be installed in the downhole tool 1739. For example, the sensor 1745 can be an instrumented cutting assembly that is installed and / or connected to the bond element pocket 1747. A second downhole tool 1739-2 can then be connected to the downhole tool 1739, such as by a threaded connection. The connection of the second downhole tool 1739-2 with the downhole tool 1739 can result in the engagement and / or connection of the electronics housing 1742 with the adapter 1746. A seal such as an O-ring can be installed at the connection of the adapter 1746 with the electronics housing 1742 as part of the connection of the second downhole tool 1739-2 with the downhole tool 1739. The electronics associated with the sensor 1745 can then be placed in the electronics housing 1742, and an end cap can be installed. In some embodiments, the electronics are positioned as part of the connection of the second downhole tool 1739-2 with the downhole tool 1739 (e.g., in embodiments where the electronics housing 1742 does not include an end cap). In this way, the downhole tool 1739 can be assembled to implement the electronics housing system 1740.

[0117] Figure 18This is a side sectional view of an electronic housing system 1840 implemented in conjunction with a downhole tool 1839 according to at least one embodiment of the present disclosure. As discussed herein, the electronic housing system 1840 may include one or more of an electronic housing 1842, an adapter 1846, a cable conduit 1844, and a sensor 1845.

[0118] In some implementations, adapter 1846 is part of downhole tool 1839. For example, having the features described herein... Figure 16 to Figure 17-2 The adapter 1846 may be integrally formed into the body of the downhole tool 1839. For example, the adapter 1846 may be formed into the body of the downhole tool 1839 by casting, machining, milling, additive manufacturing, or other methods, or a combination of these methods. The adapter 1846 may be integrally formed onto the head 1878 of the downhole tool 1839. In some embodiments, the adapter 1846 extends from the head 1878 of the downhole tool 1839. For example, one or more features of the adapter 1846 may extend from the body of the downhole tool 1839 into the bore 1841 of the downhole tool 1839. In some embodiments, the adapter 1846 extends into the body of the downhole tool 1839. For example, one or more features of the adapter 1846 may be embedded in the head 1878 of the downhole tool 1839. In this way, the adapter 1846 can be integrally molded into the body of the downhole tool 1839 to facilitate the inclusion of the electronics housing system 1840 into the downhole tool 1839, for example, by simplifying the system by reducing parts and / or connections. This can also facilitate the assembly of the downhole tool 1839 implementing the electronics housing system 1840.

[0119] As described herein, the electronic housing 1842 can be positioned within the inner bore 1841 of the downhole tool 1839. The adapter 1846, integrally formed with the downhole tool 1839, can be configured in accordance with the above description. Figure 16 to Figure 17-2 The same manner described herein is used to engage and / or connect the electronic housing 1842. For example, the electronic housing 1842 may be included in the second downhole tool and may be positioned within the bore 1841 of the downhole tool 1839 to engage with or be connected to the adapter due to the connection of the second downhole tool to the downhole tool 1839. In some embodiments, the electronic housing 1842 is not included in the second downhole tool or is not associated with the second downhole tool. For example, the electronic housing 1842 may be connected or supported by engagement of the electronic housing 1842 with the adapter 1846, and in this way the electronic housing 1842 may be positioned within the bore 1841 of the downhole tool 1839. This may further simplify the assembly of the electronic housing system 1840 and / or the downhole tool 1839 and / or the BHA.

[0120] Figure 19 is a side view cross-section of an electronics housing system 1940 implemented in conjunction with a downhole tool 1939 in accordance with at least one embodiment of the present disclosure. As discussed herein, the electronics housing system 1940 can include one or more of an electronics housing 1942, an adapter 1946, a cable conduit 1944, and a sensor 1945.

[0121] In some embodiments, the electronics housing 1942 is part of the adapter 1946. For example, the electronics housing 1942 can be integrally formed with the adapter 1946. In this way, the electronics housing 1942 can be positioned within the bore 1941 of the downhole tool 1939 by connecting the adapter 1946 with the downhole tool 1939. This can facilitate implementation of the electronics housing system 1940 by simplifying the electronics housing system 1940 (e.g., reducing parts) and / or simplifying assembly of the downhole tool 1939. For example, electronics can be positioned in the electronics housing 1942, e.g., as part of the installation of the adapter 1946. The adapter 1946 having an electronics housing integral with the adapter 1946 can include one or more features discussed above in connection with the electronics housing 1942. For example, the adapter 1946 can include a fluid passage to flow drilling fluid through the body of the downhole tool 1939. Figure 16 to Figure 17-2

[0122] Figure 20 A flowchart of a method 2060 or series of acts using a junction element assembly as discussed herein is shown in accordance with at least one embodiment of the present disclosure. While Figure 20 acts are shown in accordance with one embodiment, alternative embodiments can perform one or more of the following: add, omit, reorder, and / or modify Figure 20 any of the acts shown.

[0123] The method 2060 includes an act 2061 of engaging a downhole formation with a junction element of a junction element assembly. For example, the junction element can engage the downhole formation during drilling of a well downhole. The junction element can engage the downhole formation after a cutting guide element in a turn. For example, the junction element can follow a rotational path having a same radius as a radius of a rotational path of the cutting guide element.

[0124] ​Method 2060 includes an act 2062 of transmitting force from the engagement element to the engagement sensor. For example, the engagement element can be subjected to a force (e.g., an axial force) associated with the engagement element engaging a downhole formation. The force can be transmitted through the engagement element to a base of the engagement element. The engagement sensor can be positioned at the base of the engagement element, and in this way can make one or more measurements associated with the force transmitted through the engagement element. In some embodiments, the engagement element is axially fixed. For example, the engagement element can not move axially in response to a force exerted on the engagement element and / or corresponding to the sensor making a measurement associated with the force on the engagement element.

[0125] Method 2060 can include an act 2063 of receiving, with a processor, the engagement measurements. For example, the sensor can be connected to or associated with electronics including a processor, which can receive and / or store the measurements of the sensor. The processor can be positioned in an electronics housing.

[0126] Various embodiments of the present invention described herein are primarily described with respect to one engagement element assembly, such as drill bit 410 of FIG. 4 having engagement element assembly 420. However, it should be appreciated that a downhole tool (e.g., drill bit) according to any of the embodiments of the present disclosure can include two or more engagement element assemblies (e.g., according to any of the embodiments of the present disclosure described herein). For example, a drill bit can include 2, 3, 4, 5, or more engagement element assemblies for making multiple measurements. In some embodiments, the engagement element assemblies are each oriented and / or configured the same. In some embodiments, one or more of the engagement element assemblies are oriented and / or configured differently than the other engagement element assemblies. For example, a first engagement element assembly can be oriented to make measurements associated with axial force, and a second engagement element assembly can be oriented to make measurements associated with rotational force or torque. In some embodiments, multiple engagement element assemblies are configured to make measurements associated with axial force, but the assemblies are positioned at different radii and / or positioned behind different cutting guide elements. In some embodiments, multiple engagement element assemblies are oriented to make measurements associated with rotational force at the same radius in order to ensure more accurate measurements. One or more of the multiple engagement element assemblies can be oriented and / or configured and / or combined in any other way in order to make one or more measurements associated with the drill bit and / or the formation, as described herein. Figure 2-6 and Figure 16-19 For example, a drill bit can include 2, 3, 4, 5, or more engagement element assemblies for making multiple measurements. In some embodiments, the engagement element assemblies are each oriented and / or configured the same. In some embodiments, one or more of the engagement element assemblies are oriented and / or configured differently than the other engagement element assemblies. For example, a first engagement element assembly can be oriented to make measurements associated with axial force, and a second engagement element assembly can be oriented to make measurements associated with rotational force or torque. In some embodiments, multiple engagement element assemblies are configured to make measurements associated with axial force, but the assemblies are positioned at different radii and / or positioned behind different cutting guide elements. In some embodiments, multiple engagement element assemblies are oriented to make measurements associated with rotational force at the same radius in order to ensure more accurate measurements. One or more of the multiple engagement element assemblies can be oriented and / or configured and / or combined in any other way in order to make one or more measurements associated with the drill bit and / or the formation, as described herein.

[0127] The embodiments shown herein illustrate downhole tools (e.g., drill bits) having instrument assemblies with various components having particular configurations and / or orientations. It should be understood, however, that the instrument assemblies of the present disclosure are not limited to implementation only in drill bits of a drilling system. Rather, the techniques described herein can be used in conjunction with any downhole tool. For example, one or more of the instrument assemblies described herein can be implemented in a reamer, stabilizer, or any other downhole tool (e.g., a downhole tool that contacts and / or engages an inner wall of a borehole).

[0128] Additionally, it should be understood that the sensor engagement elements described herein in various embodiments are not limited to sensor engagement elements that perform cutting, or configurations in which a borehole is cut, extended, widened, etc. To this end, the sensor engagement elements can be any type of engagement element used to engage or interface with a borehole. For example, one or more downhole tools can implement engagement elements having superhard (e.g., diamond) tips or coatings that are not necessarily intended or limited only to cutting a formation. For example, a stabilizer can include one or more engagement elements (such as stabilizer pads) for engaging with a borehole for the purpose of stabilizing or centering one or more components of a drilling tool assembly, rather than performing cutting. Such engagement elements can be implemented as the sensor engagement elements described herein in order to perform the techniques described herein. Other downhole tools can implement other engagement elements for the purpose of engaging a borehole, without necessarily being limited to cutting. In other words, the sensor engagement elements described herein can be any engagement element implemented in conjunction with any downhole tool.

[0129] Further, it should be understood that the instrument assemblies of the present disclosure are not limited to only the configurations and / or orientations shown and described herein. For example, an instrument assembly of a downhole tool can include a sensor engagement element that can be oriented at an angle to the vertical direction, in a radial or outward direction, or in any other orientation described herein for engaging a borehole. In this manner, any type of downhole tool can include an instrument assembly (including an engagement element) having any configuration for making downhole measurements, and the instrument assembly can be configured, oriented, and adapted to operate in the manner in which the given downhole tool engages a borehole.

[0130] Industrial Applicability As discussed in detail herein, the present disclosure includes a number of practical applications having the features described herein that provide benefits and / or address issues associated with making downhole measurements using instrumented engagement elements and generally measuring and / or recording parameters in a downhole drilling environment. Some example benefits are discussed herein in connection with various features and functionality provided by the instrumentation technology discussed herein in connection with one or more downhole tools. It should be appreciated that the benefits expressly discussed in connection with one or more embodiments described herein are provided by way of example, and are not intended to be an exhaustive list of all possible benefits of the systems, methods, and apparatuses described herein.

[0131] For example, by implementing instrumented engagement elements that make measurements associated with forces (or changes in forces) corresponding to engagement of the engagement elements and the borehole, various properties and / or characteristics of the borehole can be detected. In some cases, the formation through which the BHA is operating can have characteristics such as: formation fractures, different types of rock veins, changes in inclination or orientation of layers of the formation, etc. By making measurements associated with forces (or more specifically changes in forces) exerted on the instrumented engagement elements as the instrumented engagement elements engage one or more of these characteristics, one or more of these characteristics can be detected. In this way, various characteristics of the borehole can be detected, thereby facilitating generation of an image of the borehole or mapping of characteristics of the borehole and / or detecting downhole dynamics. Imaging these characteristics can be beneficial for developing and / or implementing strategies for drilling operations, such as more confidently knowing a drilling direction to encounter a source of oil, gas, or other valuable resource. Imaging geological characteristics can also be beneficial for determining structural properties of the borehole. Detecting downhole dynamics can be useful for understanding behavior of one or more downhole tools. This can facilitate preventing damage to one or more components of the drilling system, and ensuring efficient and / or effective operation of the drilling system.

[0132] Some conventional borehole imaging methods involve placing an imaging tool into the borehole. As a result, drilling operations are typically stopped, and the drilling tool assembly is tripped out of or removed from the borehole. This results in costly downtime of the drilling operation, as well as additional downtime to trip the drilling tool assembly out of the borehole and back into the borehole to accommodate implementing the imaging tool. The instrumented engagement elements described herein can be implemented in a downhole tool during operation of the downhole tool. In this way, downtime of the drilling operation can be avoided, and imaging can be accomplished, for example, while extending the borehole, thereby saving time, resources, etc.

[0133] Some conventional borehole surveying and / or characterization methods require specialized tools to be implemented into a borehole as part of a drilling tool assembly and / or as part of a BHA, such as MWD and / or LWD tools. MWD and LWD tools are typically implemented above one or more downhole tools (e.g., a drill bit or reamer) or above the borehole. MWD and LWD tools can take measurements and / or help generate images associated with the borehole. However, because these tools are located at the elevation of the drilling tools (e.g., up to 100 feet), any information collected by these measurement tools is effectively delayed with respect to the drilling tools located further downhole. In other words, MWD and LWD tools cannot truly characterize the downhole dynamics as the drilling tools interact with the formation and / or cannot truly characterize the formation near the point of engagement of the drilling tools. Thus, conventional tools can have a practical limit in their utility in making real-time decisions regarding the operation of drilling tools located further downhole. In contrast, the techniques described herein can be implemented to make measurements at the point of engagement of one or more drilling tools with the formation. In this way, real-time information related to the area immediately adjacent to the drilling tools can be leveraged to guide decisions regarding the operation of the drilling tools.

[0134] The following non-limiting examples illustrate various arrangements contemplated herein.

[0135] In some embodiments, an instrument assembly includes an electronics housing disposed in a body of a downhole tool, an engagement element assembly connected to the electronics housing, an engagement sensor positioned at a base of the engagement element assembly, and an electronics housing seal configured to seal pressure of at least a portion of the electronics housing. In some embodiments, the electronics housing is oriented along a longitudinal direction of the downhole tool. In some embodiments, the engagement element assembly includes an engagement element. In some embodiments, the engagement sensor includes a strain gauge. In some embodiments, the engagement element assembly is removably connected to the electronics housing. In some embodiments, the seal includes an O-ring or a gasket. In some embodiments, an engagement element of the engagement element assembly is positioned behind a cutting pilot element of the downhole tool in a steering direction. In some embodiments, an engagement element of the engagement element assembly extends a sensor a greater axial distance than a cutting axial distance of a cutting pilot element element. In some embodiments, the engagement sensor is at least partially positioned in a sealed portion of the electronics housing.

[0136] In some embodiments, an engagement element assembly includes: an engagement element having a distal end and a base; an engagement sensor positioned at the base of the engagement element; a connector configured to hold the engagement element in an engagement element pocket in a body of a downhole tool such that a force exerted on the distal end of the engagement element is transferred to the base of the engagement element; and a seal configured to seal pressure of the engagement element pocket. In some embodiments, the engagement element is positioned in an engagement element housing, and the engagement element housing includes the connector and the seal. In some embodiments, the engagement element is a non-planar engagement element. In some embodiments, the connector is configured to removably hold the engagement element in the engagement element pocket. In some embodiments, the connector is configured to hold the engagement element in the engagement element pocket with threads or a snap ring. In some embodiments, the connector is configured to hold the engagement element such that the engagement element is configured to engage a borehole. In some embodiments, the connector is configured to hold the engagement element in the engagement element pocket such that the engagement element is axially fixed.

[0137] In some embodiments, a method of using an engagement element assembly includes: engaging a downhole formation with an engagement element of the engagement element assembly; transferring a force from the engagement element to a force sensor, wherein the force sensor is positioned at a base of the engagement element, wherein the force is associated with the engagement element engaging the downhole formation, and wherein the engagement element is axially fixed; and receiving, with a processor positioned in an electronics housing, an engagement measurement from the engagement sensor. In some embodiments, engaging the downhole formation contact includes engaging the downhole formation during drilling of a well downhole. In some embodiments, engaging the downhole formation contact includes engaging the downhole formation with the engagement element trailing a cutting guide element in a turn and through a rotational path having a same radius as a radius of the cutting guide element. In some embodiments, the method includes sealing the electronics housing with the engagement element to prevent fluid from seeping into the electronics housing.

[0138] In some embodiments, an electronics housing includes a conduit disposed in a body of a downhole tool, an opening at a proximal end of the conduit positioned at an outer surface of the downhole tool, wherein the conduit is configured to be removably connected to an engagement element assembly at the opening, and a sealing surface configured to engage a sealing surface of the engagement element assembly to form a seal, wherein the sealing surface is configured to maintain a pressure of the conduit. In some embodiments, the conduit is oriented in a longitudinal direction of the downhole tool. In some embodiments, the conduit includes a sleeve fixed within the conduit. In some embodiments, the outer surface of the downhole tool is a downhole end of the downhole tool. In some embodiments, the conduit is configured to be removably connected to the engagement element assembly with threads positioned adjacent to the opening. In some embodiments, the conduit is configured to be removably connected to the engagement element assembly such that an engagement element of the engagement element assembly is able to engage a borehole.

[0139] In some embodiments, an electronics housing adapter includes a body configured to connect to a downhole tool at an inner bore of the downhole tool, a first connector configured to form a first sealed connection with an electronics housing positioned within the inner bore, and a second connector configured to form a second sealed connection with a cable conduit at least partially extending through a body of the downhole tool. In some embodiments, the electronics housing adapter includes one or more eyelets for providing fluid flow from the inner bore to an outer surface of the downhole tool. In some embodiments, the body is configured to connect to the inner bore of the downhole tool such that the adapter is positioned between a head and a shank of the downhole tool. In some embodiments, the first sealed connection prevents fluid in the inner bore from seeping into the electronics housing. In some embodiments, the second sealed connection prevents fluid in the inner bore from seeping into the cable conduit. In some embodiments, the body is configured to be removably connected to the downhole tool. In some embodiments, the first sealed connection is a removable connection. In some embodiments, the second sealed connection is a removable connection.

[0140] In some embodiments, an electronics housing system includes an electronics housing positionable within a downhole tool and a cable conduit for passing one or more cables from a sensor, at least partially through a body of the downhole tool, and to the electronics housing. In some embodiments, the electronics housing is positionable within a bore of the downhole tool. In some embodiments, the cable conduit is configured to pass the one or more cables through the body of the downhole tool and to the bore. In some embodiments, the bore is a fluid passage of the downhole tool. In some embodiments, the downhole tool is a first downhole tool, and wherein the electronics housing is included in a downhole tool configured to connect to the first downhole tool. In some embodiments, the cable conduit connects to an engagement element pocket at an outer surface of the downhole tool. In some embodiments, the engagement element pocket is configured to seal to prevent fluid infiltration into the cable conduit. In some embodiments, the downhole tool is a downhole drill bit. In some embodiments, an adapter is positionable within the downhole tool for receiving one or more cables from the cable conduit. In some embodiments, the electronics housing includes an opening, and wherein the adapter is configured to connect to the electronics housing at the opening so as to pass the one or more cables from the cable conduit through the adapter and to the electronics housing. In some embodiments, the adapter is configured to connect to the electronics housing to form a first sealed connection. In some embodiments, the adapter is configured to connect to the cable conduit to form a second sealed connection.

[0141] In some embodiments, an engagement element housing includes a housing body configured to removably connect to an engagement element pocket formed in a body of a downhole tool such that a distal end of the housing body is positioned at an outer surface of the downhole tool, a seal configured to seal the housing body and the engagement element pocket to maintain pressure in the engagement element pocket, and a measurement pocket configured to house one or more sensors for making one or more downhole measurements. In some embodiments, the housing body is configured to removably connect to the engagement element pocket with threads or a snap ring. In some embodiments, the engagement element housing includes a tensioner for tightening the connection of the housing body to the engagement element pocket. In some embodiments, the tensioner is a hex head tensioner. In some embodiments, the seal is an O-ring or a gasket. In some embodiments, the seal is configured to prevent fluid in a bore from infiltrating the engagement element pocket.

[0142] In some embodiments, an instrument assembly includes an engagement element housing including: a housing body configured to be removably connected to an engagement element recess in a body of a downhole tool such that a distal end of the housing body is positioned at an outer surface of the downhole tool; a seal configured to seal the housing body and the engagement element recess to maintain pressure in the engagement element recess; a measurement recess; a sensor at the measurement recess. In some embodiments, an engagement element is disposed in the measurement recess and extends from the distal end of the housing body. In some embodiments, the engagement element is axially fixed in the measurement recess. In some embodiments, the engagement element is removably connected to the housing body. In some embodiments, the engagement element is configured to engage a borehole. In some embodiments, the sensor includes a strain gauge positioned on the diaphragm. In some embodiments, an engagement element is disposed in the measurement recess, a base of the engagement element engages the diaphragm, and wherein the strain gauge measures strain on the diaphragm corresponding to a force exerted on the engagement element. In some embodiments, strain on the diaphragm is correlated to pressure of drilling fluid exerted on the diaphragm. In some embodiments, the measurement recess further includes a mud filter. In some embodiments, the measurement recess extends into a sidewall of the housing body, and wherein the measurement recess includes an opening positioned toward a sealed portion of the engagement element recess. In some embodiments, the measurement recess extends into an engagement element held by the housing body, and wherein the measurement recess includes an opening positioned toward a sealed portion of the engagement element recess. In some embodiments, the measurement recess houses a temperature sensor.

[0143] In some embodiments, an instrument assembly includes an engagement element housing including: a housing body configured to be removably connected to an engagement element recess in a body of a downhole tool such that a distal end of the housing body is positioned at an outer surface of the downhole tool; a seal configured to seal the housing body and the engagement element recess to maintain pressure in the engagement element recess; and a measurement recess including a diaphragm; an engagement element disposed in the measurement recess and configured to engage a borehole; and a sensor positioned on the diaphragm in a sealed portion of the engagement element. In some embodiments, a temperature sensor extends at least partially through the housing body from the sealed portion of the engagement element recess.

[0144] In some embodiments, an instrument assembly includes an electronics housing disposed in a body of a downhole tool, a bonding element assembly connected to the electronics housing, a strain sensor positioned at a base of the bonding element assembly, and a seal between the bonding element assembly and the electronics housing, the electronics housing seal configured to seal pressure of at least a portion of the electronics housing.

[0145] In some embodiments, a bonding element assembly includes a bonding element having a distal end and a base, a strain sensor positioned at the base of the bonding element, a connector configured to hold the bonding element in a bonding element pocket in a body of a downhole tool such that engagement of the bonding element with a borehole is measured by the strain sensor as strain at the base of the bonding element, and a seal configured to seal pressure of the bonding element pocket.

[0146] Embodiments of instrumented bonding elements have been described primarily with respect to wellbore drilling operations; instrumented bonding elements described herein can be used in applications other than wellbore drilling. In other embodiments, instrumented bonding elements according to the present disclosure can be used externally of a wellbore or other downhole environment for exploration or production of natural resources. For example, instrumented bonding elements of the present disclosure can be used in boreholes for placement of utility lines. Accordingly, the terms “wellbore,” “borehole,” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0147] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the technology disclosed herein. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation can not be described in the specification. It should be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions are made to achieve the developer’s specific goals, such as compliance with system-related and business-related constraints, which can vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill in the art having the benefit of this disclosure.

[0148] Embodiments of the present disclosure can utilize special-purpose or general-purpose computing systems that include computer hardware, such as, for example, one or more processors and system memory. Embodiments within the scope of the present disclosure also include physical and other computer-readable media for carrying or storing computer-executable instructions and / or data structures, including application programs, tables, data, libraries, or other modules for performing particular functions or for directly selecting or executing other modules. Such computer-readable media can be any available media or memory that can be accessed by a general or special purpose computing system. Computer-readable media that store computer-executable instructions (or software instructions) are physical storage media. Computer-readable media that carry computer-executable instructions are transmission media. Thus, as an example and not by way of limitation, embodiments of the present disclosure can include at least two distinctly different kinds of computer-readable media: physical storage media and transmission media. Combinations of physical storage media and transmission media can also be included within the scope of computer-readable media.

[0149] Both physical storage media and transmission media can be used to store software instructions that implement embodiments of the present disclosure in the form of computer-readable program code. Physical storage media can also be used to store such software instructions persistently or permanently. Examples of physical storage media include physical memory (e.g., RAM, ROM, EPROM, EEPROM, etc.), optical disks (e.g., CD, DVD, HD-DVD, Blu-ray Discs, etc.), memory cards (e.g., SD card, Memory Stick, etc.), storage devices (e.g., disk drives, hard drives, solid-state drives, etc.), flash memory or other solid-state storage, or any other physical non-transmission medium that can be used to store program code in the form of computer-executable instructions or data structures and that can be accessed by a general or special purpose computing system, whether such computer-executable instructions are stored for a short time or for an extended time.

[0150] A "network" or "communication network" can generally be defined as one or more data links that enable the transport of electronic data between computer systems and / or modules, engines, and / or other electronic devices. When information is transferred or provided over a communication network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computing device, the computing device properly views the connection as a transmission medium. Transmission media can include a communication network and / or data links, carrier waves, wireless signals, and the like, which can be used to carry desired program code means or instructions and which are accessed by a general or special purpose computing system.

[0151] Further, upon reaching various computer system components, program code in the form of computer-executable instructions or data structures can be transferred automatically from transmission media to physical storage media (or vice versa). For example, computer-executable instructions or data structures received by way of network or data link can be buffered in RAM within a network interface module (NIM), then eventually transferred to computer system RAM and / or to less volatile physical storage media at a computer system. Thus, it should be understood that physical storage media can be included in computer system components that also (or even primarily) utilize transmission media.

[0152] The articles "a", "an", and "the" are intended to mean that there are one or more of the elements in the preceding descriptions. The terms "comprising", "including", and "having" are intended to be inclusive and allow for other elements to be present. Additionally, it should be understood that references to "one embodiment" or "an embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate those features. For example, any element described with respect to an embodiment described herein can be combinable with any element of any other embodiment described herein. As those of ordinary skill in the art will appreciate, the numerical, percentage, ratio, or other values stated herein are intended to encompass values approximately the same as those stated, e.g., to within 1%, 0.1%, or 0.01% of the value. Thus, the values recited are intended to be broad enough to encompass at least values sufficiently similar to the stated value to perform a desired function or achieve a desired result.

[0153] In view of the present disclosure, those of ordinary skill in the art will appreciate that the functions performed by the various elements described herein can be performed by analogous structures, and that equivalent structures (including functional "means-plus-function" clauses) are intended to encompass structures which perform the same function, operate in the same manner, and provide the same results as structures described herein. It is the applicant's explicit intention that no claim be invoked as invoking means-plus-function or other functional claiming under 35 U.S.C. § 112, paragraph 6, except where the word "means" and / or other functional language is expressly recited in the claim. Each addition, deletion, and modification of the embodiments falling within the meaning and range of equivalency of the claims is intended to be covered.

[0154] The terms "about," "approximately," and "substantially" as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms "about," "approximately," and "substantially" can refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Additionally, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any reference to "up" and "down" or "above" or "below" merely describe the relative position or movement of related elements.

[0155] The disclosure can take other specific forms without departing from the spirit or essential characteristics thereof. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes in and equivalent forms of the described claims are to be embraced as falling within the scope of the claims.

Claims

1. An instrument assembly comprising: an electronics housing disposed in a body of a downhole tool; an engagement element assembly connected to the electronics housing; an engagement sensor positioned at a base of the engagement element assembly, wherein the engagement sensor is configured to make measurements corresponding to engagement of the engagement element assembly and a borehole; and an electronics housing seal configured to isolate at least a portion of the electronics housing from downhole pressure.

2. The instrument assembly of claim 1, wherein the electronics housing is oriented along a longitudinal direction of the downhole tool.

3. The instrument assembly of claim 1, wherein the engagement element assembly comprises an engagement element.

4. The instrument assembly of claim 1, wherein the engagement sensor comprises a strain gauge and / or a load cell.

5. The assembly of claim 1, wherein the engagement element assembly is removably connected to the electronics housing.

6. The assembly of claim 1, wherein the electronics housing seal comprises an O-ring or a gasket.

7. The assembly of claim 1, wherein the electronics housing seal is an integral seal and is integrally formed as part of the body of the downhole tool.

8. The instrument assembly of claim 7, wherein the integral seal is a membrane integrally formed in the body of the downhole tool, and wherein the membrane is part of the engagement sensor.

9. The instrument assembly of claim 1, wherein an engagement distance of the engagement element assembly from the formation is less than 1 mm.

10. The instrument assembly of claim 1, wherein an engagement element of the engagement element assembly is positioned behind a cutting pilot element of the downhole tool in a steering direction.

11. The instrument assembly of claim 1, wherein an engagement element of the engagement element assembly extends a sensor extending axial distance that is greater than a cutting axial distance of a cutting pilot element element.

12. The instrument assembly of claim 1, wherein the engagement sensor is positioned at least partially in a sealed portion of the electronics housing.

13. An engagement element assembly comprising: an engagement element having a distal end and a base; an engagement sensor positioned at the base of the engagement element; a connector configured to hold the engagement element in an engagement element pocket in a body of a downhole tool such that a force exerted on the distal end of the engagement element is transferred to the base of the engagement element; and a seal configured to seal pressure of the engagement element pocket.

14. The engagement element assembly of claim 13, wherein the engagement element is positioned in an engagement element housing, and the engagement element housing comprises the connector and the seal.

15. The engagement element assembly of claim 13, wherein the engagement element is a non-planar engagement element. ​ 16. The junction element assembly of claim 13, wherein the connector is configured to removably retain the junction element in the junction element pocket.

17. The junction element assembly of claim 13, wherein the connector is configured to retain the junction element in the junction element pocket with a thread or a snap ring.

18. The junction element assembly of claim 13, wherein the connector is configured to retain the junction element such that the junction element is configured to engage a borehole.

19. The junction element assembly of claim 13, wherein the connector is configured to retain the junction element in the junction element pocket such that the junction element is axially fixed.

20. A method of using a junction element assembly, comprising: engaging a downhole formation with a junction element of the junction element assembly; transmitting a force from the junction element to a force sensor, wherein the force sensor is positioned at a base of the junction element, wherein the force is associated with the junction element engaging the downhole formation, and wherein the junction element is axially fixed; and receiving, with a processor positioned in an electronics housing, a junction measurement from the junction sensor.

21. The method of claim 20, wherein engaging the downhole formation contact comprises engaging the downhole formation during drilling of a wellbore.

22. The method of claim 20, wherein engaging the downhole formation contact comprises engaging the downhole formation with the junction element trailing a cutting pilot element in a turn and through a rotational path having a same radius as a radius of the cutting pilot element.

23. The method of claim 20, further comprising sealing the electronics housing with the junction element to prevent fluid infiltration into the electronics housing.

Images