Anti-sticking drill pipe system based on intelligent sensing and debris capture-transport-milling coordination and control method thereof

Abstract

The present application relates to the field of geological drilling technology, and discloses a kind of based on intelligent perception and the prevention of sticking pipe system and control method of the coordination of fragment capture-transportation-rolling, realize the efficient safe removal of annular bulk fragment and the independent prevention and control of sticking risk.The present application acquires multi-source signal by multi-source fusion perception short section in real time, and the downhole intelligent control unit autonomously distinguishes hole wall instability and bulk rock fragment sticking risk;When sticking hazard occurs, carry out drilling fluid circulation preliminary chip removal first, and if the risk is not removed, drive annular fragment screen capture assembly to expand, and intercept oversized rock fragments exceeding screen aperture.Subsequently, the drill pipe is lifted and the hard rock section with complete well wall is identified, and the crushing roller is pressed against the rock mass in the hard rock section to achieve rolling and crushing relying on the rotary power of the drilling machine.

Description

Technical Field

[0001] This invention relates to the field of geological drilling technology, specifically to an anti-sticking drill pipe system and its control method based on intelligent sensing and debris capture-transfer-crushing coordination. Background Technology

[0002] During drilling in fractured strata (such as fault zones, weathered crusts, and altered rock layers), the rock mass on the borehole wall is prone to instability and spalling, causing rock blocks to fall and accumulate in the annular space between the drill pipe and the borehole wall, which can lead to stuck drill accidents, affecting drilling efficiency and operational safety.

[0003] Existing anti-jamming drill bit technologies are mainly divided into three categories: (1) Optimization of drilling fluid and drilling process: By increasing the viscosity and shear strength of drilling fluid and adding flocculants or structural agents to suspend and carry rock cuttings, the effect is limited in the case of large annulus or large rock blocks, and it is easy to reduce mechanical drilling speed and increase circulation pressure.

[0004] (2) Passive protection of downhole tools: Using devices such as centralizers, spiral clamps, or hydraulically expandable sheaths to keep the drill string centered to increase the annular clearance, or to provide temporary support for the borehole wall. This method can only provide passive protection and cannot remove fallen rock fragments. Furthermore, the expanded material may be damaged or unrecoverable in complex well sections.

[0005] (3) Monitoring and early warning while drilling: Early warning of stuck pipe is issued by monitoring surface engineering parameters (torque, tension, riser pressure) or downhole parameters (vibration, annular pressure). This type of technology achieves condition monitoring, but lacks a linkage execution mechanism. After the early warning, it relies on the driller to adjust the parameters and cannot take direct measures for the rock blocks that have fallen.

[0006] To overcome the above-mentioned shortcomings, there is an urgent need for an intelligent anti-jamming drill system that can actively sense and prevent borehole wall instability, actively capture and remove large debris in the annulus, and realize automated control of the risk of jamming drill from early warning to autonomous elimination. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide an anti-jamming drill pipe system and its control method based on intelligent sensing and debris capture-transfer-crushing coordination, so as to achieve efficient and safe removal of large debris in the annulus and autonomous prevention and control of the risk of stuck drill pipe.

[0008] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: On the one hand, the present invention provides an anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination, comprising: Multi-source fusion sensing section is used to collect annular debris and borehole wall status signals in real time; Stress-active control short sections are used to inject reinforcing fluid into the borehole wall to suppress rock spalling; Annular debris screening and capture assembly is used to intercept and capture large rock fragments in the annular space whose particle size exceeds the screen aperture by radial expansion; The crushing roller actuator is used to extend radially in hard rock sections and work with the drill pipe to crush the captured rock cuttings. The downhole intelligent control unit receives and analyzes signals of annular debris status and borehole wall stability collected by the multi-source fusion sensing sub, determining the risk of borehole wall instability and stuck drill bit. When the risk of borehole wall instability is determined, the drive stress actively regulates the sub to inject reinforcing fluid into the borehole wall to suppress rock spalling. When the presence of large rock fragments in the annulus is determined to cause stuck drill bit, the annular debris screening and capture assembly is controlled to expand radially to intercept and capture the rock fragments. Then, based on geological data, the hard rock fracture section is determined and the drill pipe is lifted. Subsequently, the crushing roller actuator is driven to extend radially, cooperating with the drill pipe rotation to crush the rock fragments.

[0009] In this solution, based on the above system architecture, the downhole intelligent control unit serves as the core hub. It first achieves accurate risk assessment based on multi-source signal fusion analysis, and then drives the corresponding actuators to perform actions according to different situations. This forms a coherent time-series control process that integrates active borehole wall reinforcement with the capture, transportation, and crushing of large rock cuttings. This not only inhibits rock mass spalling and reduces the causes of stuck drill biting from the source, but also captures and safely crushes large rock cuttings that have already been generated in situ. It eliminates the risk of stuck drill biting from both prevention and treatment perspectives, adapts to complex downhole conditions in fractured formations, and achieves proactive, intelligent, and full-process anti-stuck drill biting control.

[0010] Furthermore, the multi-source fusion sensing section is set on the drill pipe near the drill bit, and includes a housing. An ultrasonic probe array and a triaxial vibration accelerometer are embedded on the outside of the housing, and an annular pressure dynamic sensor and a strain gauge are integrated inside. The ultrasonic probe array is used to transmit ultrasonic waves into the annulus and receive echo signals, and to reconstruct a two-dimensional cross-sectional image of the annulus around the drill pipe through echo analysis. The triaxial vibration accelerometer is used to monitor in real time the vibration signals of the drill bit breaking rock, the circumferential vibration of the drill rod, and the vibration signals of rock blocks impacting the drill rod. The annular pressure dynamic sensor is used to monitor the pressure fluctuations in the annulus between the drill pipe and the borehole wall in real time.

[0011] In this scheme, the ultrasonic probe array can realize the visual and quantitative identification of debris, the vibration signal reflects the size of the rock block and the impact intensity, the pressure signal reflects the degree of annular blockage, and the fusion of multi-source information can eliminate the measurement blind spots and interference of single sensors, significantly improving the accuracy of risk assessment and providing a reliable data foundation for subsequent precise control.

[0012] Furthermore, the stress active control sub is mounted on the drill pipe and located above the multi-source fusion sensing sub, and includes multiple micro-injection units evenly distributed circumferentially; each micro-injection unit includes a micro high-pressure pump, a reservoir containing high-viscosity fluid, and a nozzle pointing towards the borehole wall; each micro high-pressure pump is electrically connected to the downhole intelligent control unit, and is driven by the downhole intelligent control unit to start / stop and output pressure.

[0013] In this scheme, multiple sets of micro-infiltration units are uniformly distributed in the circumferential direction, which can achieve uniform infiltration reinforcement of the borehole wall in the circumferential direction and avoid local stress imbalance. Through the integrated structure of micro high-pressure pump, liquid storage chamber and nozzle, high viscosity fluid can be accurately injected into the shallow micro-fractures of the borehole wall, which can improve the friction coefficient of the rock mass surface and generate micro-support stress, thereby inhibiting the spalling of large rock masses.

[0014] Furthermore, the annular debris screening and capture assembly includes: a base, a metal screen, a screen frame, a telescopic control rod, a guide rail, a slider, and a locking device; The base is fixed to the outer wall of the drill rod. A metal screen is provided on the screen frame. The upper end of the screen frame is hinged to the base, and the lower end of the screen frame is hinged to the telescopic control rod. The other end of the telescopic control rod is hinged to the slider. The slider can slide along the guide rail arranged axially along the drill rod. The movement of the slider drives the screen frame to expand or retract radially. The locking device is used to mechanically lock the screen frame after it is expanded into place.

[0015] In this solution, a mechanical transmission structure consisting of a slider, guide rail, and telescopic control rod is used to achieve stable deployment and retraction of the screen. The metal screen can accurately intercept large-sized rocks, and the locking device ensures the stability of the screen shape during the capture process, thereby improving capture reliability.

[0016] Furthermore, the crushing roller actuator includes: a radial telescopic drive member and a crushing roller made of cemented carbide; the crushing roller is installed at the end of the radial telescopic drive member, and the axis of the crushing roller is parallel to the axis of the drill rod; The radial telescopic drive is used to drive the crushing roller to extend radially, so that the working surface of the crushing roller presses against the rock block captured on the metal screen and presses the rock block against the hard rock well wall.

[0017] In this design, the crushing roller is arranged coaxially and parallel to the drill pipe. Under the push of the radial telescopic drive, it presses the rock block and forms a stable support against the hard rock well wall. When the drill pipe rotates, it can directly drive the crushing roller to rotate synchronously and crush the rock block. There is no need to add downhole rotation power, making the structure simpler and more reliable. The hard rock layer has high strength and small deformation, which can provide sufficient rigid reaction force, so that the external force is concentrated on the rock block and causes it to fracture brittlely. This not only greatly improves the crushing efficiency, but also does not cause structural damage to the stable well wall.

[0018] Furthermore, the metal screen of the annular debris screening and capture assembly is also equipped with a micro-vibration sensor and a stress sensor. The micro-vibration sensor is used to monitor the vibration signal of rock impacting the screen and determine whether the rock is effectively captured. The stress sensor is used to monitor the stress on the screen structure.

[0019] In this solution, the micro-vibration sensor can accurately determine whether large rock fragments have fallen into the screen capture area by collecting the vibration characteristics generated by the impact of rock blocks, and provide a trigger signal for the downhole intelligent control unit to complete the capture. The stress sensor monitors the stress on the screen structure in real time, and provides timely feedback when the load exceeds the preset threshold to avoid structural failure of the screen under the impact or compression of rock blocks. The two work together to achieve status monitoring and safety protection during the capture process.

[0020] On the other hand, the present invention also provides a control method for the above-mentioned anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination, comprising the following steps: S1. Multi-source fusion sensing section real-time acquisition of annular debris and borehole wall status signals; S2. The downhole intelligent control unit comprehensively judges whether there is a risk of borehole instability or stuck drill based on the annular debris and borehole wall status signals; if there is a risk of borehole instability, proceed to step S3; if there is a risk of stuck drill, proceed to step S4; otherwise, return to step S1. S3. The downhole intelligent control unit drives the stress-actively regulating sub to inject reinforcing fluid into the borehole wall to fill the fractures and inhibit rock spalling. After the process is completed, return to step S1. S4. The downhole intelligent control unit controls the deployment of the annular debris screening and capture assembly, which radially sweeps the annulus through a metal screen to capture large rock fragments with a particle size exceeding the screen aperture. S5. After capture is completed, the downhole intelligent control unit controls the drill pipe to lift the screen containing large rock cuttings to the hard rock section; S6. The downhole intelligent control unit drives the breaking roller actuator to extend, so that the breaking roller presses the rock cuttings captured in the screen against the hard rock well wall; S7. The downhole intelligent control unit controls the rotation of the drill pipe, which drives the crushing roller to revolve, using the rigid reaction force of the hard rock layer to crush the rock cuttings; S8. After the cuttings are broken up, the downhole intelligent control unit controls the retraction of the breaking roller and the closing of the screen. The annulus is checked again by multi-source fusion sensing sub. If it is clear, normal drilling resumes and returns to step S1.

[0021] In this solution, based on the above control process design, an integrated and coordinated prevention and control system is achieved, which includes real-time sensing of multi-source signals, active reinforcement of borehole wall instability, capture and transportation of large rock cuttings, and efficient crushing of hard rock sections. This system suppresses borehole wall spalling and avoids secondary damage to the wellbore caused by in-situ crushing of fractured formations. It also improves the efficiency of rock cuttings crushing by utilizing the rigid reaction force of hard rock layers. At the same time, drilling is resumed only after closed-loop detection confirms that the annulus is unobstructed. This effectively reduces the risk of stuck drill pipe during drilling in fractured formations and improves the continuity, safety, and overall drilling efficiency of downhole drilling operations.

[0022] Furthermore, in step S2, the downhole intelligent control unit comprehensively judges whether there is a risk of borehole instability or stuck pipe based on the annular debris and borehole wall status signals, specifically including: Based on the two-dimensional cross-sectional images of the borehole obtained by the ultrasonic probe array, the integrity of the borehole wall, the degree of fracture development and the rock mass spalling are identified to determine whether there is a risk of borehole wall instability. By combining the vibration characteristic signals collected by the triaxial vibration accelerometer to analyze the impact intensity of rock cuttings and the magnitude of rock block size, and by combining the pressure fluctuation changes monitored by the annular pressure dynamic sensor to determine the degree of annular flow blockage, it is determined whether the amount of annular debris accumulation and the maximum rock block size exceed the safety threshold. If the threshold is exceeded, it is determined that there is a risk of stuck drill.

[0023] In this scheme, wellbore stability is directly assessed by relying on borehole morphology images, and the annular blockage and rock cuttings size are determined by combining vibration and pressure signals. This effectively avoids the defects of misjudgment by a single signal, making the risk trigger threshold more reliable and providing a precise basis for subsequent graded treatment of borehole reinforcement and rock cuttings capture and breakage.

[0024] Furthermore, in step S4, before the downhole intelligent control unit controls the deployment of the annular debris screening and capture assembly, the following steps are also included: the downhole intelligent control unit first controls the drill pipe to idle and circulate drilling fluid for preliminary debris removal. Based on the feedback of annular pressure, vibration, and imaging signals after preliminary debris removal, it is determined whether the risk of stuck pipe has been eliminated. If the risk of stuck pipe has been eliminated after preliminary debris removal, the process returns to step S1. If the risk of stuck pipe still exists, the annular debris screening and capture assembly is deployed again, and large pieces of rock cuttings are captured by radially sweeping the annulus through the screen.

[0025] In this solution, a preliminary cuttings removal process with drilling fluid circulation is added. This allows for the priority use of conventional drilling techniques to remove fine rock cuttings on its own. Only when conventional cuttings removal fails to eliminate the problem and large rock cuttings remain in the annulus will the screen capture and subsequent crushing process be initiated. This avoids unnecessary mechanical actions, reduces drill string wear, and the control logic of graded treatment is more in line with the actual downhole conditions, balancing drilling efficiency and control precision.

[0026] Furthermore, in step S5, the identification method for hard rock strata includes: the downhole intelligent control unit combines signals collected by multi-source fusion sensing subsections with preset geological stratigraphic data to comprehensively identify hard rock strata. Two-dimensional cross-sectional images of the annulus obtained by an ultrasonic probe array are used to identify the density of the rock mass and the density of fracture development in the borehole wall, and to determine the stability of the well wall structure. Combined with the rock-breaking vibration signals of the drill bit collected by a triaxial vibration accelerometer, the vibration amplitude and frequency characteristics are analyzed. If the vibration amplitude is greater than the preset threshold and the frequency is stable without obvious abrupt changes, it is determined that the hardness of the corresponding stratum rock mass meets the requirements. At the same time, the matching degree between the stratum depth and lithology is verified by comparing with the preset geological stratum data, and finally the location of the hard rock stratum suitable for rock cutting is determined.

[0027] In this scheme, the identification of hard rock strata relies on real-time downhole sensing signals to accurately determine the current formation hardness, avoiding misjudging broken or soft strata as hard rock strata. It also uses preset geological data for auxiliary verification to improve the accuracy and reliability of hard rock strata identification.

[0028] The beneficial effects of this invention are: (1) Implement proactive anti-jamming measures to improve reliability: This invention overcomes the shortcomings of existing technologies that can only passively isolate risks. It directly captures and breaks down large pieces of debris that are the cause of stuck drill bits, thus eliminating the risk of stuck drill bits at the source and improving the effectiveness of preventing stuck drill bits.

[0029] (2) Utilizing geological characteristics to improve crushing safety and efficiency: This invention transports the rock blocks to be crushed to a hard rock layer for crushing, relying on the rigid support of the hard rock layer to form stable crushing conditions, avoiding the risk of borehole wall collapse caused by in-situ operation in the crushed strata, balancing crushing efficiency and well wall protection, and adapting to complex downhole working conditions.

[0030] (3) Energy-saving and low equipment requirements: The crushing power in this invention is provided by the top drive rotation of the drilling rig itself, eliminating the need for additional downhole high-power crushing motors, ultra-high pressure pumps, and other equipment. This reduces system energy consumption, simplifies equipment structure, improves system reliability and stability, and reduces equipment investment and maintenance costs.

[0031] (4) High intelligence and adaptability: This invention constructs a fully intelligent control system that automates decision-making and execution from risk identification, initial cuttings removal, and cuttings capture to fragmentation and status verification. It requires no manual intervention, reduces reliance on operator experience, provides rapid response and precise operation, and is adaptable to complex and ever-changing downhole working environments, further improving the continuity and safety of drilling operations. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the annular debris screening and capture assembly in an embodiment of the present invention.

[0033] Figure 2 This is a schematic diagram of the metal screen and screen frame structure in an embodiment of the present invention.

[0034] Figure 3 This is a schematic diagram of the crushing roller actuator structure in an embodiment of the present invention.

[0035] Figure 4 This is a flowchart of the control method for the anti-jamming drill pipe system in an embodiment of the present invention.

[0036] The markings in the diagram are as follows: 1 is the drill rod; 2 is the base; 3 is the screen frame; 4 is the slider; 5 is the telescopic control rod; 6 is the guide rail; 7 is the slide rail; 8 is the locking device; 9 is the crushing roller; 10 is the metal screen; 11 is the micro-vibration sensor; 12 is the stress sensor. Detailed Implementation

[0037] This invention aims to provide an anti-jamming drill pipe system and its control method based on intelligent sensing and debris capture-transfer-crushing coordination, so as to achieve efficient and safe removal of large debris in the annulus and autonomous prevention and control of the risk of stuck drill pipe. Its core idea is to break away from the traditional approach of passive isolation and post-event handling, and instead focus on an integrated prevention and control system centered on source control of the wellbore and annular debris removal. This system constructs a full-process anti-sticking system with intelligent perception, graded early warning, and differentiated risk-based collaborative handling. By fusing multi-source sensor signals, it achieves accurate identification of potential wellbore instability and the risk of large rock cuttings sticking. On the one hand, it relies on active fluid reinforcement technology to suppress rock spalling from the wellbore at the source, reducing the causes of sticking. On the other hand, it utilizes the rigid reaction force of the hard rock formation to create an anvil-like crushing effect. The system is designed with a graded treatment process, including pre-drilling fluid cuttings removal, large rock cuttings interception and capture, and off-site transportation and fixed-point crushing. The entire process relies on the rotational power of the drilling rig itself to achieve rock cuttings crushing, without the need for additional high-power downhole drive equipment. At the same time, the entire process is autonomously decided by the downhole intelligent control unit, which not only removes the risk of large annular debris sticking and protects the wellbore from secondary damage, but also ensures the reliability of system operation.

[0038] To facilitate a better understanding of the technical solutions of this invention, some of the technical terms involved in this invention will be explained first: Multi-source fusion sensing: refers to the technology of integrating signals from multiple sensors such as vibration, sound waves, and pressure, and using algorithms to comprehensively judge the state of the borehole wall and the condition of annular debris.

[0039] Active stress control refers to the technique of actively applying controllable radial pressure or injecting specific fluids into the fractured rock mass around the borehole to improve its local stress state and enhance its self-stabilizing ability.

[0040] Annular debris screening and capture assembly: refers to a deployable metal mesh structure with a specific aperture, used to allow small rock cuttings to pass through while intercepting and capturing large rock fragments that may cause the drill to get stuck.

[0041] The "anvil effect" of hard rock strata refers to the principle of using the upper, hard, and strong intact rock strata (such as marble and granite) as a solid supporting base to provide a reaction force for the crushed and captured rock blocks, thereby greatly improving the crushing efficiency.

[0042] Large rock cuttings: These are rock fragments whose particle size exceeds the mesh size of a metal screen. These rock cuttings cannot be discharged with the drilling fluid and are prone to accumulating and getting stuck in the annulus, which can lead to blockage of the annulus flow channel and eventually cause drill string stuck accidents. Therefore, they need to be intercepted and captured by a screen and then crushed at specific points.

[0043] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0044] This embodiment provides an anti-sticking drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination, comprising several main parts: a multi-source fusion sensing sub, a stress-active control sub, an annular debris screening and capture assembly, a breaker roller actuator, and a downhole intelligent control unit. The specific implementation methods of each part are as follows: I. Multi-source fusion sensing section: Installed near the drill bit, it includes a housing, with an ultrasonic probe array and a high-sensitivity triaxial vibration accelerometer embedded on the outside of the housing, and an annular pressure dynamic sensor and strain gauge integrated inside.

[0045] An ultrasonic probe array is used to periodically emit sound waves and receive echoes. Through algorithms, a two-dimensional cross-sectional image of the annulus around the drill pipe can be reconstructed, allowing direct observation of the size, shape, number, and relative position of the dropped blocks.

[0046] A triaxial vibration accelerometer is used to monitor in real time the vibration signals of the drill bit breaking rock, the circumferential vibration of the drill pipe, and the vibration signals of rock blocks impacting the drill pipe; these vibration signals are used to analyze the rock breaking state of the drill bit and the characteristic frequencies of rock blocks colliding with the drill pipe.

[0047] Annular pressure dynamic sensors are used to monitor pressure fluctuations in the annulus between the drill pipe and the borehole wall in real time, which can help determine changes in annular flow.

[0048] Strain gauges are used to acquire stress and strain signals of the short section cylinder wall in real time, monitor the extrusion load, axial force and torque changes of the drill bit, and thus help determine the degree of annular debris compression.

[0049] II. Stress-Actively Controlled Short Section: This short section is located above the multi-source fusion sensing short section. Its core consists of multiple circumferentially distributed "micro-infusion units", each of which contains a micro high-pressure pump, a liquid storage chamber, and a nozzle pointing towards the orifice wall.

[0050] When the system determines that the risk of formation fracturing ahead is high through sensing, the control unit commands stress to actively adjust the operation of the short section. The high-pressure pump injects high-viscosity fluid into the shallow micro-fractures of the borehole wall in a pulsed manner. Through physical-chemical reactions (such as increasing the friction coefficient of the fracture surface and generating micro-support stress), a temporary "reinforcing ring" is formed behind the drill bit, which inhibits large-scale spalling from the source.

[0051] III. Annular Debris Screening and Capture Assembly: This assembly is integrated with the crushing roller actuator within the same "treatment section," which is located above the stress-active adjustment section. See also Figure 1 and Figure 2 The annular debris screening and capture assembly includes: a base 2, a metal screen 10, a screen frame 3, a telescopic control rod 5, a guide rail 6, a slider 4, and a locking device.

[0052] The base 2 is fixed to the outer wall of the drill rod 1 and is hinged to one end of the screen frame 3. The other end of the screen frame 3 is hinged to one end of the telescopic control rod 5, and the other end of the telescopic control rod 5 is connected to the slider 4 located in the guide rail 6. The slider 4 can slide in the guide rail 6. The screen frame 3, the telescopic control rod 5, the guide rail 6, and the slider 4 constitute the unfolding / retracting mechanism. It is understandable that in order to control the telescopic control rod 5 to drive the slider 4 to move along the axial direction of the drill rod 1 in the guide rail 6, a drive motor must be provided.

[0053] Based on this structure, when the slider 4 moves downward along the guide rail 6, the annular debris screening and capture assembly is gradually unfolded; conversely, when the slider 4 moves upward along the guide rail 6, the screen frame 3 is gradually retracted.

[0054] When the screen frame 3 is deployed into position, it is secured by a mechanical locking device. At this time, the metal screen 10 installed on the screen frame 3 unfolds to form an umbrella shape to intercept and capture annular debris. The metal screen 10 is woven from high-strength, high-wear-resistant alloy wire, and the mesh size is scientifically designed to allow drill cuttings smaller than the critical safety size (such as 10-15mm) to pass through normally, but can intercept rock blocks larger than this size.

[0055] like Figure 2As shown, the metal screen 10 is also equipped with a micro-vibration sensor 11 and a stress sensor 12. The micro-vibration sensor 11 is used to collect the micro-vibration signal generated by the rock block impacting the screen, so as to determine whether the large rock debris has been effectively intercepted and captured by the screen. The stress sensor 12 is used to monitor the load-bearing stress change of the screen frame 3 and the screen body in real time, and to provide feedback on the screen's pressure state, so as to avoid excessive rock debris load causing screen deformation and damage.

[0056] IV. Crushing Roller Actuator: It mainly includes a radial telescopic drive component and a crushing roller 9 made of hard alloy; the crushing roller 9 is installed at the end of the radial telescopic drive component, and the axis of the crushing roller 9 is parallel to the axis of the drill rod 1.

[0057] In one exemplary embodiment, the radial telescopic drive can be a hydraulic arm used in conjunction with a slide rail and a locking device, such as... Figure 3 As shown, the radial telescopic drive component drives the crushing roller 9 to complete the radial telescopic action along the guide rail 7, and the locking device 8 mechanically locks and fixes the extended working position to ensure the stability of the structure during crushing operation.

[0058] V. Downhole Intelligent Control Unit: The downhole intelligent control unit is the core scheduling center of the entire anti-sticking system. It is used to receive and analyze the annular debris status and borehole wall stability signals collected by the multi-source fusion sensing sub, and determine the risk of borehole wall instability and sticking. When the risk of borehole wall instability is determined, the drive stress actively regulates the sub to inject reinforcing fluid into the borehole wall to suppress rock spalling. When the presence of large rock fragments in the annulus is determined to cause sticking, the annular debris screening and capture assembly is controlled to expand radially to intercept and capture the rock fragments. Then, based on geological data, the hard rock fracture section is determined and the drill pipe is lifted. Subsequently, the crushing roller actuator is driven to extend radially and cooperate with the drill pipe rotation to crush the rock fragments.

[0059] Specifically, the control unit connects in real time to all sensing devices within the multi-source fusion sensing section, synchronously receiving annular two-dimensional cross-sectional image signals, microseismic and stress sensing signals, annular pressure dynamic signals, and vibration characteristic signals output by the ultrasonic probe array. This enables real-time reception, filtering, noise reduction, and data preprocessing of downhole multi-source sensing data. Based on the preprocessed sensing signals, differentiated analysis is performed: using ultrasonic imaging data to analyze borehole wall morphology, fracture development, and rock mass spalling status, the risk of borehole instability is determined; coupled verification is performed using vibration impact characteristics and annular pressure fluctuation parameters to analyze annular cuttings size, accumulation, and annular flow status, identifying the risk of large cuttings exceeding the limit and causing the drill string to stick; simultaneously, a preset safety threshold range is built-in, and risk identification and judgment are achieved by comparing signal characteristics with the threshold; based on the risk assessment results, preset prevention and control measures are implemented. The logic outputs precise timing control commands to each actuator: if a risk of borehole instability is determined, the stress-active control sub is directly driven to perform fluid injection reinforcement operations; if a risk of stuck drill bit is determined, the drilling fluid circulation and idling cuttings removal command is issued first, and the risk status is verified a second time after cuttings removal. If the risk is not eliminated, the full-process timing action commands for screen deployment and capture, drill pipe displacement and positioning, breaker roller extension, drill pipe linkage rotation, and mechanism reset and retraction are issued sequentially; throughout the entire process of each mechanism's action, real-time feedback signals from sensing devices are continuously collected to monitor the mechanism's working status, the progress of the handling operation, and changes in the downhole environment; after all the corresponding risk handling procedures are completed, the multi-source sensing signals are called again to conduct annular patency verification. After confirming that the hidden danger has been completely eliminated, the mechanism retraction and reset command is issued, and normal drilling operations are resumed, and then the real-time monitoring cycle is returned.

[0060] Based on the aforementioned anti-jamming drill pipe system, this embodiment also provides a control method applied to the system, see [link to relevant documentation]. Figure 4 It includes the following implementation steps: 1. Multi-source signal monitoring: In this step, the multi-source fusion sensing sub collects annular debris and borehole wall status signals in real time. These signals are transmitted to the downhole intelligent control unit for subsequent risk identification.

[0061] 2. Risk identification and assessment: In this step, the downhole intelligent control unit comprehensively judges whether there is a risk of borehole instability or stuck drill based on the annular debris and borehole wall status signals. If there is a risk of borehole instability, proceed to step 3; if there is a risk of stuck drill, proceed to step 4; otherwise, return to step 1.

[0062] More specifically, the downhole intelligent control unit uses two-dimensional cross-sectional images of the annulus obtained by an ultrasonic probe array to identify the integrity of the borehole wall, the degree of fracture development, and the rock mass spalling, thereby determining whether there is a risk of borehole wall instability.

[0063] The downhole intelligent control unit analyzes the impact intensity and size of rock cuttings by combining vibration characteristic signals collected by a triaxial vibration accelerometer, and judges the degree of annular flow blockage by combining pressure fluctuation changes monitored by annular pressure dynamic sensors. In turn, it determines whether the amount of annular debris accumulation and the maximum rock size exceed the safety threshold. If they exceed the threshold, it is determined that there is a risk of stuck drill.

[0064] 3. Handling the risk of borehole wall instability: In this step, when the current borehole wall is determined to have a risk of instability, the downhole intelligent control unit drives the stress-active adjustment sub. The miniature high-pressure pump in the sub injects high-viscosity fluid into the shallow fractures of the borehole wall in a pulsed manner, filling the fractures and increasing the friction coefficient of the structural surface to form a "reinforcing ring." This suppresses the spalling of large rock masses, thereby reducing the risk of stuck drill bit caused by large rock mass spalling at the source. After the treatment is completed, return to step 1 to continue monitoring.

[0065] 4. Pre-emptive handling of drill bit jamming risk: In this step, when the annular debris accumulation or maximum block size exceeds the limit, the downhole intelligent control unit first instructs the drilling rig to idle the drill pipe and maintain circulation for 2-5 minutes, attempting to use hydrodynamics and centrifugal force to remove some of the carryable debris. Based on the annular pressure, vibration, and imaging signal feedback after the initial debris removal, it is determined whether the stuck pipe risk has been eliminated. If the stuck pipe risk has been eliminated after the initial debris removal, return to step 1; if the stuck pipe risk still exists, subsequent steps are required to capture and break up the rock cuttings to directly remove large rock cuttings and reduce the risk of stuck pipe.

[0066] 5. Large rock debris capture: In this step, the downhole intelligent control unit commands the annular debris screening and capture assembly to operate. The metal screen expands radially, like an "umbrella" spread out in the annulus. The drill pipe continues to rotate slowly, allowing the screen to sweep across the annular area, intercepting and capturing large pieces of rock debris larger than the screen aperture on the screen surface.

[0067] 6. Rock fragmentation: In this step, after confirming the capture is complete (judged by sensor signals on the screen), the screen is kept in an extended state and locked. Then, the drill string is raised to a hard rock section (such as granite or marble). The hard rock section is identified as follows: using an annular two-dimensional cross-sectional image obtained by an ultrasonic probe array, the density of the borehole wall rock mass and the density of fracture development are identified to determine the stability of the well wall structure, so as to avoid carrying out breaking operations in the well wall damaged section; combined with the drill bit rock breaking vibration signal collected by a triaxial vibration accelerometer, the vibration amplitude and frequency characteristics are analyzed. If the vibration amplitude is greater than the preset threshold and the frequency is stable, it is determined that the hardness of the corresponding formation rock mass meets the requirements; at the same time, the formation depth and lithology matching degree are verified by comparing with the preset geological formation data, and finally the location of the hard rock section with intact well wall, hard lithology and suitable for rock cutting is determined.

[0068] Once the drill string reaches the target hard rock section, keep the drill string stationary (do not feed). Then, control the action of the breaker roller actuator; the breaker roller extends radially until its working face firmly presses against the captured rock fragment, pressing it against the hard well wall (hard rock layer). The entire drill string rotates at a low speed (e.g., 20-60 rpm). Since the breaker roller and the disposal section housing are fixed, the rotation of the drill string causes the breaker roller to revolve around the drill string axis. Under the crushing force of the breaker roller, the rock fragment is subjected to a huge local point load. Because the underlying hard rock layer has extremely high strength and stiffness, it undergoes almost no plastic deformation, thus providing perfect reaction force support for breaking. This means that almost all the applied force is used to induce stress concentration and brittle fracture in the rock fragment, resulting in extremely high breaking efficiency. Simultaneously, the hard rock layer well wall mainly undergoes elastic deformation under local contact stress, and because its strength is much higher than that of the rock fragment, it does not suffer significant damage.

[0069] The fine particles generated during the crushing process fall through the mesh of the screen and are carried out of the wellhead by the continuous circulation of drilling fluid.

[0070] 7. Risk elimination confirmation and structural reconfiguration: In this step, after the crushing is completed, the downhole intelligent control unit controls the retraction of the crushing roller and the closing of the screen. The annulus is then reconfirmed as open through multi-source fusion sensing sub. If it is open, normal drilling resumes and the process returns to step 1. If the annulus is not open, large rock blocks are captured and fixed-point crushing is performed.

[0071] It should be noted that the above embodiments are only preferred embodiments, and some means in the embodiments can be replaced by similar means. For example, for rock cuttings crushing operations, in addition to the method of rotating and crushing the rock blocks by driving the drill rod to rotate and crush them, a variety of equivalent alternatives can be used: the drill rod can be driven to make small up-and-down reciprocating movements, and the crushing roller can be used to impact and crush the rock blocks; or, a high-frequency vibrator can be integrated inside the crushing roller, and high-frequency vibration can be superimposed on the crushing operation to accelerate the disintegration of the rock blocks by means of fatigue crushing mechanism.

[0072] In terms of hard rock strata identification, in addition to relying on preset geological data and multi-source sensing signals to identify strata, an adaptive transfer judgment method can also be adopted. During the drill pipe lifting process, the vibration spectrum and drill pipe rotation torque changes are monitored in real time. Based on the well wall regularity and the vibration baseline value, suitable broken hard rock strata are automatically identified and the machine is stopped at the designated location.

[0073] In addition, there are multiple alternative methods for annular condition sensing. In addition to ultrasonic imaging sensing, downhole optical camera systems can be used to identify annular debris, or resistivity imaging sensors can be used to determine the distribution of annular deposits.

[0074] Therefore, although embodiments of the present invention have been described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and all such changes and modifications will not depart from the protection scope of the present invention.

Claims

1. A drill pipe anti-jamming system based on intelligent sensing and debris capture-transfer-crushing coordination, characterized in that, include: Multi-source fusion sensing section is used to collect annular debris and borehole wall status signals in real time; Stress-active control short sections are used to inject reinforcing fluid into the borehole wall to suppress rock spalling; Annular debris screening and capture assembly is used to intercept and capture large rock fragments in the annular space whose particle size exceeds the screen aperture by radial expansion; A crushing roller actuator is used to extend radially in a hard rock section and cooperate with the drill pipe rotation to crush captured rock cuttings. The crushing roller actuator includes: a radial telescopic drive and a crushing roller made of cemented carbide. The crushing roller is installed at the end of the radial telescopic drive, and the axis of the crushing roller is parallel to the axis of the drill pipe. The radial telescopic drive is used to drive the crushing roller to extend radially, so that the working surface of the crushing roller presses against the rock cuttings captured on the metal screen and presses the rock cuttings against the hard rock well wall, using the rigid reaction force provided by the hard rock well wall to crush the rock cuttings. The downhole intelligent control unit receives and analyzes signals of annular debris status and borehole wall stability collected by the multi-source fusion sensing sub, determining the risk of borehole wall instability and stuck drill bit. When the risk of borehole wall instability is determined, the drive stress actively regulates the sub to inject reinforcing fluid into the borehole wall to suppress rock spalling. When the presence of large rock fragments in the annulus is determined to cause stuck drill bit, the annular debris screening and capture assembly is controlled to expand radially to intercept and capture the rock fragments. Then, based on geological data, the hard rock fracture section is determined and the drill pipe is lifted. Subsequently, the crushing roller actuator is driven to extend radially, cooperating with the drill pipe rotation to crush the rock fragments.

2. The anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 1, characterized in that, The multi-source fusion sensing section is set on the drill pipe near the drill bit. It includes a housing, with an ultrasonic probe array and a triaxial vibration accelerometer embedded on the outside of the housing, and an annular pressure dynamic sensor integrated inside. The ultrasonic probe array is used to transmit ultrasonic waves into the annulus and receive echo signals, and to reconstruct a two-dimensional cross-sectional image of the annulus around the drill pipe through echo analysis. The triaxial vibration accelerometer is used to monitor in real time the vibration signals of the drill bit breaking rock, the circumferential vibration of the drill rod, and the vibration signals of rock cuttings impacting the drill rod. The annular pressure dynamic sensor is used to monitor the pressure fluctuations in the annulus between the drill pipe and the borehole wall in real time.

3. The anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 1, characterized in that, The stress active control sub is installed on the drill pipe and located above the multi-source fusion sensing sub. It includes multiple micro-injection units evenly distributed along the circumference. Each micro-injection unit includes a micro high-pressure pump, a reservoir containing high-viscosity fluid, and a nozzle pointing towards the borehole wall. Each micro high-pressure pump is electrically connected to the downhole intelligent control unit and is driven by the downhole intelligent control unit to start, stop, and output pressure.

4. The anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 1, characterized in that, The annular debris screening and capture assembly includes: a base, a metal screen, a screen frame, a telescopic control rod, a guide rail, a slider, and a locking device; The base is fixed to the outer wall of the drill rod. A metal screen is provided on the screen frame. The upper end of the screen frame is hinged to the base, and the lower end of the screen frame is hinged to the telescopic control rod. The other end of the telescopic control rod is hinged to the slider. The slider can slide along the guide rail arranged axially along the drill rod. The movement of the slider drives the screen frame to expand or retract radially. The locking device is used to mechanically lock the screen frame after it is expanded into place.

5. The anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 4, characterized in that, The metal screen of the annular debris screening and capture assembly is also equipped with a micro-vibration sensor and a stress sensor. The micro-vibration sensor is used to monitor the vibration signal of rock debris impacting the screen and to determine whether the rock debris is effectively captured. The stress sensor is used to monitor the stress on the screen structure.

6. A control method for an anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination, applied to the anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in any one of claims 1 to 5, characterized in that, The method includes the following steps: S1. Multi-source fusion sensing section real-time acquisition of annular debris and borehole wall status signals; S2. The downhole intelligent control unit comprehensively judges whether there is a risk of borehole instability or stuck drill based on the annular debris and borehole wall status signals; if there is a risk of borehole instability, proceed to step S3; if there is a risk of stuck drill, proceed to step S4; otherwise, return to step S1. S3. The downhole intelligent control unit drives the stress-actively regulating sub to inject reinforcing fluid into the borehole wall to fill the fractures and inhibit rock spalling. After the process is completed, return to step S1. S4. The downhole intelligent control unit controls the deployment of the annular debris screening and capture assembly, which radially sweeps the annulus through a metal screen to capture large rock fragments with a particle size exceeding the screen aperture. S5. After capture is completed, the downhole intelligent control unit controls the drill pipe to lift the screen containing large rock cuttings to the hard rock section; S6. The downhole intelligent control unit drives the breaking roller actuator to extend, so that the breaking roller presses the rock cuttings captured in the screen against the hard rock well wall; S7. The downhole intelligent control unit controls the rotation of the drill pipe, which drives the crushing roller to revolve, using the rigid reaction force of the hard rock layer to crush the rock cuttings; S8. After the cuttings are broken up, the downhole intelligent control unit controls the retraction of the breaking roller and the closing of the screen. The annulus is checked again by multi-source fusion sensing sub. If it is clear, normal drilling resumes and returns to step S1.

7. The control method for the anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 6, characterized in that, In step S2, the downhole intelligent control unit comprehensively judges whether there is a risk of borehole instability or stuck pipe based on the annular debris and borehole wall status signals, specifically including: Based on the two-dimensional cross-sectional images of the borehole obtained by the ultrasonic probe array, the integrity of the borehole wall, the degree of fracture development and the rock mass spalling are identified to determine whether there is a risk of borehole wall instability. By combining the vibration characteristic signals collected by the triaxial vibration accelerometer to analyze the impact intensity and size of the cuttings, and by combining the pressure fluctuation changes monitored by the annular pressure dynamic sensor to determine the degree of annular flow blockage, it is determined whether the amount of annular debris accumulation and the maximum cuttings size exceed the safety threshold. If they exceed the threshold, it is determined that there is a risk of stuck drill.

8. The control method for the anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 6, characterized in that, In step S4, before the downhole intelligent control unit controls the deployment of the annular debris screening and capture assembly, the following steps are also included: The downhole intelligent control unit first controls the drill pipe to idle and circulate drilling fluid for preliminary debris removal. Based on the feedback of annular pressure, vibration, and imaging signals after preliminary debris removal, it is determined whether the risk of stuck pipe has been eliminated. If the risk of stuck pipe has been eliminated after preliminary debris removal, the process returns to step S1. If the risk of stuck pipe still exists, the annular debris screening and capture assembly is deployed again, and large pieces of rock cuttings are captured by radially sweeping the annulus through the screen.

9. The control method for the anti-jamming drill pipe system based on intelligent sensing and debris capture-transfer-crushing coordination as described in claim 6, characterized in that, In step S5, the identification method for hard rock strata includes: the downhole intelligent control unit combines signals collected by multi-source fusion sensing subsections with preset geological stratigraphic data to comprehensively identify hard rock strata. Two-dimensional cross-sectional images of the annulus obtained by an ultrasonic probe array are used to identify the density of the rock mass and the density of fracture development in the borehole wall, and to determine the stability of the well wall structure. Combined with the rock-breaking vibration signals of the drill bit collected by a triaxial vibration accelerometer, the vibration amplitude and frequency characteristics are analyzed. If the vibration amplitude is greater than the preset threshold and the frequency is stable, it is determined that the hardness of the corresponding stratum rock mass meets the requirements. At the same time, the matching degree between the stratum depth and lithology is verified by comparing with the preset geological stratum data, and finally the location of the hard rock stratum suitable for rock cutting is determined.

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