Sensor system with internal sensor and piezoelectric power supply

Abstract

A drilling system (10) is capable of withstanding downhole conditions at the bottom of a wellbore and drilling conditions caused by sustained motion and vibration. The drilling system (10) includes a drill bit (20) and a sensor system (40) having a system housing (30), a primary power source (50), and an internal sensor (70). The primary power source (50) includes a piezoelectric plate (52) for converting radial vibrations into electrical energy. The internal sensor (70) is locally powered by the primary power source (50) at a distal downhole location at the bottom of the wellbore. The internal sensor (70) collects data related to the downhole conditions and is in communication with the primary power source (50) to generate validated data based on the amount of electricity generated by the primary power source (50). The validated data is more accurate and reliable than the data collected by the internal sensor (70) and can be used to guide the drill bit (20) through a path through the formation in a drilling operation.

Description

[0001] Priority Statement

[0002] This application claims the rights of the following non-provisional application, which is incorporated herein by reference in its entirety:

[0003] U.S. Patent Application No. 18230654, filed on August 6, 2023, entitled "Sensor System with Internal Sensor and Piezoelectric Power Supply". Technical Field

[0004] This invention relates to drilling control based on downhole conditions at the bottom of the wellbore. More specifically, this invention relates to a piezoelectric generator-powered sensor located within the drill bit of a drill string assembly at the bottom of the well. Even more specifically, this invention relates to a sensor that works in conjunction with a piezoelectric power source, which powers the sensor and verifies the data acquired by the sensor, thereby enabling more accurate assessment of downhole conditions during drilling and achieving precise control of the drill bit. Background Technology

[0005] To explore and extract hydrocarbons such as oil and natural gas, wellbores need to be drilled deep into underground formations. Wellbores are formed by drilling a drill string, which consists of a drill bit connected to multiple long tubular sections or drill pipes. The drill string extends from the surface to the bottom of the wellbore. By rotating the drill bit, the drill string is driven through the formation, thus forming the wellbore. In rotary drilling operations, the drill bit is driven to rotate by rotating the drill string from the surface. Guided drilling requires downhole data to determine the drill bit's position, orientation, and velocity. Subsequently, the drill bit's position, orientation, and velocity can be adjusted to guide it along a predetermined trajectory through the formation to form the wellbore. The collected data is used to generate estimated and predicted values ​​for the drill bit to guide its movement through the formation and avoid obstacles. Weight on bit (WOB), mud pump pressure, rate of penetration (ROP), gravity toolface (GTF), inclination (INC), azimuth (AZI), and other conventional oilfield measurement parameters (such as depth, temperature, and pressure) are used to determine the bit projection (PTB), true vertical depth (TVD), and other wellbore estimates. When the bit is at the bottom of the well, the bit projection is particularly relevant to the position and orientation of the wellbore tip. The bit projection and other predicted values ​​are not actual measurements at the bottom of the well.

[0006] Estimating downhole conditions is less accurate than actual measurement. Direct measurement data can improve the accuracy of existing downhole condition predictions. Using measured data (rather than estimates based on long-distance extrapolation) leads to more precise determinations of downhole conditions.

[0007] Several patents and published documents have disclosed a sensor for directly measuring the wellbore end at the drill bit. U.S. Patent No. 7,064,676, granted to Hall et al. on June 20, 2006; U.S. Patent No. 7,604,072, granted to Pastusek et al. on October 20, 2009; U.S. Patent No. 8,100,196, granted to Pastusek et al. on January 24, 2012; U.S. Patent No. 11,111,732, granted to Zhan et al. on September 7, 2021; and U.S. Patent No. 11,346,207, granted to Alshaikh et al. on May 31, 2022, all disclose a sensor system, power supply, and firmware for measuring downhole conditions at the drill bit. By fixing the sensor within the drill bit body, the problems of it being subjected to severe vibration and drilling contact conditions due to its placement on the drill bit are solved. Conventional power supplies include batteries and wired power transmitted via the bottom drill string assembly. U.S. Patent No. 10,167,718, granted to Pelletier et al. on January 1, 2019, adds a piezoelectric power supply to an optical sensor on a drill bit. U.S. Patent No. 8,596,381, granted to Hall et al. on December 3, 2013, discloses a center-mounted pressure sensor powered by a piezoelectric element.

[0008] The intense movement and vibration at the bottom of the wellbore often affect the durability and accuracy of sensors there. The sensors on the drill bit are also located at considerable distances, requiring a reliable local power source that cannot be periodically removed and recharged. While existing battery and piezoelectric power supplies can address the issue of the drill bit's remote location, the data acquired by the sensors remains unreliable. Current sensor systems have added additional sensors further above the wellbore or on the drill bit to repeatedly generate the same distorted signal, thus facilitating detection. There remains a need for remote power supply and more accurate data.

[0009] The purpose of this invention is to provide a sensor system for a drill string assembly to guide drilling operations using accurate data on downhole conditions.

[0010] Another objective of this invention is to provide a sensor system that integrates a reliable local power supply within the drill bit at the bottom of the wellbore.

[0011] Another objective of this invention is to provide a sensor that works in conjunction with a piezoelectric power supply to achieve power supply and data acquisition.

[0012] Another objective of this invention is to provide a piezoelectric power supply for converting radial vibration, torsional vibration and vertical vibration into electrical energy for use by sensors on a drill bit.

[0013] Another objective of this invention is to provide a sensor that works in conjunction with a piezoelectric power supply, an additional sensor, and an additional piezoelectric power supply to achieve power supply and data acquisition.

[0014] Another objective of this invention is to provide a sensor system that incorporates multiple sensors and a reliable local piezoelectric power supply within the drill bit.

[0015] The present invention also aims to provide a sensor system having multiple sensors, a power management module, a control module and a piezoelectric power supply, so as to guide drilling operations using accurate data of downhole conditions.

[0016] Another object of the present invention is to provide a method for using a sensor system to control a drill bit based on data verified by a piezoelectric power supply.

[0017] The above and other objects and advantages of the present invention will become apparent from the accompanying description, drawings and claims. Summary of the Invention

[0018] Embodiments of the present invention include a drilling system that utilizes a sensor system to guide a drilling path through a formation. The drilling system includes a drill bit, and the sensor system is located on the drill bit at a distal downhole location at the bottom of the wellbore. The sensor system includes: a system housing; a main power supply including a piezoelectric plate for converting radial vibrations into electrical energy; and an internal sensor connected to the main power supply. The internal sensor acquires data at the distal downhole location of the drill bit at the bottom of the wellbore. In some embodiments, the internal sensor is an accelerometer, and the acquired data is vibration data. The motion and vibration of the drill bit are converted into electrical energy to power the internal sensor. The internal sensor is communicatively connected to the main power supply to generate validated data based on the vibration data acquired by the internal sensor and the electrical charge generated by the piezoelectric plate of the main power supply. The validated data possesses the accuracy and reliability required to guide the drill bit and control drilling operations.

[0019] The sensor system housing has a distal end, a proximal end, a housing central axis, a central chamber, and a power supply chamber. The power supply chamber is located at the proximal end. The housing central axis extends longitudinally through the system housing, and this housing central axis can be coaxial with the axis of the internal channel of the drill bit.

[0020] The main power supply is installed within a power supply chamber and includes multiple piezoelectric plates arranged radially around the central axis of the housing within the power supply chamber. At least one housing capacitor is connected to the multiple piezoelectric plates to store the electrical energy generated by the piezoelectric plates. The piezoelectric plates are uniformly distributed around the central axis of the housing. Each piezoelectric plate may include a piezoelectric element and an electrode plate. The main power supply may also include additional piezoelectric components (e.g., a torsional vibration energy generator and a vertical vibration energy generator). In an embodiment where both a vertical vibration energy generator and a torsional vibration energy generator are provided, the main power supply generates electrical energy from three different vibration directions to power an internal sensor at a distal downhole location on the drill bit. Validated data can be obtained based on the electrical charge and data acquired by the internal sensor.

[0021] The internal sensors are connected to the main power supply. Multiple internal sensors can be configured based on the power output and power management of the main power supply. These internal sensors, or any one of them, can be a temperature sensor, weight sensor, tilt sensor, azimuth sensor, depth sensor, pressure sensor, vibration sensor, accelerometer, or other sensors used to monitor downhole conditions. One internal sensor can be an accelerometer in one direction, while another internal sensor can be an accelerometer in a different direction. In some embodiments, the drilling system includes a circuit board, and the internal sensors are mounted on the circuit board.

[0022] The internal sensor is connected to the main power supply to power itself using electrical energy generated by piezoelectric plates. The internal sensor also communicates with the main power supply to generate validated data based on data acquired by the internal sensor and the electrical energy generated by the main power supply. The internal sensor may be an accelerometer used to acquire vibration data, and the validated data is derived from the vibration data and the electrical energy generated by the main power supply. The validated data can be used to guide the drill bit through the formation to form the desired wellbore.

[0023] Embodiments of the present invention include a drilling system with a mounting base. A sensor system can be housed in the mounting base for installation within an internal passageway of the drill bit. The mounting base may have a support to position the system housing within the drill bit.

[0024] Other embodiments include a sensor system having a cap and a sensor body. The cap is integrated with a system housing, and the sensor body is detachably mounted within the cap. The sensor body includes an external sensor and an auxiliary power source connected to the external sensor. The external sensor may be a pressure sensor, and the auxiliary power source includes a piezoelectric element. The sensor body, the internal sensor, and the main power source are communicatively connected to generate verified data based on different acquired data and the amount of electricity generated by the main power source. In some embodiments, the verified data is also derived based on the amount of electricity generated by the auxiliary power source.

[0025] In embodiments with a circuit board, the drilling system may include electronic components (e.g., a power management module and a control module) for data processing. Computer hardware and firmware are mounted on the circuit board for data storage, processing, analysis, and communication. The power management module and control module are mounted on the circuit board to be powered by the mains power supply. The control module may include a communication unit for transmitting data and receiving instructions via wireless or wired communication. The drilling system includes at least internal sensors and the mains power supply that are communicatively connected to the power management module and control module to generate verified data based on data related to downhole conditions and the amount of electricity generated by the mains power supply.

[0026] A method for drilling into rock formations to create wellbores for oil and gas exploration and production includes: running a drilling system into the formation, drilling with a drill bit to create the wellbore, and powering internal sensors with a main power source. The method includes acquiring data related to downhole conditions through the internal sensors and generating validated data based on the downhole condition-related data and the power generated by the main power source. Finally, the method includes controlling the drill bit based on the validated downhole condition-related data. Attached Figure Description

[0027] Figure 1 This is a perspective view of an embodiment of the drilling system according to the present invention.

[0028] Figure 2 This is a cross-sectional view of an embodiment of the drill bit of the drilling system according to the present invention.

[0029] Figure 3 This is a cross-sectional view of an embodiment of the drilling system according to the present invention.

[0030] Figure 4 This is a cross-sectional view of the sensor system and mounting base in an embodiment of the drilling system according to the present invention.

[0031] Figure 5 This is a perspective view of the mounting base in an embodiment of the drilling system according to the present invention.

[0032] Figure 6 A perspective view of an embodiment of the sensor system in a drilling system according to the present invention having a main power supply.

[0033] Figure 7 According to Figure 6 The illustration shows an embodiment of a sensor system with a main power supply and a sectional view of the mounting base of the drilling system of the present invention.

[0034] Figure 8 This is another perspective view of an embodiment of the sensor system of the drilling system according to the present invention.

[0035] Figure 9This is a perspective view of an embodiment of the system housing of the drilling system according to the present invention.

[0036] Figure 10 According to Figure 9 Another perspective view of an embodiment of the system housing shown.

[0037] Figure 11 According to Figure 9 A front view of an embodiment of the system housing shown.

[0038] Figure 12 This is a front end view of an embodiment of the main power supply located in the power supply chamber of the system housing in the drilling system according to the present invention.

[0039] Figure 13 This is a front view of the opposite end face of an embodiment of the main power supply located in the power supply chamber of the system housing in the drilling system according to the present invention.

[0040] Figure 14 This is a front view of an embodiment of the cap and sensor body of the system housing in the drilling system according to the present invention. Detailed Implementation

[0041] The sensors on the drill bit must withstand both extreme downhole conditions at the bottom of the well and extreme drilling conditions due to the continuous movement and vibration of the drill bit. These dual extreme conditions often lead to inconsistent and inaccurate data, and the sensor's power supply must also be able to withstand these drill bit conditions. The drilling system 10 of this invention solves the problems of local power supply and data accuracy at remote locations through a sensor system 40 with a piezoelectric power supply that works in conjunction with internal sensors. The movement and vibration of the drill bit are converted into energy to power the internal sensors, and the internal sensors communicate with the piezoelectric power supply, thereby generating verified data based on data collected by the internal sensors at the downhole location and the electrical power generated by the piezoelectric power supply.

[0042] Figures 1-3 A drilling system 10 of the present invention is shown, which is used to drill a wellbore in a formation. This wellbore provides access to the interior of the formation for the extraction of oil and gas. The drilling system 10 includes a drill bit 20 and a sensor system 40, wherein the drill bit 20 has an end 22, a connecting end 24 opposite to the end, and an internal channel 26 extending from the connecting end toward the end. The drill bit 20 has cutting teeth that engage with the formation, and other channels and cavities may also be provided within the drill bit 20 to accommodate other accessories such as force modulation control devices. In the present invention, at least the internal channel 26 is provided to accommodate the sensor system 40. The internal channel 26 illustrated in this embodiment is located at the center of the drill bit, but it may also be located at other locations within the drill bit 20.

[0043] Figure 3 , Figure 4 and Figures 6-8 The sensor system 40 is shown, which includes a system housing 42, a main power supply 50, and an internal sensor 70. Figures 9-11 An embodiment of the system housing 42 is shown, having a distal end 44, a proximal end 46 opposite the distal end, a housing central axis 47, a central chamber 48 located between the distal and proximal ends, and a power supply chamber 49 located between the central chamber and the proximal end. The power supply chamber 49 is located at the proximal end 46. The housing central axis 47 extends longitudinally through the system housing 42. This housing central axis 47 may be coaxial with the axis of the internal passage 26 of the drill bit 20.

[0044] The main power supply 50 is installed inside the power supply chamber 49, and its schematic structure is shown below. Figure 8 As shown. Figures 6-7 An embodiment of a main power supply 50 is shown, which includes a plurality of piezoelectric plates 52 arranged radially around a central axis 47 of the housing within a power supply chamber 49. A housing capacitor 58 is also provided, connected to the plurality of piezoelectric plates 52, wherein the piezoelectric plates 52 convert radial vibrations into electrical energy, which is stored in the housing capacitor 58. In some embodiments, an additional housing capacitor 59 may be provided, and multiple capacitors may be provided to store the electrical energy generated by the piezoelectric plates 52. Figures 6-8 An internal sensor 70 is shown connected to a main power supply 50. The internal sensor 70 collects data related to downhole conditions. In one embodiment of the invention, the internal sensor 70 may be an accelerometer, so vibration data is the data collected by the internal sensor 70. The internal sensor 70 is communicatively connected to the main power supply 50 to generate validated data based on downhole condition-related data (e.g., vibration data) and the electrical energy generated by the main power supply 50. In one embodiment, the vibration of the drill bit 20 is measured as vibration data by the internal sensor 70, and the same vibration is converted into electrical energy stored in a housing capacitor 58 by the radial vibration of a piezoelectric plate 52. Validated data is obtained based on validated or corrected vibration data derived from the radial vibration energy value generated by the main power supply 50. Vibration data measured directly at a remote downhole location can be adjusted to eliminate noise and distortion. The electrical energy generated by the main power supply is another measure of the vibration data, and these two measures of the vibration data can determine validated data with higher accuracy and reliability. This validated data can be used to guide the drill bit's path through the formation to form the desired wellbore. This invention does not extrapolate vibration data from remote downhole locations, nor does it use vibration data with lower reliability collected at remote downhole locations. Instead, it generates verified data.

[0045] Figures 6-7 and Figures 12-13 An embodiment is shown in which multiple piezoelectric plates 52 are evenly distributed around the central axis 47 of the housing. Figures 12-13Three piezoelectric plates 52 are shown distributed at 120-degree intervals around the central axis of the housing. Each piezoelectric plate 52 may consist of a piezoelectric element 54 and an electrode plate 56. The piezoelectric plates 52 are connected in series or in parallel to the housing capacitor 58, and may also be connected to an additional housing capacitor 59.

[0046] Embodiments of the main power supply 50 also include a torsional vibration energy generator 60. The torsional vibration energy generator 60 can be piezoelectric, electromagnetic, or electrostatic. In addition to the radial vibration energy generated by the main power supply 50, torsional vibration energy can also be captured for use at remote downhole locations. The torsional vibration energy generator 60 being piezoelectric is a feature of this invention. Figures 6-7 The example shown. Figure 12 and Figure 13 Also shown is a torsional vibration energy generator 60, which acts as a piezoelectric element and converts torsional vibration into electrical energy by extending longitudinally through the power supply chamber 49 parallel to the central axis 47 of the housing. The torsional vibration energy generator 60 is also connected to the housing capacitor 58.

[0047] Figures 3-4 and Figures 6-8 The drilling system 10 is shown, wherein the internal sensor 70 is an accelerometer. In other embodiments, the internal sensor 70 may be other types of sensors. In an alternative embodiment, the internal sensor 70 includes an azimuth sensor that collects torsional data. When the main power supply 50 includes a torsional vibration energy generator 60, the validated data is obtained based on the electrical charge generated by the main power supply 50 and the data collected by the azimuth sensor, which is the internal sensor 70.

[0048] Another embodiment of the main power supply 50 includes a vertical vibration energy generator 62, such as Figures 3-4 As shown. The vertical vibration energy generator 62 can be piezoelectric, electromagnetic, or electrostatic. The piezoelectric nature of the vertical vibration energy generator 62 is a feature of this invention. Figures 6-7 The illustrated embodiment. In addition to the radial vibration energy generated by the main power supply 50, vertical vibration energy can also be generated at the distal downhole location. Figures 6-7 A vertical vibration energy generator 62 is shown extending perpendicularly to the central axis 47 of the housing and mounted within the power supply chamber 49, positioned between the plurality of piezoelectric plates 52 and the central chamber 48. The vertical vibration energy generator 62 is also connected to the housing capacitor 58. When the main power supply 50 includes the vertical vibration energy generator 62, verified data is obtained based on the electrical charge generated by the main power supply 50 and vibration data from the internal sensor 70.

[0049] In embodiments where both a vertical vibration energy generator 62 and a torsional vibration energy generator 60 are provided, the main power supply 50 generates energy from three different vibration orientations to power internal sensors 70 located at the distal downhole position on the drill bit 20. Verified data can be obtained based on energy values ​​and data from different types of internal sensors 70 (including accelerometers in different orientations).

[0050] Figure 6 and Figure 8 An embodiment of the sensor system 40 is shown, comprising a plurality of internal sensors 70, 74. Additional internal sensors 74 may also be connected to the main power supply 50 to acquire additional data related to additional downhole conditions. The additional internal sensor 74 may be a temperature sensor, weight sensor, tilt sensor, azimuth sensor, depth sensor, pressure sensor, vibration sensor, or accelerometer. Yet another internal sensor 74 may acquire data related to yet another additional downhole condition. Various combinations include an internal sensor 70 being an accelerometer and an additional internal sensor 74 being a temperature sensor. Temperature and vibration data can be used to more accurately determine downhole conditions to guide the drill bit's movement through the formation. In an alternative embodiment, the additional internal sensor 74 is also communicatively connected to the main power supply 50 to generate validated data based on data acquired by an additional internal sensor 75 corresponding to another downhole condition and the power generated by the main power supply 50. For example, an internal sensor 70, which is an accelerometer in one direction, and an additional internal sensor 74, which is another accelerometer in a different direction, can both be communicatively connected to the main power supply 50 to generate verified data based on the corresponding vibration data from each accelerometer and the electrical power generated by the main power supply 50.

[0051] Figures 3-4 and Figures 6-8 The drilling system 10 is shown to include a circuit board 72 located within a central chamber 48. Internal sensors 70 can be mounted on the circuit board 72, and a main power supply 50 is connected to the circuit board 72 and thus connected to the internal sensors 70.

[0052] Figure 3 and Figure 4 An embodiment of a drilling system 10 with a mounting base 30 is shown. A sensor system 40 can be housed within the mounting base 30, thereby positioning it within the internal passage 26 of the drill bit 20. As drilling mud flows through the internal passage 26 of the drill bit 20, the drilling mud can pass through the mounting base 30. The flow of drilling mud through the mounting base 30 exposes the sensor system 40 to the drilling mud, allowing the internal sensor 70 and any additional internal sensor 74 to detect downhole conditions (including downhole conditions related to the drilling mud). The mounting base 30 stabilizes the sensor system 40 and sets its position and orientation within the drill bit 20 and in the drilling mud flow. Figure 3As shown, the mounting base 30 can mount the sensor system 40 in the internal channel 26 and position it at the center of the drill bit 20. The mounting base 30 has a first end 32 and a second end 34 opposite to the first end 32. Figure 3 The first end 32 is shown facing the end 22 of the drill bit 20, and the second end 34 is shown facing the connecting end 24 of the drill bit 20. During drilling operations, drilling mud flows through the internal channels 26 of the drill bit 20. Downhole conditions (including downhole conditions related to drilling mud) can be detected by the internal sensor 70 and any additional internal sensor 74, including pressure sensors exposed to the drilling mud.

[0053] like Figure 5 As shown, an embodiment of the mounting base 30 includes at least one support 36 located at the second end 34. The support 36 may be a wedge-shaped column, which allows drilling mud in the internal channel 26 to flow through the mounting base 30 and surround the sensor system 40. Figure 5 Three wedge-shaped supports 36 are shown, evenly distributed around the periphery of the mounting base 30 at the annular portion of the second end 34. The supports 36 define the position and layout of the sensor system 40 within the drill bit 20 and stabilize the sensor system 40 relative to the drill bit 20. Downhole conditions (including those related to drilling mud) can be detected by the sensor system 40. The supports 26 can engage with the inner wall 28 of the internal channel 26, while the first end remains suspended within the internal channel 26 without contacting the inner wall 28. The internal sensor 70 is connected to the system housing 42, which differs from the piezoelectric plate 52, causing vibrations at the internal sensor 70 to differ from those at the piezoelectric plate 52 in the power supply chamber 49. This difference can be used to generate validated data based on the vibration data of the internal sensor 70 (acting as an accelerometer) and the electrical charge generated by the main power supply 50.

[0054] Figure 6 , Figure 7 and Figure 14 An embodiment of a sensor system 40 including a cap body 80 and a sensor body 90 is shown. The cap body 80 and system housing 42 are joined between a central chamber 48 and a distal end 44. The cap body 80 may be integrally formed with the system housing 42. The cap body 80 has a distal end 82, a proximal end 84 opposite to the distal end, and a cap channel 86 extending from the distal end 82 toward the proximal end 84. The sensor body 90 is detachably mounted in the cap channel 86. The sensor body 90 has a distal end 92 and a proximal end 94 opposite to the distal end. Figure 7In this embodiment, the sensor body 90 includes an external sensor 96 and an auxiliary power supply 98 connected to the external sensor 96. The external sensor 96 may be a pressure sensor. The auxiliary power supply 98 is located at the distal end 82 of the cap body to convert pressure into electrical energy. In some embodiments, the auxiliary power supply 98 includes a piezoelectric element 99 and a sensor body capacitor 97 connected to the piezoelectric element 99. Additional sensor body capacitors may be added as needed. Figure 7 An embodiment of the auxiliary power supply 98 is also shown, which further includes a thermoelectric generator 95 connected to the sensor body capacitor 97 to convert heat into electrical energy and store it in the sensor body capacitor 97. The thermoelectric generator 95 may be aligned with the piezoelectric element 99 within the cap channel 86.

[0055] Similar components to the cap 80 and sensor body 90 exist in the prior art. Other locally powered pressure sensors are located on the tip of the drill bit. However, the cap 80 and sensor body 90 of the drilling system 10 are located in different positions within the drill bit 20. Furthermore, the relationship between the sensor body 90, the internal sensor 70, and the main power supply 50 is novel to the prior art. In embodiments where the internal sensor 70 functions as a pressure sensor, the pressure data from the internal sensor 70 and the electrical charge generated by the auxiliary power supply 98 can be used to generate verified data guiding the drill bit 20. In some embodiments, the verified data can also be obtained based on pressure data from the external sensor 96.

[0056] An embodiment with circuit board 72 also shows the drilling system 10 including a power management module 100 and a control module 102. The power management module 100 and control module 102 are computer hardware and firmware mounted on circuit board 72 for data storage, processing, analysis, and communication. The power management module 100 is mounted on the circuit board to be powered by the main power supply 50. The power management module 100 is communicatively connected to the main power supply 50 and all internal sensors 70, 74 in embodiments of the drilling system 10. Internal sensors 70 can be locally powered at a remote location on the drill bit 20, and other components located at remote locations (e.g., additional internal sensors 74) can also be locally powered by the main power supply 50. The control module 102 is communicatively connected to the internal sensors 70 and the main power supply 50 to acquire downhole condition-related data from the internal sensors 70 and the power generated by the main power supply 50. The control module 102 may include a communication unit 103 (e.g., an antenna) for transmitting data and receiving commands via wireless or wired communication. The drilling system 10, located at the distal end of the drill bit 20, may not be able to complete all the data processing from all internal sensors locally on the drill bit 20. A data-sharing processing approach can be adopted, allowing a more complex drilling system 10 with multiple internal sensors 70, 74 to generate verified data for guiding the drill bit 20 based on the power generated by the main power supply 50 and the data from any of the internal sensors 70, 74.

[0057] The drilling system 10 includes at least an internal sensor 70 and a main power supply 50, which are communicatively connected to the power management module 100 and the control module 102, thereby generating verified data based on data related to downhole operating conditions and the power generated by the main power supply 50. In embodiments with an additional internal sensor 74, the additional internal sensor 74 may also be communicatively connected to the power management module 100 and the control module 102. In embodiments with a sensor body 90, an auxiliary power supply 98 and an external sensor 96 may also be communicatively connected to the power management module 100 and the control module 102. The control module 102, which is communicatively connected to the main power supply 50, the auxiliary power supply 98, the internal sensor 70, and the external sensor 96, can generate verified data based on data from the internal sensor 70, data from the external sensor 96, the power generated by the main power supply 50, and the power generated by the auxiliary power supply 98, depending on the type of the internal sensor 70 and the external sensor 96.

[0058] In an embodiment where the external sensor 96 is used as a pressure sensor, pressure data and electrical quantity generated by the auxiliary power supply 98 through the piezoelectric element 99 can generate verified data. In an embodiment where the additional internal sensor 74 is used as a temperature sensor, temperature data can be generated based on the electrical quantity of the auxiliary power supply 98 (which has a thermoelectric generator 95 connected to the sensor body capacitor 97) to generate verified data. In an embodiment where the internal sensor 70 is used as an accelerometer, the data is vibration data, and the vibration data can be generated based on the electrical quantity generated by the main power supply 50 and the electrical quantity generated by the auxiliary power supply 98 to generate verified data.

[0059] Embodiments of the present invention include a method for drilling in rock formations to form a wellbore for oil and gas exploration and production. The method includes running a drilling system 10 into the rock formation and drilling a wellbore using a drill bit 20. An internal sensor 70 may be powered by a main power supply 50. The method includes acquiring data related to downhole conditions via the internal sensor 70 and generating verified data based on the downhole condition-related data and the electrical power generated by the main power supply 50. The method concludes by controlling the drill bit 20 according to the verified downhole condition-related data. Powering the internal sensor 70 includes converting radial vibrations of the system housing 42 into electrical energy.

[0060] The method can be performed using a sensor system 40 having a cap 80 and a sensor body 90. Using this auxiliary structure, the method can further include acquiring pressure data via an external sensor 96 and powering the external sensor 96 using an auxiliary power supply 98. The method can also include generating verified pressure data based on the pressure data and the electrical charge generated by the auxiliary power supply 98. The verified pressure data can also be used in steps involving drill bit control.

[0061] Data-driven drill bit guidance relies on data accuracy. Improving data accuracy correspondingly improves drill bit guidance performance. Insufficient data accuracy at the bottom of the wellbore has been a long-standing problem. Extreme drilling conditions and downhole operating conditions, coupled with the extreme environments in which the drill bit's sensors operate, consistently lead to inaccurate and inconsistent data collected by these sensors. Sensors located on the drill string, far from the drill bit, can provide more reliable data and utilize mathematical calculations to estimate the actual operating conditions of the drill bit at the bottom of the wellbore. This invention reverses the trend of placing sensors far from the drill bit and introduces an alternative for improving data from internal sensors on the drill bit.

[0062] The drilling system of the present invention includes a sensor system comprising a piezoelectric power supply and internal sensors located within the drill bit. The internal sensors are connected to the piezoelectric power supply, thereby receiving power at a distal downhole location of the drill bit at the bottom of the wellbore. The internal sensors are communicatively connected to the piezoelectric power supply to generate validated data based on data acquired by the internal sensors and the electrical charge generated by the piezoelectric power supply. The validated data has higher accuracy and sufficient reliability to guide drilling operations compared to data acquired by the internal sensors. The drilling system provides a local and reliable power supply to the internal sensors located within the drill bit at the distal bottom of the wellbore. A main power supply based on piezoelectric plates powers the internal sensors, and the generated electrical charge and data acquired by the internal sensors can generate validated data with higher accuracy and reliability (e.g., validated vibration data from an internal sensor acting as an accelerometer). The main power supply can be a piezoelectric power supply for converting radial, torsional, and vertical vibrations into electrical energy. The main power supply can power at least the internal sensors. Multiple internal sensors can be powered, thereby enabling the acquisition of various types of data from each internal sensor. The drilling system can generate more accurate and reliable verified data based on these different data collected and the power generated by the main power source.

[0063] Existing piezoelectric pressure sensors can be integrated into the sensor system of this invention. Verified data can also be obtained based on pressure data from these pressure sensors and the secondary piezoelectric power supply. The secondary piezoelectric power supply does not alter the relationship between the internal sensor and the main power supply of this invention.

[0064] The drilling system can also integrate electronic components for data processing. These relationships between the power management and control modules and the internal sensors and piezoelectric plates are also included. The drilling path of the drill bit can be determined through controlled guidance based on validated data derived from real-time data acquired from sensors and the electrical charge received from the piezoelectric plates on the drill bit at the bottom of the wellbore (i.e., the furthest point in the wellbore).

[0065] The above disclosure and description of the present invention are merely illustrative. Various changes can be made to the details of the illustrated structures, constructions, and methods without departing from the essential spirit of the present invention.

Claims

1. A drilling system, the drilling system comprising: A drill bit having an end, a connecting end opposite to the end, and an internal channel extending from the connecting end toward the end; as well as A sensor system, the sensor system being installed in the internal channel and comprising: A system housing having a distal end, a proximal end opposite the distal end, a housing central axis, a central chamber located between the distal end and the proximal end, and a power supply chamber located between the central chamber and the proximal end; Main power supply, the main power supply being installed in the power supply chamber and comprising: Multiple piezoelectric plates, arranged radially around the central axis of the housing within the power supply chamber, convert radial vibrations into electrical energy; and A housing capacitor, the housing capacitor being connected to the plurality of piezoelectric plates; and An internal sensor, connected to the main power supply, is used to collect data related to downhole operating conditions. The internal sensors are communicatively connected to the main power supply to generate verified data based on the data related to the downhole working conditions and the power generated by the main power supply.

2. The drilling system according to claim 1, wherein, The plurality of piezoelectric plates includes three piezoelectric plates evenly distributed around the central axis of the housing.

3. The drilling system according to claim 1, wherein, Each of the plurality of piezoelectric plates includes a piezoelectric element and an electrode plate.

4. The drilling system according to claim 1, wherein, The main power supply also includes an additional housing capacitor connected to the housing capacitor.

5. The drilling system according to claim 1, wherein, The main power supply also includes a torsional vibration energy generator, which extends longitudinally through the power supply chamber parallel to the central axis of the housing and is connected to the housing capacitor to convert torsional vibration into electrical energy.

6. The drilling system according to claim 1, wherein, The main power supply also includes a vertical vibration energy generator, which extends perpendicular to the central axis of the housing and is installed in the power supply chamber between the plurality of piezoelectric plates and the central chamber. It is also connected to the housing capacitor to convert vertical vibration into electrical energy.

7. The drilling system according to claim 1, wherein, The internal sensors include accelerometers, the data related to downhole operating conditions is vibration data, and the confirmed data is confirmed vibration data obtained based on the vibration data and the electrical power generated by the main power supply.

8. The drilling system according to claim 1, further comprising: A circuit board on which the internal sensor is mounted.

9. The drilling system according to claim 1, further comprising: The fixing base has a first end and a second end opposite to the first end, and the fixing base includes a support located at the second end. The power supply chamber is detachably mounted in the mounting base to position the sensor system in the internal channel.

10. The drilling system according to claim 1, wherein, The sensor system also includes: A cap body, located between the central chamber and the distal end, the cap body having a distal end, a proximal end opposite the distal end, and a cap channel extending from the distal end toward the proximal end; and A sensor body, detachably mounted within the cap channel, having a distal end and a proximal end opposite the distal end. The sensor body includes: An external sensor, including a pressure sensor, located at the distal end of the cap body to convert pressure into electrical energy; and A secondary power supply, which is connected to the external sensor. The auxiliary power supply includes: piezoelectric elements; and A sensor body capacitor is connected to the piezoelectric element.

11. The drilling system according to claim 1, wherein, The auxiliary power source also includes a thermoelectric generator, which is connected to the sensor body capacitor to convert heat into electrical energy.

12. The drilling system according to claim 1, wherein, The sensor system also includes: An additional internal sensor, connected to the main power supply, is used to collect data related to another downhole operating condition. The confirmed data is obtained based on the data related to another downhole condition, the data related to the downhole condition, and the electricity generated by the main power source.

13. The drilling system according to claim 1, wherein, The internal sensor is an accelerometer, and The additional internal sensors are selected from temperature sensors, weight sensors, tilt sensors, orientation sensors, depth sensors, pressure sensors, vibration sensors, and accelerometers.

14. The drilling system according to claim 1, further comprising: The circuit board, on which the internal sensor is mounted, and the main power supply is connected to the circuit board.

15. The drilling system according to claim 8, further comprising: A power management module is mounted on the circuit board and is communicatively connected to the main power supply and the internal sensors. as well as The control module is communicatively connected to the internal sensors and the main power supply. The internal sensors and the main power supply are communicatively connected to the power management module and the control module to generate the verified data.

16. The drilling system according to claim 15, wherein, The internal sensors include accelerometers, and the data related to downhole operating conditions is vibration data. The confirmed data is obtained based on the vibration data and the electricity generated by the main power supply.

17. The drilling system according to claim 15, wherein, The sensor system also includes: A cap body, located between the central chamber and the distal end, the cap body having a distal end, a proximal end opposite the distal end, and a cap channel extending from the distal end toward the proximal end; and A sensor body, detachably mounted within the cap channel, having a distal end and a proximal end opposite the distal end. The sensor body includes: An external sensor, including a pressure sensor, located at the distal end of the cap body to convert pressure into electrical energy; and A secondary power supply, which is connected to the external sensor. The auxiliary power supply includes: piezoelectric elements; and A sensor body capacitor, which is connected to the piezoelectric element. The control module is communicatively connected to the internal sensor, the main power supply, the external sensor, and the auxiliary power supply to generate the confirmed data.

18. The drilling system according to claim 17, wherein, The internal sensors include accelerometers, and the data related to downhole operating conditions is vibration data. The confirmed data is obtained based on the vibration data, the amount of electricity generated by the main power supply, and the amount of electricity generated by the auxiliary power supply.

19. A drilling method, the drilling method comprising the following steps: The drilling system according to claim 1 is lowered into the formation; The drill bit is used to drill and form a wellbore; The internal sensors are powered by the main power supply. The data related to the downhole operating conditions are collected through the internal sensors. as well as Based on the data related to the downhole operating conditions and the power generated by the main power source, the confirmed data is generated. The step of powering the internal sensor includes the step of converting radial vibration into electrical energy; as well as The drill bit is controlled based on the confirmed data.

20. The drilling method according to claim 19, wherein, The sensor system also includes: A cap body, located between the central chamber and the distal end, the cap body having a distal end, a proximal end opposite the distal end, and a cap channel extending from the distal end toward the proximal end; and A sensor body, detachably mounted within the cap channel, having a distal end and a proximal end opposite the distal end. The sensor body includes: An external sensor, including a pressure sensor, located at the distal end of the cap body to convert pressure into electrical energy; and A secondary power supply, which is connected to the external sensor. The auxiliary power supply includes: piezoelectric elements; and A sensor body capacitor, which is connected to the piezoelectric element. The method further includes the following steps: The external sensor is powered by the auxiliary power source. Pressure data is acquired using the external sensor; and Based on the pressure data and the electricity generated by the auxiliary power source, confirmed pressure data is generated. The step of controlling the drill bit is performed based on the confirmed pressure data.

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