DOWNHOLE FEEDBACK ELECTRIC ACTUATOR (EDB)

Abstract

Embodiments of a bidirectional overrunning clutch and a rear-driveable downhole electric actuator are disclosed. In one embodiment, an actuator is coupled to a target mechanism positioned downhole, the actuator comprising: a housing; a motor; a dynamic sealing system; a ball screw and a ball nut; and an engagement system; wherein the ball screw comprises a sliding rod extending from a distal end of the housing and configured to connect to the target mechanism.In one embodiment, the engagement mechanism is a bidirectional overrunning clutch comprising: an input shaft, the input shaft having a multi-surface profile at its distal end with a plurality of engaging surfaces; a clutch body comprising a cage and a plurality of rollers within the cage; and an output shaft; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces and the output shaft upon rotation of the input shaft. Figure for abstract: Figure 1.

Description

Title of the invention: DOWNHOLE FEEDBACK-DRIVE ELECTRIC ACTUATOR (EDB)

[0001] STATE OF THE ART

[0002] Hydrocarbons, such as oil and gas, are generally obtained from subterranean formations which may be located onshore or offshore. The development of subterranean operations as well as the processes involved in extracting hydrocarbons from a subterranean formation can be complex. A number of different steps such as, for example, drilling a wellbore at the desired location, treating the wellbore to optimize hydrocarbon production and performing the steps necessary to produce and treat the hydrocarbons from the subterranean formation are generally involved in subterranean operations.

[0003] To extend the wellbore, drilling a wellbore may include introducing a drill bit into the formation and rotating the bit. It may be necessary in some operations to control the direction in which the wellbore is extended by changing the axis of the bit relative to the wellbore. For this purpose, complex mechanisms are generally used which increase the costs associated with the drilling operation.

[0004] BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Embodiments of the disclosure may be better understood by referring to the accompanying drawings.

[0006] [Fig.l] is a schematic view of a well system, according to certain embodiments.

[0007] [Fig.2] is a partial sectional view of one embodiment of a bidirectional overrunning clutch, according to certain embodiments.

[0008] [Fig.3A], [Fig.3B] and [Fig.3C] are front views of an embodiment of a model of a bidirectional overrunning clutch shown in three positions, according to certain embodiments.

[0009] [Fig.4A], [Fig.4B], [Fig.4C], [Fig.4D] and [Fig.4E] are perspective views components of a bidirectional overrunning clutch, according to certain embodiments.

[0010] [Fig.5] is a side sectional view of a downhole electric feedback drive (EDB) actuator, according to certain embodiments.

[0011] [Fig.6] is a side sectional view of another embodiment of an EDB actuator.

[0012] [Fig.7A] and [Fig.7B] are the diagrams which present different systems using an EDB actuator and a clutch, according to certain embodiments.

[0013] [Fig.8] is a system diagram showing another system using an EDB actuator and a clutch, according to certain embodiments. DETAILED DESCRIPTION

[0014] The following description includes exemplary systems, methods, techniques, and program flows that implement certain aspects of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. In some instances, well-known instructions, protocols, structures, and techniques have not been presented in detail so as not to obscure the description.

[0015] Currently, a downhole environment includes many devices that can use hydraulic power to operate and, more specifically, to move parts of these devices from one position to another. These devices include downhole valves, including, but not limited to, ball valves, sliding sleeve valves, chemical injection valves, gas lift valves, and interval control valves (ICVs), as well as lockout and closure systems, packers, and flappers.

[0016] The industry has recently called for hydraulic systems to be replaced with electric systems; however, challenges are posed by the limitation of electrical power and the requirement for maintenance-free tools, which in some cases may be necessary over a period of 20 years or more. To address the challenge of maintenance-free operation, redundant drive systems and / or replacement tools may be applied. Embodiments of a downhole (DBO) feedback-driven electric actuator disclosed herein allow for both replacement and redundant actuator systems in their normal operation.

[0017] Examples of EDB actuators for use in a downhole system or wellbore environment are disclosed herein. The EDB actuator may be standalone or used with redundant actuators to operate target mechanisms, including valves, latch and close systems, packers, flappers, and / or any other device that may be positioned in a completion well or fracturing system. An electric motor coupled to an engagement system may be comprised by the EDB actuator, wherein the engagement system may be used to engage and / or disengage the actuator. The actuator may include a ball screw and a ball nut supported by a ball bearing. The components of The actuator may be encapsulated in at least one actuator housing containing a lubricant such as oil or dielectric oil. The oil may compress and expand. Any volume displacement may be accommodated by at least one compensator coupled to the actuator housing, the compensator may include a bellows, piston, bladder, diaphragm, or other suitable components. The ball screw has a sliding rod that projects from the actuator housing and may be coupled to a target downhole component (such as a valve, flapper, packer, etc.). The actuator may also include a dynamic sealing system that seals an interior chamber of the housing from an external downhole environment, such as a downhole annulus or wellbore tubing.In some cases, the motor may be positioned in a chamber and may include one or more rotary seals to enhance the safety of the motor against contamination from other components. In some embodiments, there may be only one uniform chamber and a rotary seal may not be required. When the motor rotates clockwise or counterclockwise, the engagement system engages and transfers motion to the ball screw, thereby extending or retracting the slide rod outside the actuator housing, pushing or pulling the load related to the target mechanism. The ball screw rotates in the same direction as the motor.

[0018] The engagement system allows the actuator to be actuated by the slide rod (bi-directional freewheel mode) with external force without damaging the actuator and motor, and may also allow the use of more than one actuator on the system, such as redundant actuators that may be attached, coupled, or touching each other on the same target mechanism / downhole tool, without any other switches or interlocking systems. The engagement system also allows a downhole system to switch to a second or third actuator if the first actuator is not functioning properly, without the need for an external tool or intervention or without requiring a replacement system on the output / slide rod or any parts connected thereto.Depending on the system power and firmware, the engagement system can also add the ability to operate in the event that a greater load than a single actuator can provide may be required. In addition, if an external tool may be required to actuate the target mechanism, the actuator can maintain its normal location and operating state.

[0019] Other advantages of the actuator combined with an engagement system such as a bi-directional overrunning clutch disclosed herein allow for replacement and operation as an intervention while maintaining / preserving normal operation of the actuator. The use of a system engagement such as in the clutch embodiments disclosed herein allows the use of redundant motors without any external switching method being required. Operation of the downhole devices with low power from the wellbore surface.

[0020] Currently, there are no electric actuators capable of providing redundancy or replacement without an external switching system, nor are there electric actuators capable of operating downhole devices without intervention - current embodiments require the use of coiled tubing, wireline, and / or slickline tools. The actuator embodiments described herein still allow for replacement operation using coiled tubing, wireline, and slickline tools if necessary to break up any possible scaling or other incrustation that would overextend the capacity load of the electric actuator while maintaining normal actuator operation. For example, if the actuator is unable to operate a downhole tool, such as e.g.a valve, due to abnormal behavior, after using an external tool to operate the valve by means of a replacement system, the actuator can maintain its normal function.

[0021] This document also presents examples of engagement systems. In some downhole completion and fracturing applications, certain components, such as production valves, may utilize one or more actuators. In some embodiments, there may be two or more actuators, including a primary actuator and a redundant actuator, to provide redundancy to the actuation system. A redundant system also provides greater reliability. However, previously available engagement systems (such as the traditional clutch) may damage other components of the system. There is a need for an engagement system that can engage and disengage an actuator without damaging the actuator, both when used to maintain normal operations and when replacement or service may be necessary.Further, there is a need for an engagement system capable of continuously disengaging and replacing the actuator or actuation system in the event of failure, for example, to open or close a valve such as an interval control valve (ICV). This document provides a bidirectional overrunning clutch ("clutch") that can engage and disengage an actuator without causing damage. For example, embodiments of the clutch can recoil the actuator without applying torque to the motor.

[0022] The bidirectional overrunning clutch may include an input shaft whose distal end has a multi-surface profile. The multi-surface profile multiple may include multiple engagement surfaces. A clutch body may include a cage at a distal end of the clutch body that may be positioned around the input shaft. The cage may include apertures for positioning multiple rollers within the cage. An output shaft may be coupled to the clutch body around the cage. The plurality of rollers is configured to engage the plurality of engagement surfaces to transfer motion and torque to the output shaft as the input shaft rotates. The rollers may automatically engage and disengage the input shaft and the output shaft, such that when rotation of the input shaft changes or stops, rotation of the output shaft automatically changes or stops. The clutch may therefore engage and disengage an actuator in a controlled manner.The clutch can use an anti-rotation friction force that allows the input shaft to automatically change direction of rotation.

[0023] The bidirectional overrunning clutch examples ("clutch") presented herein provide an engagement system capable of transitioning from an engaged drive mode, either clockwise (CW) or counterclockwise (CCW), to a freewheeling (or inactive) mode. Directional rotation of the input shaft automatically causes rotation of the output shaft, without any electronic mechanism being required to transition from the freewheeling mode to one of the two engaged modes (CW or CCW).

[0024] Examples of bidirectional overrunning clutches have never been used or applied in downhole environments. Although similar bidirectional clutches may be available, these clutches require an external system to change the direction of rotation and cannot change the direction of rotation automatically, as described herein. Furthermore, previously known bidirectional clutches, such as those used in aircraft applications, are not configured for the temperature and pressure conditions present in most downhole environments.

[0025] The clutch described herein has several advantages over traditional clutches that are currently used as engagement systems in downhole environments. To engage and disengage the clutch, it is not necessary to consume more energy than the rotation of the motor present on the EBD actuator. The clutch engages automatically, primarily as a result of the angular rotation of the input shaft. Embodiments of the clutch can provide high torque, and the embodiments can provide temporary and permanent disengagement capabilities for downhole components for which the clutch can be used as an engagement mechanism.

[0026] The bidirectional overrunning clutch can be used in several downhole applications. The examples presented herein are used with completion tools requiring both a drive / engagement mode (CW and CCW) and an overrunning mode in the same equipment. The drive mode is required when the clutch input shaft rotates and transmits motion to the clutch output shaft in the same direction. The overrunning mode is required when the clutch output shaft rotates freely and no motion is transferred to the input shaft. The bidirectional overrunning clutch can be used when a redundant system is required and can also be used when additional tool intervention may be required when a primary actuator or a redundant actuator does not have sufficient force to move the load.

[0027] Examples of embodiments

[0028] [Fig.l] is a schematic presentation of an exemplary well system, according to some implementations. In particular, [Fig.l] is a diagram of a well system 100 that includes a wellbore 102 in a subterranean formation 101. The wellbore 102 includes a liner 104 and a number of perforations 114, 116 formed in the liner 104. Each set of perforations 114, 116 is located in a respective reservoir 130, 132 to allow reservoir fluids (i.e., oil, water, and gas) from the respective reservoirs 130, 132 to flow into the wellbore 102 and into the tubular string 106 (the production tubing). The tubular string 106 includes at least one packer 112 that can prevent mixing of fluids produced from the reservoirs 130, 132 into the wellbore 102. A production assembly 108 can allow entry of produced fluid from the reservoir 130 into the tubular string 106.Similarly, a production assembly 110 may allow the entry of produced fluid from the reservoir 132 into the tubular column 106.

[0029] In some cases, the production assemblies 108, 110 may include one or more components requiring electrical rather than hydraulic power. The one or more components may include one or more valves, such as production valves, one or more interval control valves, ports, packers, sleeves, or other components that may be used to control flow into or out of the well system 100, as well as locking and snag systems, packers, and valves. The well system 100 may also include an actuator, such as an EDB actuator for actuating one or more components in the production assemblies 108, 110. The EDB actuator embodiments disclosed herein may be electrically powered and used to actuate one or more valves, sleeves, or other components. sliding valves, packers, ports, or other components, to control flow into or out of the well system 100, as well as locking and closing systems, packers, and valves. Embodiments of the EDB actuator may utilize an engagement system, such as a bi-directional overrunning clutch shown herein, to engage and disengage the motor from the EDB actuator. Embodiments of the bi-directional overrunning clutch shown herein may operate in a downhole or frac zone environment and be capable of recoiling the EDB actuator without applying torque to the motor.

[0030] A flowline 120 coupled to the wellhead 118 of the wellbore 102 and a separator 122 may allow fluid produced by the tubular string 106 to flow to the separator 122. The separator 122 may be configured to separate phases of the fluid produced from the wellbore 102. For example, oil, water, and gas may be separated from each other after passing through the separator 122. All of the fluid produced from the wellbore 102 may then flow to a tank battery, via the flowline 124, which may include components such as the storage tank 126, to store the produced fluid.

[0031] [Fig.2] is a partial sectional view of one embodiment of a bidirectional overrunning clutch 200. The clutch 200 includes an input shaft 202 having a multi-surface profile 204 at a distal end thereof and an end journal 218 at an opposite end. The multi-surface profile 204 has a plurality of engagement surfaces 206. In the examples shown, the multi-surface profile is a hexagonal profile with six engagement surfaces 206, however other examples may have more or fewer engagement surfaces. Similarly, the end journal 218 may have a hexagonal or other shape. The clutch body 208 includes a cage 210 at its distal end. The cage 210 may be positioned around the multi-surface profile 204. The cage may house a plurality of rollers 212 configured to engage the plurality of engagement surfaces 206 as the input shaft 202 rotates.An output shaft 214 is coupled to the clutch body 208 around the cage 210. As the input shaft 202 rotates, the plurality of rollers 212 engage the plurality of engagement surfaces 206, thereby transferring motion and torque to the output shaft 214 such that the output shaft 214 rotates in the same direction as the input shaft 202. The clutch 200 may have three modes of operation: freewheeling (may also be inactive), clockwise, and counterclockwise, which will be shown and described in more detail in [Fig.3A]-3C.

[0032] The clutch 200 may use an anti-rotation friction force on the cage 210, which allows the input shaft 202 to automatically change direction of rotation. Some embodiments of the clutch 200 may also include a friction mechanism 220 positioned in an opening in the proximal end of the body 208. The friction mechanism 220 may be used to create the anti-rotation friction force to provide opposing resistance to the rotational movement of the cage 210 until interference contact between the input shaft 202, the rollers 212, and the output shaft 214 is achieved. The friction mechanism 220 may be generated by the axial load and the coefficient of friction. The axial load may be provided by various mechanisms, such as, for example, a coil or Belleville spring, magnets, interference contact with a bushing, etc.

[0033] Embodiments of the clutch 200 disclosed herein may provide an engagement system independently for each actuator. Embodiments of the clutch 200 may also withstand operating temperatures in a downhole environment of between -18°C and 200°C and a pressure environment of 20,000 psi. The clutch 200 may also operate even when immersed in a dielectric fluid or other oils, such that the clutch 200 and an actuator coupled to the clutch 200 may be chemically compatible while maintaining operational characteristics in the fluid, which may be exposed to a combination of pressure and temperatures.The clutch 200 may also provide high torque capacity, and embodiments may provide temporary and permanent disengagement capabilities for an actuator for which the clutch may be used as an engagement mechanism.

[0034] Referring now to [Fig. 3A]-3C there is shown an embodiment of a bidirectional overrunning clutch 300 in different modes of operation, a freewheeling (or inactive) mode and two engaged modes, clockwise (CW) and counterclockwise (CCW). The bidirectional overrunning clutch 300 is constructed similarly to clutch 200 and like reference numerals are used to designate like elements. [Fig. 3A] shows the clutch 300 in the freewheeling (or inactive) mode. In the freewheeling mode, the output shaft 314 rotates freely, either clockwise or counterclockwise. The input shaft 302 does not rotate. As shown herein, there is clearance between the rollers 312 positioned in the cage 310 and both the output shaft 314 and a plurality of engaging surfaces 306 of an input shaft 302.Thus, the rollers 312 are not engaged with the output shaft 314 or the input shaft 302 and the rollers 312 roll freely. In this state, the output shaft 314 can rotate freely without transmitting any motion. or torque to the input shaft 302. Rotation of the input shaft 302 allows the clutch 300 to engage or disengage the actuator.

[0035] [Fig.3B] shows the clutch 300 in the clockwise (CW) mode. As the input shaft 302 rotates, the rollers 312 contact and engage on a first side of each of the engagement surfaces 306. As the input shaft 302 rotates, the rollers are free to move due to the clearance between the input shaft 302, the rollers 312, and the output shaft 314. Progressing with rotation of the input shaft 302, the clearance decreases until the rollers 312 engage both the input shaft 302 and the output shaft 314, thereby engaging the clutch 300. Once the clutch 300 is engaged, all components rotate together. Once engaged, the rollers 312 are pushed outward to engage the output shaft 314, thereby transferring CW motion and torque to the output shaft 314, so that the output shaft rotates in the CW direction and all components rotate together.

[0036] [Fig.3C] shows the counterclockwise (CCW) clutch 300. When the input shaft 302 rotates counterclockwise, the rollers 312 contact and engage the plurality of engagement surfaces 306. Once engaged, the rollers 312 rotate and are pushed outward to engage the output shaft 314, thereby transferring CCW motion and torque to the output shaft 314, such that the output shaft rotates in the CCW direction and all components rotate together.

[0037] To ensure engagement between the rollers 312 and the output shaft 314 and the input shaft 302, resistance is created opposite to the rotational movement on the cage 310, until interference contact between the rollers 312 of the input shaft 302 and the output shaft 314 is achieved. The resistance may be a friction mechanism generated by the axial load and the coefficient of friction, such as the friction mechanism 220 as described.

[0038] Referring now to [Fig.4A]-4E there are shown examples of components that may comprise the clutch 200 or clutch 300 shown and described herein. [Fig.4A] shows an example of an input shaft 402 that includes a multi-surface profile 404 at its distal end and a hexagonal journal 418 at the other end, however any other end journal such as a square profile, a splined profile, or a shaft with a key may be used. The multi-surface profile 404 includes a plurality of engagement surfaces 406. [Fig.4B] shows an embodiment of a clutch body 408, and more particularly a distal end of the body 408 including a cage 410 for housing a plurality of rollers therein. [Fig.4C] shows an embodiment of a roller 412 which can be positioned in the cage 410 and engage the engagement surfaces 406 of the input shaft 402.

[0039] [Fig.4D] shows an embodiment of an output shaft 414 that can couple to the distal end of the clutch body 408 ([Fig.4B]) and around the cage 410 ([Fig.4B]). The output shaft 414 may include openings 416 to receive the fasteners of a transmission shaft that can be coupled thereto or any other end journal such as a square, hexagonal or even a splined profile or a shaft with a key. [Fig.4E] shows an embodiment of a friction mechanism 420 that can be used with the clutch 200. The friction mechanism 420 shown is a spring, however any other friction system can be used, for example a helical spring or Belleville spring, magnets, an interference contact with a ring, etc.

[0040] Referring now to [Fig. 5], there is shown an embodiment of an EDB actuator 500 that may be coupled and used to actuate a target component within a wellbore. The EDB actuator 500 may include a housing 502 including an electric motor 504. The actuator may also include a mechanism for converting linear displacement into rotation, such as a ball nut 510 and a ball screw 512 in this embodiment, converting rotation into linear displacement and vice versa, depending on the mode of operation. An engagement system 506 is coupled to the motor 504, the ball nut 510, and the ball screw 512 and is configured to engage and disengage the ball screw 512 and the nut 510. The ball screw 512 includes a sliding rod 514 that can mate with the target component. The ball nut 510 may be supported by a thrust bearing 516.The housing 502 may include at least one interior chamber 518 that may contain a lubricant and / or a dielectric oil. As the oil is compressed and expanded by pressure and temperature, the volume change or displacement of the oil may be compensated for by at least one compensator 520 fluidly connected to the interior chamber 518. The compensator 520 may include at least one of a bellows, a piston, a bladder, or a diaphragm. In some embodiments, a dynamic sealing system 522 may be positioned at one end of the housing 502 to seal the interior chamber 518 from the external environment of the wellbore (such as the annulus or casing).In some embodiments, the interior chamber 518 may also include a rotary seal 524 to provide additional sealing and prevent contamination of the oil in which the electrical components are positioned.

[0041] When the motor 504 rotates clockwise or counterclockwise. The engagement system 506, the ball nut 510 and the ball screw 512 also rotate and the sliding rod 514 moves away or retracts towards the housing actuator 502, thereby pushing or pulling the target components, which may be a valve or other target component. In this embodiment, the engagement system 506 may include a bidirectional overrunning clutch such as the clutch 200 or 300 mentioned above.

[0042] In other embodiments, the engagement system 506 may include a freewheel hub that applies torque in a first direction from the motor 504 to the ball nut 510 to convert rotation to linear movement, however then the freewheel hub rotates freely when torque is applied in a second direction from the ball nut to the motor. In other embodiments, the engagement system 508 may include a two-way ratchet clutch acting in the same manner as explained for the two-way clutch and the freewheel hub.

[0043] In another embodiment, the ball screw 512 and ball nut 510 may be replaced with a planetary roller screw and nut, and may be engaged by the engagement system 508, which may be a two-way overrunning clutch such as clutch 200, or a freewheel hub, or a two-way ratchet clutch.

[0044] Referring now to [Fig. 6] there is shown another embodiment of an EDB actuator 600 according to some embodiments. The EDB actuator 600 is similar to the EDB actuator 500, however an interior chamber 618 of the housing 602 may be fluidly coupled with a first compensator 620 and a second compensator 621 to compensate for the volume change or displacement of the oil / dielectric oil in the interior chamber 618 as the oil is compressed and expanded by pressure and temperature.

[0045] The bidirectional overrunning clutch and EDB actuator embodiments presented herein may be used in several downhole applications and situations. The clutch / engagement system and EDB actuator embodiments may be used where a redundant system is required, such as in [Fig. 7A] and 7B, and / or are suitable for field intervention if necessary, such as presented in [Fig. 8].

[0046] Referring now to [Fig.7A], there is shown an example of a bi-directional overrunning clutch used as an engagement system with a downhole target mechanism, when a redundant actuator is used. In this example, when it is necessary to operate the actuator, Motor 1, Motor 2 is deactivated and disengaged from Ball Nut 2 by Clutch 2, so that Motor 1 is able to move the required load (related to actuation of the downhole target mechanism) without compromising, stressing or moving Motor 2. Such drilling systems may include two or more actuators. In [Fig.7A], the main actuator is activated and the main motor, Motor 1, is On. The redundant actuator is in freewheel mode and the redundant motor, Motor 2, is Off. This system allows the load to be pushed and pulled using the main actuator's ball screw.

[0047] Referring now to [Fig.7B], there is shown another example of a bi-directional overrunning clutch used as an engagement system with a downhole target mechanism when a redundant actuator is used. In this example, when it is necessary to operate the actuator, Motor 2, Motor 1 is deactivated and disengaged from Ball Nut 1 by Clutch 1, so that Motor 2 is able to move the required load (related to the actuation of the downhole target mechanism) without compromising, stressing, or moving Motor 1. Such drilling systems may include two or more actuators. In [Fig.7B], the primary actuator is in the overrunning mode and the redundant motor, Motor 1, is deactivated. The redundant actuator is activated and the redundant motor, Motor 2, is activated. This system is capable of pushing and pulling the load with the redundant actuator ball screw.In other examples, Engine 1 and Engine 2 may operate together.

[0048] Referring now to [Fig.8], there is shown an example of a bidirectional overrunning clutch used as an engagement system when intervention may be required to actuate a target mechanism positioned downhole, such as e.g. a valve. The system comprises a primary actuator and a redundant actuator. The primary and redundant actuators and motors are deactivated and the load can be applied via an intervention tool without any transfer or movement of the primary and redundant motors. In this scenario, both actuator engagement systems will be in the overrunning mode (inactive position).Once the intervention tool has performed the required actuation, the intervention tool can be withdrawn - the primary and redundant actuators and motors retain their normal functions and can be used for further actuations as needed (as shown and discussed in [Fig.7A] and 7B). Insertion of an intervention tool can be triggered by manual user intervention or by reviewing actions taken by downhole tools that indicate that intervention may be required.

[0049] Plural instances may be provided for the components, operations, or structures described herein as a single instance. Finally, the boundaries between different components, operations, and data stores are somewhat arbitrary, and particular operations are presented in the context of specific illustrative configurations. Other assignments of functionality are contemplated and may fall within the scope of this disclosure. In general, Structures and functionalities shown as separate components in the example configurations may be implemented as a combined structure or component. Similarly, structures and functionalities shown as a single component may be implemented as separate components. These and other variations, modifications, additions, and enhancements may be included within the scope of the disclosure.

[0050] The use of the phrase "at least one of" preceding a list with the conjunction "and" should not be considered an exclusive list and should not be interpreted as a list of categories with one element from each category, unless expressly stated otherwise. A clause that states "at least one of elements A, B and C" may be infringed with only one of the elements mentioned, several of the elements mentioned, one or more of the elements in the list and another element not mentioned.

[0051] Examples of Embodiments

[0052] Aspects disclosed herein include: [to be completed after approval of the project by the inventors - essentially repeats the language of the claim]

[0053] Aspect A: A clutch for use in a downhole environment, comprising an input shaft, the input shaft having a multi-surface profile at its distal end, the multi-surface profile having a plurality of engaging surfaces; a body, the body comprising; a cage at the distal end of the body and positioned around the input shaft; and a plurality of rollers within the cage; and an output shaft coupled to the body; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces as the output shaft rotates.

[0054] Aspect B: A feedback-driven downhole electric actuator, comprising an actuator housing; a motor positioned in the actuator housing; a dynamic sealing system; a ball screw and a ball nut; and an engagement mechanism coupled to the motor, a mechanism for converting rotation into linear motion; wherein the mechanism for converting rotation into linear motion comprises a sliding rod extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to connect a target mechanism

[0055] Aspect C: A downhole system comprising: a target mechanism; and an actuator coupled to the target mechanism wherein the actuator comprises: an actuator housing; a motor positioned within the housing; a dynamic sealing system; a ball screw and a ball nut; and an engagement mechanism coupled to the motor, the ball screw, and the ball nut; the ball screw including a sliding rod extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to connect to the target mechanism.

[0056] Aspects A, B and C may comprise one or more of the following additional elements in combination:

[0057] Element 1: further comprising a friction mechanism.

[0058] Element 2: wherein the friction mechanism is a helical spring, a Belleville spring or a magnet.

[0059] Element 3: wherein the plurality of rollers are disengaged from both the input shaft and the output shaft in a freewheeling mode.

[0060] Element 4: wherein the output shaft rotates freely while the plurality of rollers are disengaged from the input shaft.

[0061] Element 5: wherein the input shaft rotates in the same direction as the output shaft when the clutch is in the engaged mode.

[0062] Element 6: wherein the engagement mode is either clockwise or counterclockwise.

[0063] Element 7: wherein the mechanism for transforming rotation into linear motion comprises a ball screw and a ball nut.

[0064] Element 8: wherein the actuator housing comprises an interior chamber containing a dielectric oil.

[0065] Element 9: further comprising at least one compensator fluidly coupled to the inner chamber.

[0066] Element 10: further comprising a rotary joint positioned between the motor, the ball screw and the ball nut.

[0067] Element 11: wherein the engagement mechanism is a bidirectional overrunning clutch comprising: an input shaft, the input shaft having a multi-surface profile at its distal end, the multi-surface profile having a plurality of engaging surfaces; a clutch body, the body comprising; a cage at a distal end of the clutch body and positioned about the input shaft; and a plurality of rollers within the cage; and an output shaft coupled to the clutch body; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces and the output shaft upon rotation of the input shaft.

[0068] Element 12: wherein the engagement mechanism is a freewheel hub.

[0069] Element 13: wherein the engagement mechanism is a ratchet clutch two lanes.

[0070] Element 14: wherein the mechanism for transforming rotation into linear motion comprises a planetary screw and a roller, and wherein the engagement system is one of the following: a two-way overrunning clutch, a freewheel hub, and a two-way ratchet clutch.

[0071] Element 15: wherein the target mechanism is an interval control valve.

[0072] Element 16: further comprising a second (redundant) actuator coupled to the target mechanism.

[0073] Element 17: further comprising an intervention tool configured to lock the target mechanism.

[0074] Statement 1. A clutch for use in a downhole environment, comprising an input shaft, the input shaft having a multi-surface profile at its distal end, the multi-surface profile having a plurality of engaging surfaces; a body, the body comprising; a cage located at the distal end of the body and positioned around the input shaft; and a plurality of rollers within the cage; and an output shaft coupled to the body; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces as the output shaft rotates.

[0075] Statement 2. The clutch according to statement 1, further comprising a friction mechanism; and optionally, wherein the friction mechanism is one of coil springs, Belleville springs and magnets.

[0076] Statement 3. A clutch according to statement 1, wherein the plurality of rollers are disengaged from both the input shaft and the output shaft in a freewheeling mode.

[0077] Statement 4. A clutch according to statement 3, wherein the output shaft rotates freely while the plurality of rollers are disengaged from the input shaft.

[0078] Statement 5. The clutch according to statement 1, wherein the input shaft rotates in the same direction as the output shaft when the clutch is in an engaged mode; and optionally, wherein the engaged mode is clockwise or counterclockwise.

[0079] Statement 6. A feedback-driven downhole electric actuator, comprising an actuator housing; a motor positioned within the actuator housing; a dynamic sealing system; a ball screw and a ball nut; and an engagement mechanism coupled to the motor, the ball screw, and the ball nut; wherein the ball screw comprises a sliding rod extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to engage a target mechanism.

[0080] Statement 7. A feedback-driven downhole electric actuator according to statement 6, wherein the actuator housing comprises a chamber interior containing a dielectric oil; and optionally, further comprises at least one compensator fluidly coupled to the interior chamber.

[0081] Statement 8. A feedback-driven downhole electric actuator according to statement 6, further comprising a rotary joint positioned between the motor, the ball screw and the ball nut.

[0082] Statement 9. A feedback driven downhole electric actuator according to statement 6: wherein the engagement mechanism is a bidirectional overrunning clutch comprising: an input shaft, the input shaft having a multi-surface profile at its distal end, the multi-surface profile having a plurality of engaging surfaces; a clutch body, the body comprising; a cage located a distal end of the clutch body and positioned around the input shaft; and a plurality of rollers within the cage; and an output shaft coupled to the clutch body; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces and the output shaft when the input shaft rotates.

[0083] Statement 10. A feedback driven downhole electric actuator according to statement 6, wherein the engagement mechanism is a freewheel hub; and optionally, wherein the engagement mechanism is a two-way ratchet clutch.

[0084] Statement 11. A feedback-driven downhole electric actuator according to statement 6, comprising a planetary screw and a roller for converting rotation into linear motion in place of the screw and ball nut, and wherein the engagement system is one of the following: a two-way overrunning clutch, a freewheel hub, and a two-way ratchet clutch.

[0085] Statement 12. A downhole system comprising: a target mechanism; and an actuator coupled to the target mechanism wherein the actuator comprising: an actuator housing; a motor positioned within the housing; a dynamic sealing system; a ball screw and a ball nut; and an engagement mechanism coupled to the motor, the ball screw, and the ball nut; wherein the ball screw comprises a sliding rod extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to connect a target mechanism.

[0086] Statement 13. A downhole system according to statement 12, wherein the engagement mechanism is a two-way overrunning clutch, a freewheel hub, and a two-way ratchet clutch.

[0087] Statement 14. A downhole system according to statement 12, wherein the target mechanism is an interval control valve.

[0088] Statement 15. The downhole system according to statement 12, further comprising a second actuator coupled to the target mechanism; and optionally, further comprising an intervention tool configured to lock the target mechanism.

Claims

Claims

1. A feedback-driven downhole electric actuator (500, 600), comprising: an actuator housing (502); a motor (504) positioned within the actuator housing; a dynamic sealing system (522); a ball screw (512) and a ball nut (510); and an engagement mechanism (506) coupled to the motor, the ball screw, and the ball nut; wherein the ball screw includes a sliding rod (514) extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to connect a target mechanism.

2. The feedback-driven downhole electric actuator of claim 1, wherein the actuator housing comprises an interior chamber (518) containing a dielectric oil; and optionally, further comprises at least one compensator (520) fluidly coupled to the interior chamber.

3. The feedback-driven downhole electric actuator of claim 1, further comprising a rotary joint (524) positioned between the motor, the ball screw, and the ball nut.

4. The feedback-driven downhole electric actuator of claim 1, wherein the engagement mechanism is a bidirectional overrunning clutch (200) comprising: an input shaft (202), the input shaft having a multi-surface profile (204) at its distal end, the multi-surface profile having a plurality of engaging surfaces; a clutch body (208), the body comprising; a cage (210) located at a distal end of the clutch body and positioned around the input shaft; and a plurality of rollers (212) within the cage; and an output shaft (214) coupled to the clutch body; wherein the plurality of rollers is configured to engage the plurality of engaging surfaces and the output shaft when the input shaft rotates.

5. A feedback-driven downhole electric actuator according to claim 1, wherein the engagement mechanism is a freewheel hub; and optionally, wherein the engagement mechanism is a two-way ratchet clutch.

6. A feedback-driven downhole electric actuator according to claim 1, comprising a planetary screw and roller for converting rotation into linear motion in place of the screw and ball nut, and wherein the engagement system is one of the following: a two-way overrunning clutch, a freewheel hub, and a two-way ratchet clutch.

7. A downhole system comprising: a target mechanism; and an actuator (500) coupled to the target mechanism, the actuator comprising: an actuator housing (502); a motor (504) positioned within the housing; a dynamic sealing system (522); a ball screw (512) and a ball nut (510); and an engagement mechanism (506) coupled to the motor, the ball screw, and the ball nut; wherein the ball screw comprises a sliding rod (514) extending from a distal end of the actuator housing and through the dynamic sealing system, the sliding rod configured to connect a target mechanism.

8. A downhole system according to claim 7, wherein the engagement mechanism is a two-way overrunning clutch, a freewheel hub and a two-way ratchet clutch.

9. The downhole system of claim 7, wherein the target mechanism is an interval control valve.

10. The downhole system of claim 7, further comprising a second actuator coupled to the target mechanism; and optionally, further comprising an intervention tool configured to lock the target mechanism.

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