Adjustable Bend Angle Downhole Motor
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Solution Overview
Problem
Directional drilling in hydrocarbon recovery operations faces challenges in precisely controlling the inclination of the drill bit due to extreme downhole conditions and uncertainty about formation strata locations, which affects drilling accuracy and efficiency.
Innovation Solution
A downhole motor with an adjustable bend angle is used, allowing real-time modification of the drill bit's inclination by altering the bend angle between the drill bit and the drill string, facilitated by a selectively engageable torque coupling and harmonic gear box, enabling precise directional control without the need for surface intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed bend angle motor is used, then the device structure is simple, but the drilling direction cannot be adjusted in real-time
Solution Approach 1:
The patent applies the dynamics principle by making the bend angle adjustable rather than fixed. The motor assembly includes a movable housing that can be repositioned along the drive shaft, allowing the bend angle between the drive shaft and output shaft to be dynamically changed. This enables real-time adjustment of the drill bit inclination to adapt to different drilling conditions and target formations, while maintaining a relatively simple overall structure through the use of a slider mechanism and spring-loaded engagement.
2Productivity
If the bend angle is adjusted by surface intervention, then the motor structure is simple, but the drilling time increases due to repeated trips
Solution Approach 1:
The patent applies the self-service principle by enabling the bend angle adjustment to be performed downhole without requiring retrieval to the surface. The motor assembly includes a slider mechanism that can be actuated by drilling fluid pressure or mechanical means while the motor is in position, allowing the operator to adjust the bend angle in real-time based on downhole conditions. This eliminates the need for repeated trips to the surface, significantly improving drilling efficiency and productivity.
3Adaptability or versatility
If a selective torque coupling mechanism is added, then the bend angle can be adjusted downhole, but the device complexity increases
Solution Approach 1:
The patent applies the intermediary principle by introducing a slider mechanism as a mediator between the drive shaft and the housing. The slider engages with slots in the housing and can be actuated by drilling fluid pressure or mechanical means to move the housing axially, thereby changing the bend angle. This intermediary mechanism provides a relatively simple way to achieve downhole adjustment compared to more complex torque coupling systems, as it utilizes the existing drilling fluid flow path and requires minimal additional components.
Data Source
AI summary
An example downhole motor may include a first housing and a second housing with first and second portions characterized by non-parallel longitudinal axes. The second housing may be rotatably coupled to the first housing, and the first portion of the second housing may be arranged in a fixed, non-parallel longitudinal orientation with the first housing. A drive shaft may be at least partially within the first housing, and the motor may further comprise a selectively engageable torque coupling between the drive shaft and the second housing, positioned within the first housing.