Adjustable Gauge Mill Blades via Axial Locking Collar
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Solution Overview
Problem
Current milling tools for downhole operations face challenges in efficiently adjusting blade diameters to accommodate varying casing sizes and wellbore diameters, leading to restricted movement and reduced effectiveness in removing debris and obstructions.
Innovation Solution
The development of a milling tool with adjustable blades that utilize a locking collar and sloped tracks, allowing the blades to expand or retract radially based on the locking collar's position, enabling adaptation to different diameters and improving operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the milling tool uses fixed blades, then the structure is simple and reliable, but the tool cannot adapt to varying casing sizes and wellbore diameters
Solution Approach 1:
The blade system transitions from a fixed configuration to a dynamic, adjustable configuration. Blades are made movable along sloped tracks, allowing them to change radial position and gauge diameter based on the locking collar's axial position. This enables the milling tool to adapt to different casing sizes and wellbore diameters while maintaining operational effectiveness.
Solution Approach 2:
The invention introduces a coupling between axial and radial dimensions. The locking collar moves axially along the body, and through engagement with sloped tracks, this axial movement is converted into radial movement of the blades. This dimensional transformation allows a single axial adjustment mechanism to control blade gauge diameter, providing adaptability without excessive complexity.
2Adaptability or versatility
If the blades are made movable to adjust gauge diameter, then adaptability improves, but blade stability and positioning precision deteriorate
Solution Approach 1:
The blade system is designed to be dynamically adjustable during setup but stable during operation. The locking collar can be positioned axially to adjust blade gauge diameter, and once positioned, locking mechanisms (such as set screws or keys engaging with indexed positions) secure both the collar and blades in place. This ensures blade stability and positioning precision are maintained throughout the milling operation.
3Adaptability or versatility
If the locking collar moves axially to adjust blades, then gauge diameter changes, but the mechanism complexity increases
Solution Approach 1:
The invention uses sloped tracks that convert axial movement of the locking collar into radial movement of the blades. The sloped tracks are integrated into the body structure, eliminating the need for separate radial adjustment mechanisms. This dimensional conversion provides gauge diameter variability while keeping the mechanism relatively simple and compact.
Solution Approach 2:
The locking collar serves multiple functions: it provides the adjustment mechanism for blade position, acts as a positioning element through its axial movement, and potentially includes locking features to secure the adjusted position. The sloped tracks simultaneously guide blade movement and translate collar motion. This multi-functionality reduces the number of separate components needed, managing complexity while achieving gauge diameter variability.
Data Source
AI summary
Milling tools, systems, and assemblies may have an adjustable gauge diameter. An example mill may include a body with tracks thereon. The tracks may slope in an axial direction and may be configured to couple to multiple blades. A locking collar may be positioned on the body and may be movable between multiple locking positions. Each locking position may be axially offset from another. At each locking position, the blades may be located at a different axial position on the body. Where the tracks slope, each different axial positions of the blades may also correspond to a different radial position for the blades. A gauge diameter of the blades may be based on the locking positions of the locking collar.