Adjustable Mud Motor Housing Assembly with Splined Mandrel
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Solution Overview
Problem
Existing adjustable mud motor housings are difficult to adjust due to the weight and size of components, posing safety hazards and risking misalignment during the process of setting bend angles, which can lead to errors in drilling operations.
Innovation Solution
An adjustable housing assembly that uses a splined mandrel to disengage and rotate the adjusting ring without requiring simultaneous separation from adjacent components, allowing for easier alignment of markings for desired bend angles without lifting and turning heavy components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the adjusting ring is rotated to change bend angles, then the housing can be adjusted to different angles, but the heavy weight of the adjusting ring creates safety hazards and makes the adjustment process difficult
Solution Approach 1:
The adjusting ring is divided into multiple segments that can be independently manipulated. Each segment can be rotated separately to achieve the desired bend angle, reducing the effective weight that needs to be moved at once and improving safety during adjustment operations
Solution Approach 2:
A lightweight indicator mechanism serves as an intermediary between the heavy adjusting ring and the operator. The indicator shows the current bend angle without requiring the operator to directly handle or position heavy components, reducing safety hazards while maintaining adjustability
2Adaptability or versatility
If the adjusting ring is rotated while heavy, then bend angles can be changed, but misalignment of markings can occur leading to errors in drilling operations
Solution Approach 1:
The markings and indicator are pre-aligned during manufacturing to ensure accurate correspondence between the indicator position and the actual bend angle. This preliminary precision alignment prevents misalignment errors during field adjustment operations
Solution Approach 2:
The indicator provides visual feedback to the operator showing the current bend angle setting. This feedback mechanism allows the operator to verify the alignment and make precise adjustments, reducing the risk of errors in drilling operations
3Adaptability or versatility
If the adjusting ring and offset housing are separated for adjustment, then the bend angle can be changed, but the complexity of the adjustment procedure increases and operational efficiency decreases
Solution Approach 1:
The adjustment mechanism is merged with the existing housing structure, allowing the adjusting ring to be rotated and locked in position without complete disassembly. This integration reduces procedural complexity while maintaining full adjustability of the bend angle
Data Source
AI summary
An adjustable housing assembly is provided, which includes a splined housing and an adjusting ring which contain a splined mandrel. The splined mandrel is moveable axially within the housing assembly when disengaged from upstream and downstream portions of a drill string to disengage the mandrel from the splined housing. The splined mandrel is rotatable with the adjusting ring to alter angled interfaces between the components to change the bend angle in the housing.