Compound-Angle Bearing Housing to Cut Bit Orbit in Rotary Drilling
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Solution Overview
Problem
Directional drilling operations face challenges due to increased bit orbit diameter, friction, and vibration caused by external angles introduced by bent subs in the drill string, limiting the ability to operate in rotary mode effectively.
Innovation Solution
A bearing assembly design featuring an upper and lower bearing housing with a driveshaft positioned within, allowing for angled rotation while minimizing friction and vibration through the use of radial and thrust bearings, and a control valve assembly to manage fluid pressure and piston extension for stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bent sub with an external angle is used in the BHA, then directional drilling capability is improved, but bit orbit diameter increases and rotary mode operation is limited
Solution Approach 1:
The invention extracts the angle introduction function from a separate bent sub component and integrates it directly into the bearing housing structure. By forming the bore at an angle to the outer surface within the bearing housing itself, the patent eliminates the need for an external bent sub, thereby reducing bit orbit diameter while maintaining directional drilling capability through the integrated angled bore design
Solution Approach 2:
The patent merges the angle introduction function with the bearing housing structure by forming the bore at an angle to the outer surface. This consolidation of functions allows the bearing assembly to provide both support/rotation capabilities and directional drilling functionality without requiring separate bent sub components, thus reducing overall complexity and improving rotary mode performance
2Adaptability or versatility
If a bent sub with an external angle is used in the BHA, then directional drilling capability is improved, but friction and vibration increase
Solution Approach 1:
The invention removes the external bent sub component that causes increased friction and vibration, and instead integrates the angle introduction function directly into the bearing housing. This extraction of the angle function from a separate mechanical linkage reduces harmful friction and vibration while maintaining the ability to drill directional wellbores through the angled bore configuration
Solution Approach 2:
The angled bore acts as an intermediary structure that transmits the rotational motion from the driveshaft to the drill bit at an angle, eliminating the need for external bent subs. This intermediary angled bore configuration reduces friction and vibration by providing a direct, streamlined path for force transmission compared to external angle-introducing components
3Adaptability or versatility
If the bore longitudinal axis is angled to the bearing housing longitudinal axis, then directional drilling is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the angled bore at a predetermined angle during the bearing housing manufacturing process itself, rather than requiring post-manufacturing assembly of bent sub components. This preliminary formation of the angled bore integrates the directional capability into the base structure, reducing overall system complexity while maintaining manufacturability through standard angular machining operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient directional drilling by reducing bit orbit diameter, increasing the ability to rotate the drill string at higher RPMs, and enhancing rate of penetration and wellbore stability, while maintaining the ability to operate in both sliding and rotary modes.
Implementation Method 1
minimizing friction and vibration through the use of radial and thrust bearings
Implementation Method 2
control valve assembly to manage fluid pressure and piston extension for stabilization
Data Source
AI summary
A bearing housing for a bottomhole assembly of a downhole tool includes an upper bearing housing, lower bearing housing, and a driveshaft. The upper bearing housing and lower bearing housing include a bore defining a bore longitudinal axis. The outer surface of the upper bearing housing defining a bearing housing longitudinal axis, the bearing housing longitudinal axis formed at an angle to the bore longitudinal axis. The upper bearing housing may be formed by forming a bore through an upper bearing housing blank and subsequently forming the outer surface of the upper bearing housing concentric with the bearing housing longitudinal axis.