Reciprocating Ball Screw Piston Actuator for Wireline Drive Consistency
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Solution Overview
Problem
Current wireline deployment of drill-out and milling tools faces inefficiencies due to limited horsepower, leading to inconsistent driving and potential bit breakage when dealing with metal-based downhole obstructions, resulting in increased time and cost compared to coiled tubing or drill pipe methods.
Innovation Solution
A downhole tool assembly with a hydraulically driven reciprocating ball screw piston actuator that interfaces with a mounted ball nut, providing enhanced drive consistency through damping mechanisms to minimize 'bounce' and maintain axial force, even with low power availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If wireline deployment is used to reduce equipment size and cost, then rig-up time and footspace are reduced, but horsepower available for driving milling tools is limited to below 10 horsepower
Solution Approach 1:
The patent employs a dynamic reciprocating piston mechanism that converts limited hydraulic pressure into high-force intermittent strokes. The piston reciprocates within a cylinder, using hydraulic fluid pressure to drive forward strokes that deliver cutting force to the bit, then retracting during backward strokes. This dynamic action allows the system to achieve effective milling force despite limited continuous horsepower availability from wireline deployment.
Solution Approach 2:
The system utilizes periodic reciprocating motion of the piston to deliver cutting force to the milling bit. The piston performs repeated cycles of forward stroke (applying cutt ing force) and backward stroke (retracting to reset), creating periodic action that accumulates effective work over time. This periodic mechanism enables the limited horsepower wireline system to effectively remove metal-based obstructions that would require continuous high-power delivery.
2Power
If limited horsepower is used for drill-out operations, then wireline deployment becomes feasible, but inconsistent driving and bit bounce occur when removing metal-based obstructions
Solution Approach 1:
The patent incorporates a dampening mechanism that cushions the backward stroke of the reciprocating piston. This dampening action absorbs and dissipates rebound energy that would otherwise cause inconsistent driving and bit bounce. By providing beforehand cushioning during the piston's retracting phase, the system maintains stable contact between the bit and the obstruction, ensuring consistent cutting force application throughout the reciprocating cycle.
3Ease of operation
If reciprocating piston is used to drive the bit, then hydraulic actuation is achieved, but fluid compressibility causes bounce and inconsistency in driving
Solution Approach 1:
The dampening mechanism is specifically designed to cushion the backward stroke of the hydraulic piston, counteracting the rebound effects caused by hydraulic fluid compressibility. This cushioning action occurs during each reciprocating cycle, absorbing the elastic rebound energy stored in the compressed fluid and preventing it from translating into bit bounce or driving inconsistency.
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 and consistent removal of metal-based obstructions with less than 10 horsepower, reducing the time required for operations and avoiding bit breakage, thus making wireline deployment a viable alternative to more expensive methods.
Implementation Method 1
fluid pumped in and out of a pressurizable housing may be used to reciprocate the piston
Implementation Method 2
the actuator includes a reciprocating ball screw piston for interfacing a mounted ball nut so as to enhance the consistency of its driving of the tool
Data Source
AI summary
A rotatable downhole cutting tool configured for enhanced drive consistency in low power circumstances. The tool is equipped with a hydraulic axial drive actuator suitable for use in wireline deployment. The actuator itself includes a reciprocating piston with a ball screw that threadably interfaces a ball nut for dampening the axial drive imparted by the piston. As such, even though hydraulically driven at generally well under about 10 horsepower, bounce in the axial drive is substantially eliminated.