Bearing Support Ring Thermal Warping Reduction
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Solution Overview
Problem
Subterranean drilling systems face challenges in extending the operational lifetime of thrust-bearing apparatuses due to high on-bottom and off-bottom thrust loads, which can lead to thermal warping and reduced hydrodynamic operation efficiency.
Innovation Solution
A bearing assembly with a support ring featuring superhard bearing elements and thermal-warping-reducing features, such as radially-extending slots or a bi-material structure, to minimize thermal warping and enhance compliance, allowing for hydrodynamic operation under elevated temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the support ring is made rigid to maintain bearing surface alignment, then manufacturing precision is improved, but thermal warping under operational temperature increases
Solution Approach 1:
The support ring is segmented by incorporating radial slots that divide the ring structure into sections. These slots allow differential thermal expansion and reduce thermal warping by enabling the ring to flex and accommodate temperature-induced dimensional changes while maintaining bearing surface alignment.
Solution Approach 2:
The support ring's structural parameters are modified by adding compliance features such as radial slots and varying thickness profiles. These parameter changes enable the ring to transition from a completely rigid structure to one that has controlled flexibility, allowing it to accommodate thermal expansion while maintaining sufficient stiffness for bearing support.
2Object-affected harmful factors
If the support ring is made compliant to reduce thermal warping, then thermal warping is reduced, but bearing surface alignment may deteriorate
Solution Approach 1:
The support ring exhibits non-uniform structural properties with varying thickness and compliance features located strategically at specific positions. The radial slots and thickness variations are positioned to provide compliance where thermal expansion occurs while maintaining rigidity and precise alignment at the bearing surface contact regions.
3Temperature
If drilling fluid flow is increased to cool bearing elements, then temperature is reduced, but thrust-bearing apparatus complexity increases
Solution Approach 1:
The bearing assembly utilizes the existing drilling fluid circulation system already present in the wellbore environment. The cooling is achieved passively by allowing drilling fluid to flow through the drill string and contact the bearing elements, eliminating the need for dedicated active cooling mechanisms while effectively managing bearing temperatures.
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
The solution effectively limits the displacement of bearing surfaces out of plane, enabling hydrodynamic operation and reducing wear, thereby extending the break-in time and improving the operational efficiency of thrust-bearing apparatuses in subterranean drilling systems.
Implementation Method 1
The support ring includes at least one thermal-warping-reducing feature configured to reduce a radial moment, compared to if the at least one thermal-warping-reducing feature were absent from the support ring, which is thermally induced in the support ring when the support ring and the plurality of superhard bearing elements are exposed to operational temperature conditions
Implementation Method 2
Typically, a portion of the drilling fluid is diverted by the downhole drilling motor to cool and lubricate the bearing elements of the thrust-bearing apparatuses
Implementation Method 3
a portion of the drilling fluid is diverted by the downhole drilling motor to cool and lubricate the bearing elements
Data Source
AI summary
Various embodiments relate to a bearing assembly including a support ring configured to reduce thermal warping under operational temperature conditions, a bearing apparatus that may utilize such a thrust-bearing assembly, and applications that incorporate the disclosed bearing apparatuses such as downhole motors in subterranean drilling systems, directional drilling systems, and many other apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed circumferentially about an axis. The thrust-bearing assembly further includes a support ring having the plurality of superhard bearing elements mounted thereto. The support ring includes at least one thermal-warping-reducing feature configured to reduce a radial moment, compared to if the at least one thermal-warping-reducing feature were absent from the support ring, which is thermally induced in the support ring when the support ring and the plurality of superhard bearing elements are exposed to operational temperature conditions.