Bias Pad Actuator Pressure Ring for Wear-Resistant Directional Drilling
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Solution Overview
Problem
Directional drilling systems experience damage and strain due to contact with borehole surfaces, leading to inefficiencies and potential failure of components like the BHA and drill string.
Innovation Solution
Incorporation of a directional steering tool with an actuatable biasing element and a piston system, featuring a pressure ring made of superhard or ultrahard materials, which resists wear and erosion in downhole environments, allowing precise control and reduced damage during drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional directional drilling system is used, then the drill bit can be steered in non-linear boreholes, but the BHA and drill string components experience damage and strain leading to potential failure
Solution Approach 1:
The patent introduces a directional steering tool as an intermediary device between the drill string and the borehole wall. This tool includes a movable biasing element with a pressure ring that contacts the borehole wall to apply lateral forces for steering, while the connecting rod and piston mechanism transmits forces without direct transmission of damaging contact forces to the drill string components. The steering tool acts as a mediator that enables non-linear steering while protecting the upstream drilling system.
2Measurement precision
If a movable biasing element is used to steer the drill bit, then precise lateral movement control is achieved, but wear and erosion occur in the downhole environment
Solution Approach 1:
The patent applies a superhard or ultrahard pressure ring to the movable biasing element. This pressure ring is made from composite or advanced materials such as cubic boron nitride (cBN), polycrystalline diamond (PCD), or tungsten carbide-coated materials. These composite or enhanced materials provide extreme wear and erosion resistance while maintaining the precision of lateral movement control. The pressure ring acts as a protective composite layer that enables precise steering operations in the harsh downhole environment.
3Device complexity
If the piston is directly coupled to the movable biasing element, then the structure is simple, but the piston cannot rotate to accommodate lateral movement
Solution Approach 1:
The patent segments the coupling between the piston and the movable biasing element into two separate rotatable connections. The connecting rod serves as an intermediate segment that is rotatably connected to both the piston and the biasing element. This segmentation allows the piston to move axially while the connecting rod rotates to accommodate the lateral movement of the biasing element, providing both simplicity and rotation capability through modular connection design.
4Adaptability or versatility
If a connecting rod with rotatable connections is used, then rotation and lateral movement are accommodated, but the device complexity increases
Solution Approach 1:
The connecting rod is designed as a multi-functional universal component that simultaneously performs multiple functions: transmitting axial forces from the piston, accommodating rotation through rotatable connections, and enabling lateral movement of the biasing element. By making the connecting rod universal in its capabilities, the patent reduces the need for additional specialized components, thereby managing complexity while maintaining high adaptability for various movement and rotation requirements.
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 enhances the operational lifetime of drilling components by minimizing wear and erosion, enabling precise steering and reducing strain on the BHA and drill string, thereby improving drilling efficiency and reducing maintenance costs.
Implementation Method 1
a piston movable in the bore, wherein the piston includes a pressure ring coupled to the piston and positioned between at least a portion of the piston and an inner wall of the bore
Implementation Method 2
utilizing a superhard or ultrahard pressure ring to resist wear and erosion in the downhole environment
Data Source
AI summary
A device may include a tool housing having an outer surface. A device may include a movable biasing element radially movable relative to the outer surface. A device may include a bore in the outer surface of the tool housing at least partially in a radial direction of the tool housing. A device may include a piston axially fixed to the movable biasing element and movable in the bore. A device may include a pressure ring coupled to the piston and positioned between at least a portion of the piston and an inner wall of the bore.