Biased Control Unit Torque Transfer for Drilling Reliability
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Solution Overview
Problem
Conventional rotary steerable systems for wellbore drilling face issues with reliability due to impeller jamming and wear, leading to decreased drilling rates and increased costs, as they often require multiple rotating components that can accumulate debris.
Innovation Solution
A control unit with a single rotating tubular body and a spindle, utilizing torque transfer units with biasing elements to maintain a consistent torque independent of rotational velocity, and a torque generator to control net torque, thereby reducing the risk of jamming and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rotating components are used in conventional rotary steerable systems, then the system can achieve steering functionality, but the reliability decreases due to impeller jamming and wear
Solution Approach 1:
The patent merges multiple rotating components (impellers and multiple tubular bodies) into a single tubular body that rotates relative to the drill string. This single tubular body integrates the functions previously performed by multiple separate rotating elements, thereby eliminating jamming issues between multiple impellers and reducing wear from multiple rotating interfaces.
Solution Approach 2:
The patent extracts and eliminates the problematic multiple-rotating-component architecture from conventional systems. By removing the need for multiple impellers and separate rotating tubular bodies, the invention takes out the sources of jamming and wear that degraded reliability in traditional rotary steerable systems.
2Force
If torque transfer depends on rotational velocity in conventional systems, then torque can be generated through fluid flow, but torque consistency deteriorates when rotational velocity varies
Solution Approach 1:
The patent introduces a biasing element as an intermediary mechanical component that applies a constant force to the torque transfer unit. This biasing force acts as a mediator between the rotating tubular body and the spindle, ensuring that torque transfer remains consistent and independent of variations in rotational velocity caused by changes in drilling fluid flow properties.
3Force
If drilling fluid flow properties change, then rotational velocity of the tubular body changes, but torque transfer should remain constant
Solution Approach 1:
The patent applies preliminary action through the biasing element, which pre-loads the torque transfer unit with a constant force before rotation occurs. This preliminary mechanical bias ensures that when the tubular body rotates at varying speeds due to changes in drilling fluid properties, the torque transfer to the spindle remains consistent because the biasing force is already in place to maintain the torque relationship.
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 downhole reliability, increases drilling rates, and decreases overall drilling costs by simplifying the system and maintaining consistent torque transfer across varying rotational velocities.
Implementation Method 1
A biasing element may maintain a force against the torque transfer unit such that a first torque may be applied to the spindle that is independent of a rotational velocity of the tubular body
Implementation Method 2
A second torque may be applied to the spindle with a torque generator to control a net torque on the spindle
Implementation Method 3
A torque transfer unit may be attached to the drill string and the tubular body
Data Source
AI summary
A control unit includes a rotatable tubular body that rotates around a spindle. A torque transfer unit may be attached to the tubular body and the spindle. A force applied to the torque transfer unit by a biasing element may control a first torque applied by the tubular body to the spindle. The first torque is independent of a rotational velocity of the tubular body. A second torque is applied to the spindle with a torque generator, the second torque controlling the net torque. Controlling the net torque allows the absolute orientation of the control unit to be controlled.