Bow Spring Forming for One-Piece Centralizers
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Solution Overview
Problem
Current methods for forming one-piece centralizers with bow springs face challenges in achieving desired dimensions due to the requirement of an odd number of bow springs and limitations in the forming process, leading to issues with geometry, length, and height.
Innovation Solution
A device and method utilizing a centralizer forming machine with a press, movable arm, and form to shape bow springs, allowing for the formation of centralizers with either an even or odd number of bow springs by applying pressure to shape each bow spring individually, and optionally using hinges to reform the centralizer into a one-piece structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional forming tool is used to expand bow springs outward, then the centralizer can be formed, but the forming process cannot achieve desired dimensions (geometry, length, and height) because the forming process lacks required stroke/length
Solution Approach 1:
The patent divides the forming process into multiple sequential steps, positioning and forming each bow spring individually rather than attempting to form all bow springs simultaneously. This segmentation allows the forming tool to achieve proper stroke and length for each bow spring, resulting in desired dimensional accuracy while maintaining a relatively simple forming tool design.
Solution Approach 2:
The patent employs preliminary positioning of each bow spring before the forming action is applied. The bow springs are pre-positioned in the correct locations on the centralizer body, and then the forming tool applies pressure in a controlled sequence. This preliminary action ensures that when the forming stroke is applied, the tool has sufficient travel to achieve the desired geometry, length, and height of each bow spring.
2Adaptability or versatility
If an odd number of bow springs is used in the traditional forming process, then the centralizer can be formed with the available tooling, but this limits the design flexibility and prevents the use of even numbers of bow springs
Solution Approach 1:
The patent employs a dynamic forming process where the tool can be repositioned and reconfigured for each bow spring based on its specific location and requirements. This dynamic approach allows the same forming tool to accommodate any number of bow springs (even or odd) by adjusting the positioning and sequencing of the forming operations, thereby providing design flexibility without significantly complicating the manufacturing process.
Solution Approach 2:
The forming tool is designed with universal capabilities to handle different configurations of bow springs. By incorporating adjustable positioning mechanisms and a systematic forming sequence, the tool can accommodate centralizers with any number of bow springs, making the manufacturing process versatile and adaptable to various design requirements while maintaining ease of manufacture.
3Device complexity
If the forming tool is positioned between opposing bow springs and expanded, then the tool structure is simplified, but the forming process cannot achieve the required stroke/length to appropriately form opposite bows
Solution Approach 1:
Instead of attempting to form multiple opposing bow springs simultaneously with a single expansion action, the patent segments the forming process to address each bow spring individually or in smaller groups. This segmentation allows the forming tool to concentrate its force and stroke on specific bow springs, achieving the required geometry, length, and height for each spring while maintaining a relatively simple tool structure that can be repositioned between operations.
Solution Approach 2:
The patent employs preliminary positioning of the forming tool relative to each bow spring before the forming action is applied. By pre-positioning the tool in the correct location and orientation for each bow spring, the simple tool structure can be effectively utilized to achieve the required stroke and length for proper bow spring geometry, rather than requiring a complex tool to attempt simultaneous formation of multiple springs.
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 the precise formation of centralizers with consistent geometry, length, and height, accommodating both even and odd numbers of bow springs, and allows for the reforming of centralizers into hinged structures for improved tubular support and cement distribution in hydrocarbon drilling operations.
Implementation Method 1
actuating the press to apply pressure to the first bow spring between the form and the press
Implementation Method 2
The arm is movably coupled to leg to allow the arm to rotate about an axis of the leg
Data Source
AI summary
A device for forming bow springs in a one-piece centralizer includes a swing arm that is configured to receive the one-piece centralizer. The device and process using the device include mechanically applying, with a press, an external load onto an un-formed bow spring positioned on a form of the swing arm. When the load is applied with the device, the un-formed centralizer is forced downward to allow the bow spring to take the desired form/shape/geometry, length, and height of a formed bow spring.