Carbide Powder Coating for Drill Bit Rolling Elements

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Solution Overview

Problem

The existing drill bits, particularly those with fixed cutters, face issues of wear and tear due to the continuous exposure of cutting edges to the formation, leading to reduced efficiency and increased maintenance costs, as well as the risk of losing rolling elements during drilling operations, which can cause damage to the housing and affect the overall performance of the drilling system.

Innovation Solution

The implementation of rolling-type depth of cut control (DOCC) elements with a housing that includes access ports for external application of carbide powder, which reduces manufacturing time, prevents damage to the housing, and minimizes the risk of losing rolling elements, thereby enhancing the durability and efficiency of the drill bit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If carbide powder is applied to the inner surface of the housing, then wear resistance is improved, but manufacturing time increases

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Instead of applying carbide powder to the inner surface of the housing through access ports (conventional approach), the patent inverts the process by applying carbide powder to the outer surface of the housing. This external application method eliminates the need to access the inner surface through ports, thereby reducing manufacturing time while still achieving wear resistance protection for the housing.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the carbide powder application process from the constrained internal environment and moves it to the external environment. By taking out the application process from the housing interior and performing it on the exterior, the manufacturing process becomes more efficient and less time-consuming while maintaining the protective function.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If carbide powder is applied through access ports, then wear resistance is improved, but damage to the housing increases

Engineering Contradiction:

Improvewear resistanceVSAvoiddamage to housing

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the application direction by applying carbide powder to the outer surface rather than the inner surface. This reversal eliminates the risk of damaging the housing during the application process, as the external application method does not require accessing the inner surface through ports that could be compromised.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If rolling elements are used, then depth of cut control is improved, but risk of losing rolling elements increases

Engineering Contradiction:

Improvedepth of cut controlVSAvoidretention of rolling elements

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies carbide powder to the outer surface of the housing, creating a composite structure where the carbide layer provides enhanced friction and grip. This composite surface increases the retention of rolling elements, preventing them from being lost during drilling operations while maintaining the depth of cut control functionality.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent converts the potential harm of rolling elements being lost into a benefit by applying carbide powder that increases friction. The higher friction created by the carbide surface actually helps retain the rolling elements in place, turning what could be a harmful loss into a beneficial retention mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 reduces wear on the drill bit and the drilling system, increases the operational efficiency, and extends the life of the rolling elements by providing a robust and wear-resistant surface for the rolling elements to engage with, thus minimizing the loss of rolling elements during drilling operations.

Implementation Method 1

sending a carbide powder through the one or more access ports such that the carbide powder is directed around the plug and deposited on the inner surface

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10801269B1Through hole carbide powder onto an inner surface

Publication Date: 2020.10.13 HALLIBURTON ENERGY SERVICES INC

AI summary

A method may comprise placing a plug in a chamber of a housing, sending a carbide powder through the one or more access ports such that the carbide power is directed around the plug and deposited on the inner surface, and removing the plug from the chamber. A rolling element assembly may comprise a housing having an outer surface and inner surface, carbide powder on the inner surface, and a rolling element attached in the chamber with a portion of the rolling element extends from the chamber, wherein the rolling element is in contact with the carbide powder deposited on the inner surface.