Coaxial Dielectric Segments for Drill String Tool Data Transmission
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Solution Overview
Problem
Conventional downhole motors in directional drilling lack adjustable bend settings and real-time data collection capabilities, leading to limitations in rotational speed and tool reliability, requiring frequent trips to the surface for setting changes and resulting in increased costs and tool damage.
Innovation Solution
A drill string tool with a mud motor featuring an adjustable bend setting and integrated sensors, utilizing coaxial cables with magnetically conductive electrically insulating fibers to minimize electromagnetic interference and a centrifugal brake assembly to control rotational speed, along with data transmission coils for real-time data collection and communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional downhole motors are used with fixed bend settings, then the structure is simple and reliable, but the adaptability to different drilling sections is poor and frequent surface trips are required
Solution Approach 1:
The patent implements adjustable bend settings that can be changed from the surface without retrieving the tool. The bend housing includes multiple selectable bend angles (e.g., 0°, 1°, 2°, 3°, 4°, 5°) that can be adjusted using a setting mechanism accessible through the drill string, allowing the same tool to adapt to different wellbore sections (vertical, curved, lateral) without requiring replacement or surface retrieval.
Solution Approach 2:
The downhole motor is designed with universal applicability across different drilling sections by incorporating multiple bend settings in a single device. The motor can function in vertical sections (0° bend), curved sections (1°-3° bend), and lateral sections (higher bend settings), eliminating the need for multiple specialized tools and reducing the frequency of surface trips.
2Shape
If high bend settings are used for curved wellbore sections, then the motor can navigate curves effectively, but the rotational speed is limited to below 50 RPM causing slower drilling rates
Solution Approach 1:
The patent allows dynamic adjustment of bend settings based on the specific wellbore section being drilled. Operators can select optimal bend angles for curved sections when needed, and switch to lower or zero bend settings for vertical or lateral sections where higher rotational speeds are required, thus optimizing both curve navigation capability and drilling speed for different operational phases.
Solution Approach 2:
The bend angle parameter can be changed from the surface without tool retrieval, allowing operators to optimize the bend setting for each drilling section. For curved sections, higher bend angles (1°-3°) are selected to navigate curves effectively, while for vertical or lateral sections, lower bend angles or 0° are selected to enable higher rotational speeds and faster drilling rates.
3Productivity
If rotary drilling at high speeds is used for vertical sections, then the drilling rate is improved, but the downhole motor and bearing assembly may fail due to excessive stress
Solution Approach 1:
The adjustable bend setting allows the motor to be optimized for vertical sections by setting the bend angle to 0° or minimal values. This configuration reduces stress concentrations on the bearing assembly and motor components during high-speed rotary drilling, thereby maintaining reliability while enabling higher drilling rates in vertical wellbore sections.
4Loss of information
If sensors and data transmission systems are integrated into the downhole motor, then real-time monitoring capability is improved, but the device complexity and electromagnetic interference increase
Solution Approach 1:
The patent replaces traditional electromagnetic data transmission with inductive coupling between the rotating electronics package and the stationary drill string. This magnetic field-based transmission method eliminates the need for physical electrical contacts, reducing wear and maintenance while enabling real-time data transmission from sensors monitoring drill bit performance, motor status, and wellbore conditions.
Solution Approach 2:
The patent introduces an intermediary inductive coupling system between the rotating electronics package and the stationary drill string. This intermediary uses magnetic fields to transfer data and power without direct electrical contact, reducing electromagnetic interference and simplifying the sealing requirements while maintaining real-time monitoring capabilities.
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 on-demand adjustment of bend settings and real-time data collection during drilling, enhancing operational efficiency, reducing tool damage, and lowering costs by allowing continuous drilling operations without frequent surface trips.
Implementation Method 1
coaxial cables with magnetically conductive electrically insulating fibers to minimize electromagnetic interference
Implementation Method 2
centrifugal brake assembly to control rotational speed
Implementation Method 3
data transmission coils for real-time data collection and communication
Data Source
AI summary
A drill string tool comprising a mud motor comprising a driveshaft assembly rotatably disposed within a driveshaft housing, the mud motor comprising sensors and an adjustable bend setting. A bearing mandrel in communication with a drill bit rotatably disposed within a bearing housing. The driveshaft assembly includes a drive shaft adapter having a rotating portion and a stationary portion. The rotating portion comprising a centrifugal brake assembly in communication with an electronics package. The electronics package rotates with the driveshaft assembly at an RPM relative to the driveshaft housing. The electronics package is in communication with the motor, the sensors, the adjustable bend setting, and a collection of wired drill pipe making up the drill string by means of connections and coils. The connections comprise coaxial cables comprising an outer conductor and annular dielectric segments mounted on a center conductor wire. The segments may comprise an embedded mesh structure.