Superhard Torque Coupling Assembly for Corrosive Drilling Wear
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Solution Overview
Problem
Existing force coupling assemblies in mechanical applications, such as subterranean drilling systems, face challenges in efficiently transferring torque across rotating components while withstanding caustic and corrosive environments, leading to increased wear and maintenance costs.
Innovation Solution
The use of torque coupling assemblies featuring superhard contact elements, such as polycrystalline diamond compacts, attached to support rings, which engage and transfer torque between rotating components, providing enhanced durability and resistance to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact elements are used in force coupling assemblies, then the assembly can transfer torque between rotating components, but the contact elements experience increased wear in caustic and corrosive environments
Solution Approach 1:
The patent applies composite materials by combining a substrate material (such as metal or ceramic) with a superhard coating material (such as diamond-like carbon or cubic boron nitride) to create contact elements that possess both structural integrity and exceptional wear resistance. This composite structure allows the contact elements to withstand corrosive environments while maintaining their mechanical properties and torque transfer capability.
Solution Approach 2:
The patent changes the physical and chemical parameters of the contact elements by applying superhard coatings with specific hardness values (exceeding 40 GPa) and controlled thicknesses (5-50 micrometers). These parameter changes transform ordinary contact elements into highly wear-resistant components that can operate reliably in caustic and corrosive drilling environments.
2Duration of action of moving object
If conventional materials are used for contact elements, then the assembly structure can be simpler, but the maintenance frequency increases due to wear
Solution Approach 1:
The contact elements utilize composite material construction where a durable substrate provides structural support and a superhard coating layer provides wear resistance. This composite approach extends service life significantly while maintaining relatively simple manufacturing processes through established coating techniques such as CVD, PVD, or plasma spraying.
Solution Approach 2:
The patent applies local quality by providing superhard coating only on the contact surfaces of the contact elements rather than coating the entire component. This localized application extends service life where it is most needed while minimizing added complexity and cost, as the coating is applied only to the specific areas subject to wear.
3Object-affected harmful factors
If standard contact elements are used, then the assembly can be manufactured with conventional processes, but wear resistance is insufficient for harsh environments
Solution Approach 1:
The contact elements are manufactured as composite structures by applying superhard coatings to substrates using conventional industrial coating methods such as chemical vapor deposition (CVD), physical vapor deposition (PVD), or plasma spraying. These are established manufacturing processes that add wear resistance without requiring entirely new manufacturing approaches.
Solution Approach 2:
The manufacturing process incorporates parameter changes by controlling coating thickness (5-50 micrometers), hardness (exceeding 40 GPa), and adhesion strength to achieve optimal wear resistance. These parameter specifications transform conventional manufacturing into a process that produces highly wear-resistant components suitable for harsh drilling environments.
Data Source
AI summary
Force coupling or torque coupling assemblies, apparatuses, systems, and methods include assemblies that each include contact elements. At least some of the contact elements may be configured to remain in contact with each other when a force is applied between the assemblies.