Double Wall Flow Tube Choke System for Percussion Tool
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Solution Overview
Problem
Current percussion tools in downhole drilling face challenges in controlling air flow, with existing systems either providing insufficient percussive force at low drill system pressures or venting excessive air, leading to inefficiencies and tool damage.
Innovation Solution
The development of a percussion tool with a choke system that regulates air flow by using a choke plug to control the amount of pressurized fluid entering the central feed tube channel, allowing for high percussive force at low pressures while limiting force at higher pressures to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a top vent system is used to vent air, then percussive force is sufficient at low drill system pressures, but the system vents excessive air and the vent system commonly plugs causing work stoppages
Solution Approach 1:
The invention extracts the venting function from the central feed tube channel and creates a separate annular vent passage. This allows excess air to be vented through a dedicated pathway that is not prone to plugging, while the central channel maintains sufficient percussive force at low pressures. The separation of venting and force generation pathways resolves the contradiction between sufficient percussive force and vent system reliability.
Solution Approach 2:
The annular passage acts as an intermediary element between the central feed tube channel and the external environment. It provides a controlled pathway for excess air to escape while preventing direct plugging of the main force generation channel. This intermediary structure enables reliable venting without compromising percussive force generation.
2Reliability
If a central flow system is used to vent air, then the vent system is not prone to plugging, but inadequate percussive force is generated at low drill system pressures
Solution Approach 1:
The invention segments the air flow path into two distinct channels: a central feed tube channel for generating percussive force and an annular passage for venting excess air. This segmentation allows the central channel to maintain high percussive force at low pressures while the annular channel provides reliable plugging-free venting. The segmented architecture resolves the contradiction between vent system reliability and percussive force generation.
3Force
If high drill system pressure is used, then sufficient percussive force is generated, but excessive force is applied causing bearing spalling, steel fatigue cracking, and reduced tool life
Solution Approach 1:
The invention introduces a dynamic choking mechanism that automatically adjusts the air flow resistance based on drill system pressure conditions. At low pressures, the choke allows sufficient flow to generate adequate percussive force. At high pressures, the choke restricts flow to limit percussive force and prevent tool damage. This dynamic adjustment capability resolves the contradiction between generating sufficient percussive force and preserving tool life.
Solution Approach 2:
The choke mechanism changes the flow parameters (pressure drop, flow rate) based on operating conditions. By varying the effective flow area through the choke, the system can maintain optimal percussive force across a wide range of drill system pressures, preventing both insufficient force at low pressures and excessive force at high pressures that would reduce tool life.
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
This solution enables efficient drilling with controlled air flow, enhancing drilling rate and tool longevity by ensuring appropriate percussive energy is applied across varying drill system pressures.
Implementation Method 1
a choke system that regulates air flow by using a choke plug to control the amount of pressurized fluid entering the central feed tube channel, allowing for high percussive force at low pressures while limiting force at higher pressures
Data Source
AI summary
An apparatus, system, and method of fabricating a percussion tool that includes a flow tube. The flow tube includes upper and lower portions, inner and outer walls, and at least one opening formed in the outer wall. The upper portion extends from a top end towards a bottom end. The lower portion extends from the upper portion to the bottom end. The inner wall extends from the top end to the bottom end and defines a central channel therein. The outer wall extends from the top end towards the bottom end, surrounds a portion of the inner wall and defines an outer channel with the inner wall. The opening is fluidly communicable with a first conduit formed within a piston, which surrounds a portion of the flow tube, when in an up position and is fluidly communicable with a second conduit formed within the piston when in a down position.