Downhole Machining System with Segmented Actuators
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Solution Overview
Problem
Current downhole machining technologies, such as CNC, are limited by space and power constraints in boreholes, making it difficult to machine casings for changes like inserting control valves or creating larger openings, especially for elongated or non-standard hole geometries.
Innovation Solution
A downhole machining system comprising a first tool part with an axial extension and anchoring sections, a second tool part with a machining bit that can rotate and move radially, and actuators with gears to manage limited power, allowing for precise machining of casings with limited space and power availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CNC machining technology is used downhole, then machining precision can be maintained, but space and power requirements exceed available resources
Solution Approach 1:
The machining system is divided into modular components: a drive unit with motor, a separate machining bit assembly, and intermediate transmission elements. This segmentation allows the motor to be smaller and less power-intensive while still achieving precise machining through the coordinated action of multiple components including gears, belts, or chains for motion transmission.
Solution Approach 2:
Intermediate transmission elements such as gears, belts, or chains act as mediators between the motor and the machining bit. These intermediaries enable the motor to operate at lower power consumption levels while still delivering the necessary motion and force to the machining bit for precise casing modification.
2Manufacturing precision
If CNC machining technology is used downhole, then machining precision can be maintained, but the device size exceeds available space
Solution Approach 1:
The system is segmented into compact modular units that can be distributed along the tool string. The motor, transmission elements, and machining bit are separated into distinct components with smaller individual volumes, allowing them to fit within the constrained downhole environment while maintaining machining precision through their coordinated arrangement.
Solution Approach 2:
The transmission system utilizes intermediate elements that transmit motion through alternative pathways (rotational motion through gears, belt drives, or chain drives) rather than direct linear actuation. This dimensional transformation allows for more compact packaging of the machining system while preserving the precision required for casing modification.
3Adaptability or versatility
If larger openings or elongated holes are machined in the casing, then operational flexibility is improved, but the complexity of the machining system increases
Solution Approach 1:
The machining bit assembly is designed with dynamic capabilities, allowing it to move radially inward and outward relative to the drive unit. This dynamic positioning enables the same basic system to machine different geometries (larger openings, elongated holes, or standard holes) by adjusting the radial position and travel distance of the machining bit, thereby achieving operational flexibility without proportionally increasing system complexity.
Solution Approach 2:
The machining system is designed as a multi-functional tool capable of performing various machining operations (creating different hole sizes, elongated openings, and complex geometries) using a single integrated system. The universal design incorporates adjustable components that can adapt to different machining requirements, reducing the need for multiple specialized tools and thereby managing system complexity while enhancing versatility.
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 machining of casings with predetermined geometries and sizes, including larger openings than the bit diameter, and allows for elongated holes, capable of writing patterns like letters or logos, while maintaining efficient operation and cleaning of cuttings.
Implementation Method 1
a first actuator comprising an electrical motor for axially moving the second tool part in relation to the first tool part, a second actuator comprising an electrical motor for rotating the second tool part in relation to the first tool part, and a third actuator comprising an electrical motor for rotating the bit
Data Source
AI summary
The present invention relates to a downhole machining system (1) for machining a casing (2) in a borehole in a well having a top. The downhole machining system comprises a first tool part (4) having an axial extension (5) and an anchoring section (6); a second tool part (7) adapted to rotate and move axially in relation to the first tool part, the second tool part comprising a machining bit (8) being movable in a direction radial in relation to the axial extension; a first actuator (10) comprising an electrical motor (11A) for axially moving the second tool part in relation to the first tool part; a second actuator (12) comprising an electrical motor (13) for rotating the second tool part in relation to the first tool part; and a third actuator (14) comprising an electrical motor (11b) for rotating the bit. At least one of the actuators comprises a gear (15) for changing a rotational speed of a rotor of the motor.